SECTION 544: PROTECTIVE COATING OF NEW STRUCTURAL STEEL
544.1 Description
This Work consists of applying li quid coating Materials to ste el surfaces. The Contractor shall refer to Section 541, “Steel Structures” for galvanized (hot-dipped)” applications. The Contractor shall refer to Section 545, “Prot ective Coating of Miscellaneous Structural Steel” for two (2) coat and powder coating applicati ons. Note that Bridge railings are included in Section 545, “Protective Coating of Miscellaneo us Structural Steel.” The Contractor shall refer to Section 546, “Recoating Structures” f or field repair of liquid coatings. The Contractor shall adhere to all requirements in Section 547, “Safety and Environmental Requirements for Painting Operat ions” of this Specification.
544.1.1 Terminology and Standards
The Contractor shall use terminology in accordance with the fo llowing standards: 1. Society for Protective Coat ings (SSPC) Painting Manual Volum e 2; 2. Surface Preparation Standards, Guides, and Specifications, S ection 2 of the SSPC Painting Manual Volume 2 (SSPC-SP) American Architectural Manuf acturer’s Association (AAMA); 3. American Association of State Highway and Transportation Off icial (AASHTO); 4. American Society for Testing and Materials (ASTM); and 5. American Institute of S teel Construction (AISC).
544.2 Materials
544.2.1 Coating System
The Contractor shall select a complete coating system comprised of products meeting all performance requirements as listed in Table 544.2.1:1, “Accepta ble Product Requirements” below. Testing shall be in accordance with AASHTO R-31. All p roducts in each system shall be from the same manufacturer. All products shall be represent ed on the latest version of the manufacturer’s product data shee t as being suitable for use on Bridges and capable of being applied at the specified dry film thickness requirements in Tab le 544.3.4.4:1, “Required Film Thicknesses.” Inorganic Zinc-Rich Primer – Shall achieve minimum SSPC Paint 2 0 Level 2 requirements for amount of zinc dust in the dry film of equal t o or greater than 77% by weight. Epoxy Intermediate Coat – Shall be a two (2) component epoxy, p olyamide or polyamidoamine, including Phenalka mine coatings with minimum so lids by volume of 65%. Polyurethane Topcoat – Shall be a two (2) component aliphatic p olyurethane coating with minimum solids by volume of 65%. Table 544.2.1:1 Acceptable Product Requirements TEST REF. NO. PRODU CT(S) ACCEPTANCE CRITERIA COMMENTS Section 544: Protective Coating Of New Structural Steel Page 5 18 Table 544.2.1:1 Acceptable Product Requirements TEST REF. NO. PRODU CT(S) ACCEPTANCE CRITERIA COMMENTS Slip Coefficient ASTM A 325, Appendix A. IOZ Class B, Min. 0.5 Salt Fog Resistance ASTM B 117 P/I/T (IOZ) (A) No Delamination Allowed (B) Rust – Max creep 4mm, Avg. creep 2mm @5000 Hrs. (C) Blister – Conversion #8 @ 4000 Hrs. Cyclic Weathering Resistance ASTM D 5894 P/I/T (IOZ) (A) No Delamination Allowed (B) Rust – Max creep 4mm, Avg. creep 2mm @5040 Hrs. (C) Blister – Conversion #9 @ 4032 Hrs. Adhesion Pull-Off Strength ASTM D 4541 IOZ Alone P/I/T (IOZ) 2.4 MPa (600 psi) 2.4 MPa (600 psi) Freeze-Thaw Stability Pull-Off Strength ASTM D 4541 P/I/T (IOZ) 2.4 MPa (350 psi) 4.1 MPa (600 psi) 2.4 MPa (350 psi) 4.1 MPa (600 psi) Requires same average as adhesion pull-off strength results, with no tests measuring less than 60% of those results Field History NA P/I/T (IOZ) Five (5) Bridges with Minimum two (2) year successful field history P = Primer; I = Intermediate coat; T = Topcoat; IOZ = Inorganic Zinc Rich Primer For structural components that require a galvanized (hot-dipped ) coating, reference Section 541.2.5, “Structural Steel Coatings.” Primer information for the use of organic zinc for touch-up and repair is included in Section 546, “Recoating Structures.” If the Contract does not specify a color, the Contractor shall use the color Federal Standard 595A Color No. 22563 or approved equal.
544.2.2 Submittals
In addition to the submittals r equire per Section 106, “Control of Materials,” the Contractor shall provide the following submittals to the Projec t Manager at least 30 Days before coating operations: 1. Product data and SDS for each product in the system; 2. Surface preparation requirements; 3. Application instructions: a. Mixing and thinning directions; b. Recommended spray nozzles and pressures; c. Minimum / maximum drying times, including re-coat times for shop or field coatings; d. Temperature requirements; 4. Letter from the manufacturer detailing the coating system co mponents and the compatibility of those components to adjacent Materials includi ng but not limited to: a. Every product in the system (primer, intermediate, topcoat, etc.); b. Any pre-applied or preexisting products (such as existing co atings); c. Any post applied products (su ch as anti-graffiti coating); d. Any modifications to the surf ace preparation or application instructions related to the total system performance; 5. If the color varies from the specified color, the Contractor shall submit color samples on boards at least eight (8) inches by ten (10) inches for revi ew and approval; and 6. Documentation related to Contractor Qualifications per Secti on 546.2.3.1, “Contractor Qualifications.”
544.2.2 1 Certification
After the Department approves the coating Material, the Contrac tor shall submit: 1. Notarized manufacturer’s Cert ificates of Compliance stating that the Materials are the same as those described in the manufacturer’s product data sheets; and 2. Certified test reports from an independent Laboratory perfor med in accordance with AASHTO R-31, showing Acceptable performance results as listed o n the chart in Section 544.2.1, “Certification.” The Contractor shall submit two (2) copies of each to the Department.
544.2.2 2 Product Data Sheets
The Contractor shall provide manufacturer’s product data sheets with each Submittal that shows the following: 1. Mixing and thinning directions; 2. Recommended spray nozzles and pressures; 3. Minimum/maximum drying time, including re-coat times, for sh op or field applied coats; and 4. Manufacturer recommended applic ation procedures, including t emperature Section 544: Protective Coating Of New Structural Steel Page 5 20 requirements.
544.2.2 3 Contractor Qualifications
When the Contract requires painting more than 1,500 sq. ft of steel surface, the Contractor shall demonstrate qualification by one (1) of the fo llowing two (2) methods: Method 1 The Contractor shall obtain SSPC QP 1 certification for field p ainting or either SSPC-QP 3 certification or the AISC Sophisticated Paint Endorsement (SP E) for shop painting. The Contractor shall perform and document QA/QC inspections daily. QA/QC inspection documents shall be electronically submitted to the Project Mana ger on a weekly basis. Method 2 The Contractor shall provide a c oating Plan and provide for NAC E certified inspection (Level 2 minimum). The inspec tion services shall include but n ot be limited to: 1. Surface preparation and cleanliness inspection verifying pro file and appropriate surface preparation. 2. Confirm and document products match approved submittals and certification letters. Document the batch numbers of all coatings. 3. Inspection of primer coat to include dry film thickness read ings. Review Contractors QA/QC reports for environm ental conditions and document. 4. Observe application of stripe coat on the intermediate coat and document environmental readings during the start and stop of application . Review Contractors QA/QC reports. 5. Inspect intermediate coat to include dry film thickness read ings. Review Contractor’s QA/QC reports. 6. Observe start and stop of finish coat application and docume nt environmental conditions. 7. Inspect members after trans portation, prior to subsequent co ating and / or Final Acceptance. 8. Final Inspection to include vi sual inspection for runs, sags , and foreign Material in coating. Also perform final dry film thickness inspection. 9. Electronically submit interim reports after each inspection to the Project Manager within three (3) Working Days. 10. Electronically submit comprehensive final report including photos to the Project Manager within 14 Days of completion of inspection. Final repo rt shall include QA/QC daily inspections per formed by the Contractor. 11. Add field connection points. Any deficiencies shall be co rrected and re-inspected by the NA CE inspector prior to proceeding. Provisions for demonstration of qualifications are Incidental to the performance of the coating; no additional payment shall be made. NMDOT shall be g ranted open access to the coating operation to perform i nspections and to review document ation of Contractor inspections.
544.3 Construction Requirements
The Contractor shall apply coatings in conformance with SSPC – PA 1 “Shop, Field and Maintenance Painting of Steel” and with SSPC – PA Guide 13 “Gui de Specification for Section 544: Protective Coating Of New Structural Steel Page 5 21 Application of Coating Systems with Zinc-Rich Primers to Steel Bridges” (aka AASHTO/NSBA Steel Bridge Collaboration S 8.1).
544.3.1 Surface Preparation for Priming
The Contractor shall remove oil, grease, and other contaminants with methods specified in SSPC-SP I Solvent Cleaning, o r other Department-approved met hods. The Contractor shall blast-clean the carbon steel surfaces, in preparation for coating, in accordance with SSPC-SP 10 Near White Metal Blast Cleaning. Prior to commencing full surface preparation activities, the Co ntractor shall prepare an Acceptance standard on a flat portion of the surface to be clea ned, located by the Project Manager. The Project Manager shall make the final determinatio n as to whether prepared surfaces meet the Specificati on. The surfaces shall be evaluat ed using the SSPC-Vis 1, Visual Standard for Dry Abrasive Blast Cleaning. The Contracto r shall provide the SSPC-Vis 1 manual for the Project Manager for inspection and Acceptance. The Vis 1 Guide shall become the property of the Department. The Contractor shall select the type of abrasive. All abrasive s brought to the site shall be stored in a clean and dry environment. Abrasives shall not be recycled or re-used without NMDOT approval. The Contractor shall ensure that the abrasives produce a uniform profile from one (1) mil to three (3) mils with an angular pattern as m easured in accordance with SSPC-PA 17 / ASTM D 4417 Standard Test Methods for Field Measur ement of Surface Profile of Blast Cleaned Steel. If surface profile requirements of the coating manufacturer differ from those specified herein, the Contractor shall comply with the co ating manufacturer’s requirements. Actual replica test tapes used shall be maintain ed with the permanent Project inspection records. The profile shall be measured a minimum of three (3) times for every 500 feet of surface area, or as directed by the Project Manager. The Contractor shall prepare all corners, pockets, re-entrant a ngles, splice plates and bolted or riveted connection plates. The Contractor shall remo ve fins, tears, slivers, and burred or sharp edges found during the blast cleaning operation . The Contractor shall grind and re-blast the area in accordance with SSPC-SP 10, “Near Whit e Metal Blast Cleaning.” Immediately prior to coating application, the Contractor shall ensure that the surface complies with the degree of cleaning specified in SSPC-SP 10, i ncluding but not limited to ensuring the absence of dust, loos e residue, oil, grease, rust or other contaminants.
544.3.2 Coating Preparation
544.3.2 1 Mixing Coatings
The Contractor shall mix coatings using a power mixer. The Con tractor shall not use paint shakers. The Contractor shall mix the coatings, as much as possible, in the original containers. Only complete kits shall be mixed and used. The Contractor shall strain coatings through a 30 – 60 mesh scr een, or per coating the manufacturer’s recommendations. Z inc pigmented primers shall h ave no clumps of zinc remaining in the coating after mixing and during application. The Contractor shall agitate mixed primers continuously from st raining through application.
544.3.2 2 Thinning Coatings
The Contractor shall not thin the coatings without the approva l of the Project Manager. If it is necessary to thin the coatings, the Contractor shall thin the Material in accordance with the manufacturer’s recommendations.
544.3.3 Temperature and Weather Limitations
The application of a coating system shall occur only when the a ir and substrate temperature is within the range indicated by the manufacturer’s written instructions for both application and curing and can be expected to remain in that ra nge. The following conditions shall be considered but shall not supe rsede the manufacturer’s written instructions. The Contractor shall apply the coating w hen the air and surface temperatures are above 40 °F and at least five (5) °F above the dew point. The Contractor shall apply the coatings when the relative humidity is 85% or l ower. Coatings shall not be applied in rain, wind, snow, fog or mist. Coatings shall not b e applied on frosted or ice-coated surfaces. The Contractor shall apply inorganic zinc primers wh en the relative humidity is 50% or higher. Manufacturer may require water misting of inorganic zinc primers for proper curing.
544.3.4 Coating Applications
The Contractor shall not apply coatings until the Project Manag er approves the surface preparation. Prior to application of subsequent coats the Proj ect Manager shall verify that surfaces are free of dust and any deleterious contaminants. Th e Project Manager may waive this approval. When the Contract requires painting more than 1,500 square feet of steel surface, the Contractor shall have a coating manufacturer representative pre sent to provide technical assistance at the start of each coating operation. The Contractor shall apply subsequent coats within the recoat w indow specified by the manufacturer. If the recoat time period is exceeded, the under coat surface shall be specially treated as recommended by the manufacturer before subsequent co ats are applied. Such treatments include but are not limited to mild abrasion, solven t treatment, or use of a fog coat.
544.3.4 1—Reserved
544.3.4 2 Coating Options
The Contractor shall use one (1) of the following coating optio ns: 1. Apply the primer, intermediate, and protective topcoat in th e shop; 2. Apply the prime coat in the shop and the intermediate and pr otective topcoat in the field; or 3. Apply the primer and intermediate coat in the shop and the p rotective topcoat in the field.
544.3.4 3 Spray Equipment
The Contractor shall apply coatings with spray nozzles at press ures recommended by the coating system manufacturer. The Contractor shall use conventional or airless spray systems to apply the coatings, following manufacturer application instructions.
544.3.4 4 Film Thickness Requirements
The Contractor shall provide coating thicknesses in accordance with Table 544.3.4.4:1, “Required Film Thicknesses.” The Department will reject the co ating if the DFT (dry film thickness) gauge shows less than t he specified minimum thicknes s for any coating. Table 544.3.4.4:1 Required Film Thicknesses Coating Dry film thickness range (mils) Primer 2.0 – 4.0 Intermediate 4.0 – 6.0 Polyurethane Protective Topcoat 3.0 – 5.0 The Contractor shall determine the dry film thickness using ma gnetic film thickness gauges, SSPC PA 2 Procedure for Determining Conformance to Dry Coating Thickness Requirements. The Contractor shall calibrate the gauges on bla sted steel with plastic shims approximately the same thickness as the minimum dry film thickn ess. All dry film thickness requirements are to be measured above the peaks of the blast pr ofile.
544.3.4 5 Primer Application
The Contractor shall prime coat all Structural Steel surfaces, except as noted in Section
544.3.4 6, “Bolted and Welded Connections.”
The Contractor shall not apply primers over blasted steel that has begun to rust or bloom. The Contractor shall apply primer in a smooth, wet, continuous film. A stripe coat of primer Material shall be applied to all edges, corners, seams, crevices, interior angles, junctions of jo ining members, rivets, bolt hea ds, nuts and threads, welds and similar irregularities. The stripe coats shall be of sufficien t thickness to completely hide the surface being covered and shall be followed, as soon as practic able, by a full application of the appropriate coating to its specified thickness. The Contractor shall apply all coatings according to the latest manufacturer’s written instructions. The Contractor shall repair deficiently primed a reas in accordance with the manufacturer’s recommendations and as directed by the Project M anager. The Contractor shall remove dry overspray with light sanding. The Contractor shall give steel Bridge sole plates one (1) coat of zinc rich primer. The Contractor shall mask-off strips where sole plates will be weld ed to beam flanges and surfaces that will be in contact with elastomeric bearing pads. After w elding, the Contractor shall apply a primer touch-up to the welded areas.
544.3.4 6 Bolted and Welded Connections
The Contractor shall blast clean faying (contact) surfaces in a ccordance with SSPC-SP 10 Near White Metal Blast Cleani ng, and leave uncoated for bolt ing and/or field welding. The Contractor shall make uncoat ed areas slightly larger than t he contact areas to ensure that the bolted connections clamp down only on the blast -cleaned Material and not on painted surfaces. The Contractor shall mask off faying areas to protect them from rust during hauling and Section 544: Protective Coating Of New Structural Steel Page 5 24 storage. The Contractor shall apply a rust prohibitor to the f aying surfaces or coat the faying areas with a Class B primer (slip coefficient equal to or great er than 0.50), as listed in Table
544.2 1:1, “Acceptable Product Requirements.” The Department w ill approve the rust
prohibitor or Class B primer. Before bolting, the Contractor s hall remove the rust prohibitor. The Contractor shall not remove Class B primers before bolting, unless required. Immediately before bolting and/or field welding, the Contractor shall ensure the exposed connection areas are in accordance with SSPC-SP 10 Near White M etal Blast Cleaning. The Contractor shall apply the complete coating system to these sur faces after erection. The Contractor shall mask-off connection areas to leave neat lines between the connection area coating and previously coated areas. The Contractor shall apply the topcoats on bolted field connect ions after placing the deck.
544.3.4 7 Intermediate Coat Application
After cleaning and before applying the intermediate coating sys tem, the Contractor shall mask opposite sides of the diaphragms and stiffeners over areas that the direct tension indicators will bear on. The Contractor shall not coat these a reas until after erection and bolt tightening. Before applying the intermediate coat, the Contractor shall tie coat any galvanized components using manufacturer’s recommended tie coat Material. The Contractor shall apply the tie coat with a brush. The Contractor shall not apply the intermediate coat to the fol lowing Structural Steel surfaces: 1. Faying surfaces of bolted c onnections (Section 544.3.4.6, “B olted and Welded Connections”); 2. The top flange top surfaces of beams, girders or diaphragms to be embedded in concrete; 3. Bearing surfaces resting on co ncrete Substructures or are su bject to sliding and rotational movement; and 4. Bearing surfaces in contac t with elastomeric bearing pads. A stripe coat of intermediate Material shall be applied to all edges, corners, seams, crevices, interior angles, juncti ons of joining members, rivets , bolt heads, nuts and threads, welds and similar irregularities. The stripe coats shall be of sufficient thickness to completely hide the surface being covered and shall be followed, as soon a s practicable, by a full application of the appropriate coat ing to its specified thickne ss.
544.3.4 8 Urethane Protective Topcoat Application
The Contractor shall apply the polyurethane protective topcoat only on cured intermediate coat.
544.3.5 Handling Steel
The Contractor shall protect uncoated faying surfaces to minim ize corrosion during shipping and storage. The Contractor shall store Structural Steel on pallets so it do es not rest on dirt. The Contractor shall store beams and girders in an upright (as erec ted) position. The Contractor shall use softeners to insulate steel from chain s. The Contractor shall pad hooks and slings for hoisting steel. The Contractor shall space parts during shipment so that no rubbing occurs. The Contractor shall use rubber rollers, soft support pads, or other protective devices on Equipment support members or fasteners resting on or attached t o newly coated surfaces.
544.3.6 Protection of the Work and the Public
During the coating operations, the Contractor shall protect Str uctures from blast cleaning operations, paint splatter, splashes and smirches with protecti ve covering or other methods approved by the Project Manager. When the protective devices or procedures are ineffective, the Project Manager may suspend the Work until corrections take place. The Contractor shall remove blasting and coating debris from al l on-site Work before reopening the area to traffic.
544.3.7 Field Repair of Liquid Coatings
Field repair of liquid coatings shall be performed in accordanc e with Section 546, “Recoating Structures” and the m anufacturer’s recommendations. Field repair shall be accomplished with the same coating system used for the original application with the exception that organic zinc ric h primer may always be used. The Contractor shall field repair coated areas that are rusted or damaged. The Contractor shall prepare the surface in accordance with Section 546.3.1, “Surface Preparation of Existing Bridges and Structures” or with methods approved by the Project Manager. The Contractor shall prime large areas using spray Equipment, b r u s h , o r r o l l e r . T h e Contractor shall prime small areas with a brush. The Contracto r shall spray or brush the topcoat. Two (2) or more coats may be necessary to build up th e required film thickness. The Contractor shall apply topcoat only to areas where the topcoat is damaged. Requirements of Section 546.3, “Construction Re quirements” apply to field repai rs.
544.3.8 Inspection
The Contractor will be responsible for performing and documenti ng Quality Control (QC) inspections of all s hop / field surface preparation and coating activities. When the Contract requires painting more than 1,500 square feet of steel surface, the Contractor shall reference Section 544.2.2.3, “Contractor Qualifications.” When the Contr act required painting less than 1,500 square feet of steel surface, the Contractor shall docume nt all QC inspection activities, measurements and observations on the Daily Inspection report. These reports shall be submitted to the Project Manager a t a minimum on a weekly basis and shall account for all Work performed. The Contractor shall notify the Project Manager at least ten (1 0) Days before surface preparation and/or coating to allow adequate time to plan inspe ction activities. After completing erection, the Project Manager will inspect the surfaces to be embedded in concrete. The Contractor shall repair damaged or rusted sur faces before placing decks. After placing the deck and at an agreed upon time, the Project Manager will inspect the entire steel Structure for coating system damage. The Project Manager will mark damaged areas for Section 544: Protective Coating Of New Structural Steel Page 5 26 repair and will re-inspect after repairs are complete.
544.3.9 Final Operations
544.3.9 1 Final Cleaning
The Contractor shall clean the steel Structure, bearings, and Bridge seat tops after completing coating activities.
544.3.9 2 Stenciling
At the completion of coating operations, the Contractor shall s tencil in four (4) inch high black letters on the inside of the fascia girders at two (2) lo cations designated by the Project Manager: 1. The completion month and year; 2. The term “Section 544;” and 3. The coating manufacturer. The Contractor shall make the markings with the same Material used for the urethane protective coats. Example: “6/93-Section 544, Excel Coatings”
544.4 METHOD OF MEASUREMENT—Reserved
544.5 Basis of Payment
The Department will pay for the coating system(s) as Incidenta l to the new Steel. Section 545: Protective Coating Of Miscellaneous Structural Ste el Page 527