514Painting of Structural Steel

ITEM 514 PAINTING OF STRUCTURAL STEEL

514.01Description. This work consists of cleaning and painting all steel surfaces

514.02Materials. On existing steel, apply a three-coat paint system consisting of an organic zinc

prime coat, an epoxy intermediate coat, and a urethane finish coat. The coating system shall conform to 708.02. On new steel, apply a three -coat paint system consisting of an inorganic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat. The prime coat shall conform to 708.01, and the intermediate and finish coats shall conform to 708.02. Supply the intermediate and finish coats from the same manufacturer. The Contractor is responsible for ensuring the compatibility of the intermediate and finish coats with the prime coat. For caulking, use a single pack moisture cured polyurethane based material, which will not shrink, or sag capable of filling voids up to 1 inch (25 mm) wide. Only material that is listed on the OMM Qualified Product List website may be used.

514.03Superintendent. In addition to the requirements of 105.06, the Superintendent must

successfully complete a Bridge Painting pre -qualification course and training offered by the Department. The course must have been completed within the past four years and an individual course transcript must have been received by the Superintendent. Present transcript to the Engineer prior to commencing work. No work is permitted unless the Superintendent provides a valid course transcript.

514.04Quality Control. Quality control consists of designating quality control specialists to

control the quality of work in each phase established by Quality Control Points (QCPs). Control quality by inspection, tests, and cooperation with inspection and testing performed by t he Engineer and inspector.

quality control specialists before starting work in the field. Provide a quality control specialist for each structure, but one quality control specialist must be provided for every three structures for which work is progressing concurrently on this contract. Each quality control specialist must have a current certification from one of the following:

or higher will be accepted for 5 years from the date on their certificate after their training per the old specification. The quality control specialist must successfully complete a Bridge Painting prequalification course offered by the Department. The training course must have been completed within the past four years and an individual course transcript must have been received by the quality control specialist. Provide the following to the Office of Construction Administration to be placed on the approved Quality Control Specialist List. 379

trained prior to 7 -15-22 by a NACE or SSPC certified individual will be accepted until 5 years after their training.

Select only a quality control specialist who is approved by the Department. The Office of Construction Administration will publish a list of approved Quality Control Specialists. Present all required certificates, letters of certification, and valid identi fication to the Engineer prior to commencing work. The quality control specialist will be immediately removed from their duties as the quality control specialist and disqualified from future duties as the quality control specialist if any quality control failure occurs. A quality control failure is defined as any of the following:

that over 20 percent of the spot measurements of any one member of a structure, such as a cross frame, web, flange, stiffener, or other parts of the structure are either under the minimum or over the maximum spot thickness.

that the thicknesses of any area of a structure as described in 514.20 are either under the minimum or over the maximum specification thickness.

control specialist of any one member type, such as the cross frames, webs, flanges, stiffeners, or other parts of the structure and it is later found that the surfaces of those members were either not properly profiled or not properly cleaned as required by the Contract Documents. Occurrences are determined per structure.

allowed by the Contract Documents. Occurrences are determined per structure.

duties assigned to the quality control specialist in the Contract Documents. Occurrences are determined per structure. Suspend work if the quality control specialist is not available or has been removed. The Engineer or Inspector will immediately provide written notification to the Office of Construction Administration of any quality control failure identified above. Resume work when a quality control specialist, qualified and approved as provided in 514.04, is available. For work in the fabrication shop, each fabricator shall identify one or more full -time individuals who shall perform the duties of the painting quality control specialist. The quality control specialist may not be used to perform production duties including supervision, blasting, painting, waste disposal, mixing, operating or repairing equipment, or other tasks not associated with duties of the quality control specialist while the Contractor is performing work toward the completion of a Quality Control Point. Ensure that each quality control specialist is trained and equipped with Safety Data Sheets (SDS), product data sheets, tools, and equipment necessary to provide quality control on all aspects of the work. Each quality control specialist shall have a thoro ugh understanding of the plans for the work, 380 including any pertinent addenda, change order, or other contract documents, and these Specifications . Duties each quality control specialist shall perform include:

before each QCP.

performed according to the Contract. The fabricator’s quality control specialists shall provide the Engineer with a letter that includes specified information or check point data documenting acceptance of the work and consisting of the following:

intervals during the blasting and painting operation.

demonstrated the ability to paint, and that all spray equipment is used according to the manufacturer’s recommendation.

and approved by the quality control specialist and ready for inspection by the Engineer or the inspector before commencing the next phase of the work. At a QCP, the quality control specialist shall provide quality control tests bearing his signature to the Engineer or Inspector . The Contractor or fabricator shall provide the Engineer and inspectors access to inspect all affected surfaces. If inspection identifies a deficiency, correct the deficiency according to the Contract Documents before starting the next phase of work. Discovery of defective work or material after a Quality Control Point is past or failure of the final product before final acceptance, shall not, in any way, prevent the Department from rejecting the final product or obligate the Department to final acceptance. Final acceptance will be determined according to 514.21, Final Inspection. Quality Control Points Purpose New Steel Existing Steel

grease, etc. Yes Yes

381 Quality Control Points Purpose New Steel Existing Steel

Disposal Contain, collect, & dispose of abrasive blasting debris No Yes

apply prime coat, check coating thickness Yes Yes

Slivers Remove surface defects and slivers Yes Yes

materials (salt, dirt, etc.) Yes No

Application Check surface cleanliness, apply intermediate coat, check coating thickness Yes Yes

intermediate coat Yes Yes

apply finish coat, check coating thickness Yes Yes

system thickness Yes Yes Provide signed documentation of inspection, testing, conditions and material information to the Engineer on the following ODOT forms, or forms with the equivalent information. QCS Inspection Documentation Sign Off for QCP’s CA-S-7 QCP#1 Solvent Cleaning CA-S-12 QCP#2 Grinding Flange Edges CA-S-12 QCP#3 Abrasive Blasting CA-S-13 QCP#3 QCS & Visual Standards Information for Abrasive Blasting Test Section CA-S-11 QCP#4 Disposal of Hazardous/Non-Hazardous Waste CA-S-14 QCP#5 Prime Coat Application CA-S-15 QCP#5 Dry Film Thickness Readings for Prime Coats CA-S-2 QCP#6 Grinding Fins, Tears and Slivers CA-S-16 QCP#8 Dry Film Thickness Readings for Intermediate Coats CA-S-2 QCP#9 Caulking CA-S-16 QCP#8 Intermediate Coat Application CA-S-17 QCP#10 Finish Coat Application CA-S-17 QCP#10 Dry Film Thickness Readings for Finish Coats CA-S-2

514.05Testing Equipment. For the project duration, provide the Engineer or inspectors with

the test equipment listed below for the type of work at each work site with ongoing work. With the exception of the recording thermometer, the fabricator shall provide its quality control specialists with the test equipment listed below. The Contractor and fabricator shall maintain all testing equipment in good working order, and provide documentation or certification of calibration from the manufacturer. If the Contractor or Fabricator and the Engineer’s inspector are using different test equipment, the Contractor or Fabricator and the Engineer’s inspector will perform side -by-side testing and compare 382 results. If the difference between the Department’s and Contractor’s or Fabricator’s tests results, such as blast profile, dry film thickness, temperature, dew point and relative humidity, are greater than 1%, the Contractor or Fabricator and the Engineer will determine the reason for the differences and make necessary adjustments.

gauge for the measurement of abrasive blast profile depth within ±0.2 mils on the project at all times.

calibration thickness foils, (shims), and two sets of National Institute of Standards & Technology calibration plates. The first set of calibration plates shall be 1.5 t o 8 mils (38 to 200 μm), Model No. 1362b, and the second set shall be 10 to 25 mils (250 to 625 μm), Model No. 1363b. Other certified coating thickness standard plates for ferrous substrates must be approved for use by the Office of Construction Administration.

equipment for the measurement of dew point, accurate within 2 °F (1 °C) and within one percent relative humidity).

at least 12 hours.

514.06Work Limitations. Apply the prime coat to new structural steel inside permanent

buildings at the fabricator’s facility. If inside permanent buildings, the fabricator may perform year - round abrasive blasting and painting. Perform abrasive blasting and painting in the field from April 1 to October 31 unless otherwise approved by the Engineer . The Department will not issue a time extension due to adverse weather during the month of April. The plans or other Contract Documents may require additional work limitations for specific bridges or projects.

40 ºF (4 ºC). Do not apply Organic Zinc Primer, Epoxy Intermediate, or Urethane Finish Coats if the steel, air, and paint temperature is below 50 ºF (10 ºC). Follow the paint manufacturers printed instructions for the minimum times to handle, recoat and cure the individual coats for specified conditions and thicknesses. Monitor and document that the temperatures listed below are maintained for minimum time frames listed below, after application of each coat, by using the recording thermometer. The Contractor may use a heated enclosure or building. Supply heat continuously and uniformly to maintain the required minimum temperature within the enclosure or building. 383 Minimum Times to maintain temp. per coating. 50 F (10 C) 60 F (16 C) 70 F (21 C) Primer (Organic Zinc) 4 hrs 3 hrs 2 hrs Intermediate (Epoxy) 6 hrs 5 hrs 4 hrs Finish (Urethane) 8 hrs 6 hrs 4 hrs If combustion type heating units are used, vent the units away from the enclosure or building and do not allow exhaust fumes to enter the enclosure or building. Do not use open combustion in the enclosure or building. The fabricator may use radiant heat when painting new structural steel inside permanent shop buildings. Locate radiant heaters at least 10 feet (3 m) above all surfaces to be painted. Vent exhaust fumes to prevent fumes from contacting surfaces to be painted.

If steel was abrasive blasted when the temperature of the steel was less than 5 °F (3 °C) above the dew point, reblast the steel when the steel temperature is at least 5 °F (3 °C) above the dew point.

514.07Protection of Persons and Property. Collect, remove, and dispose of all rubbish,

buckets, rags, or other discarded materials and leave the job site in a clean condition. Except for deck bottoms and backwalls which have not been sealed or are not to have a sealer applied, protect all portions of the structure, that are not to be painted from damage or disfigurement by splashes, spatters, and smirches of paint. If the Contractor causes any damage or injury to public or private property, the Contractor shall restore the property, to a condition similar or equal to the condition existing before the damage or injury.

514.08Pollution Control. Comply with pollution control laws, rules, or regulations of Federal,

State, or local agencies and requirements of this specification.

514.09Safety Requirements and Precautions. Comply with the applicable safety requirements

of the Ohio Industrial Commission and OSHA. Provide Safety Data Sheets (SDS) at the preconstruction meeting for all paints, thinners, and abrasives used on this project. Do not begin work until submitting the SDS to the Engineer.

514.10Inspection Access and Lighting . In addition to the requirements of 105.10, furnish,

erect, and move scaffolding and other appropriate equipment to allow the inspector and the Engineer the opportunity to closely observe all affected surfaces during all phases of the work and for at least 10 workdays after completely painting each structure to allow for the Final Inspection according to 514.21. Provide artificial lighting as necessary to supplement natural light with a minimum of 30 foot candles (325 LUX) at the surface of the steel for inspection, cleaning, and painting. Prevent glare that interferes with traffic, workers and inspection. Submit fully detailed Engineered Drawings of the scaffolding or work platforms used for inspection access to the Engineer at least 14 days before installation. All details of the inspection access shall comply with the applicable safety requirements of The Ohio Industrial Commission and OSHA. Provide details and locations of all connections, to the permanent structure, 384 used for painting and inspection of the structure with the Engineered Drawings. Damage to the permanent structure shall be avoided. Do not drill into the bottom of the deck or under bearing locations or similar areas of concern for the structure. The details shall be reviewed, signed, stamped and dated by an Ohio registered Professional Engineer certifying that they meet these requirements. The Engineer will provide a written response to the submittal in accordance with 105.02. Do not begin work until the Engineers acceptance has been received. Perform all work in accordance with the accepted Engineering Drawings. Immediately cease all operations that deviate from the accepted Engineered Drawings. If a deviation is necessary, prepare revised Engineering Drawings as noted above and furnish the Engineer a copy of revised Engineering Drawings. Do not begin work until the revised drawings are accepted by the Engineer. Maintain the in -place inspection access equipment employed duri ng original painting activities or provide alternate inspection equipment such as platform lifts, bucket trucks, snooper trucks, or equivalent as approved by the Engineer. If scaffolding, or any hanger attached to the scaffolding, is supported by horizontal wire ropes, or if scaffolding is directly under the surface to be painted, comply with the following requirements:

two guardrails on all sides of the scaffolding. Place one guardrail at 42 inches (1067 mm) above the scaffolding and the other guardrail at 20 inches (508 mm) above the scaffolding.

the surface to be painted, place one guardrail on all sides of the scaffolding at 20 inches (508 mm) above the scaffolding.

guardrail at 42 inches (1067 mm) above the scaffolding and the other guardrail at 20 inches (508 mm) above scaffolding.

wide if guardrail is not used and scaffolding is suspended less than 21 inches (533 mm) below the surface to be painted. If using two or more parallel scaffolding to achieve the proper width, rigidly attach the scaffolding together to prevent differential movement.

objects such as nails, screws, and bolts. Provide a properly located opening in the guardrail to allow the Engineer and inspector access onto the scaffolding.

pipe with a nominal diameter of at least 1 1/2 inches (38 mm). If using steel angle railing, provide 2  2  3/8-inch (50  50  9 mm) steel angles or other metal shapes of equal or greater strength. If using wood railing, provide 2  4 inch (50  100 mm) nominal stock. Space uprights no more than 8 feet (2.4

scaffolding is supported from the structure being painted, provide a safety harness (not a safety belt) and lifeline for the Engineer and inspector. The lifeline shall not allow a fall greater than 6 feet (1.8 m). Provide a method to attach the lifeline to the structure that is independent of the scaffolding, cables, and brackets supporting the scaffolding.

equipment to attach the ladder onto the scaffolding capable of supporting 250 pounds (113 kg) with a safety factor of at least four. uniformly space rungs, steps, cleats, and treads no more than 12 inches (305 mm) on center. Extend at least one side rail at least 36 inches (914 mm) above the landing near the top of the ladder. 385

provide an additional landing that is capable of supporting a minimum of 1000 pounds (454 kg) and at least 24 inches (610 mm) wide and 24 inches (610 mm) lon g. Size and shape the landing so that the distance from the landing to the point where the scaffolding is accessed does not exceed 12 inches (305 mm). Firmly attach the landing to the ladder; however, do not use the ladder to support the landing.

ordinances, regulations, orders, and decrees.

514.11Job Site Visual Standards. Before starting abrasive blasting, establish job site visual

standards by preparing a test section, subsequent test sections, and by using photographs of approved test sections. Use job site visual standards and SSPC-VIS 1 standard for blasting. The Contractor or fabricator shall prepare an approximately 20 to 30 square foot (2 to 3 m²) test section from a representative area on the first structure to be painted. After the Engineer or Inspector and the Contractor or fabricator agree the test area was blast cleaned to the requirements of the Contract Documents, photograph the test section and check the steel surface for the proper profile. After the Engineer or Inspector approves the test section and the job site visual standards are documented by photographs and replica tape, the Contractor or fabricator may start abrasive blasting. The quality control specialists and Engineer or Inspector will use the job site visual standards (photographs), the Plan, Specification and requirements to determine acceptance of blast cleaning procedures. In all cases of dispute, the SSPC-VIS 1 standard shall govern. If the Contractor, Engineer, Inspector, or fabricator believe the initial test section does not establish the proper visual standard for a different structure another test section on the different structure may be performed.

514.12Quality Control Point Photographic Verification and Documentation. The Engineer

or Inspector will take a sufficient number of photographs to document the condition of the work at Quality Control Points 3, 4 and 11.

514.13Surface Preparation

oil, grease, asphalt cement, diesel fuel deposits, other petroleum products and contaminants.

all beams and girders to a radius of 1/8 ±1/16 inch (3 ±1.5 mm). This work has no weather and temperature restrictions. For shop painted steel, ground the sides of thermally cut material 1 ½ inch (40 mm) or thicker to remove the heat effected zone, as necessary, to achieve the specified surface cleaning.

or diesel fuel deposits. Before abrasive blasting, completely remove all dirt, sand, bird nests, bird droppings, and other debris from the scuppers, bulb angles, and pier and abutment seats. Abrasive blast all steel to be painted according to SSPC -SP 10 and as shown on the pictorial surface preparation standards for painting steel surfaces shown in SSPC-VIS 1. Maintain steel in a blast cleaned condition until it has received a prime coat of paint. The Contractor may commercial blast clean the back side of end cross frame assemblies that are 3 inches (75 mm) or closer to backwalls according to SSPC-SP 6. Cover and protect galvanized and metalized steel (including corrugated steel bridge flooring), adjacent concrete already or specified to be coated or sealed, and other surfaces not intended to be painted, from damage caused by blasting and painting operati ons. Repair adjacent coatings damaged 386 during the blasting operation. Backwalls and bottoms of decks not sealed nor specified to be sealed do not need to be covered and protected. For field blasting use a recyclable steel grit, recyclable amorphous metal oxides or a recyclable natural mineral, low dusting abrasive. Recycled glass abrasives with no beryllium and no more than 0.5 percent free silica will be allowed on small areas with less than 1000 square feet of field blasting on a structure. Do not use silica sands, mineral slags, and other types of non -metallic abrasives that contain more than 0.5 percent free silica, by weight, have a chlorides salts content more than 25 ppm, and contain any organic material. For shop blasting use an abrasive that produces an angular profile. All abrasives shall provide a profile from 1.5 to 3.5 mils as determined by replica tape according to ASTM D4417, Method C. Adjust the abrasive size, blast hose nozzle pressure or other means in order to provide the 1.5 to 3.5 mil profile. Clean the abrasive of paint chips, rust, mill scale, and other foreign material after each use and before each reuse. Use eq uipment specifically designed for cleaning the abrasive. Check abrasives used at the job site or fabrication shop for oil contamination at the beginning of each shift and at 4 -hour intervals. Also check each load of abrasive delivered to the job site or fabrication shop for oil contamination before use. Check for oil by placing a small sample of abrasives and tap water into a jar. Reject the abrasive if an oil film is detected on the water surface. To ensure that the compressed air is not contaminated, the quality control specialists shall blow air from the nozzle for 30 seconds onto a white cloth or blotter held in a rigid frame. If the cloth or blotter retains oil or other contaminants, suspend abr asive blasting until retests verify the problem was corrected. Perform this test at the start of each shift and at 4-hour intervals. The Contractor may simultaneously abrasive blast and paint the same bridge provided the abrasive blasting debris and dust does not contact freshly painted surfaces and does not contaminate paint during the curing period. For shop blasting, the fabricator may simultaneou sly abrasive blast and paint if the two operations are separated by distance or containment that prevents paint contamination. For surface preparation of new structural steel in the fabricator’s shop, the quality control specialist shall take replica tape readings as follows:

member per shift. These tests shall consist of taking five random readings per member.

taking five readings at random locations.

The test of a secondary member consists of taking one random reading. Remove abrasives and residue from all surfaces to be painted. Keep all structural steel that was blast cleaned in the field or the fabricator’s shop dust free. Apply a prime coat to steel that was blast cleaned in the field within 12 hours of the beginning of the abrasive blasting operation. Apply a prime coat to structural steel that was blast cleaned in the fabricator’s shop within 24 hours of the beginning of the abrasive blasting operation. If a prime coat is not applied within the times stated above, r eblast the steel before applying the prime coat. Remove all dust or abrasives from adjacent work and from the finish coat. Provide the Engineer and Inspector with field wash facilities and an adequate supply of running potable water, soap, and towels for washing face and hands during the surface preparation operation. Properly contain, test, and dispose of the wastewater. Locate a wash facility at each bridge site and in an area that will not be contaminated by the blasting debris. 387

operations in the field is a solid waste and may be a hazardous waste. Contain, collect, store, evaluate, and properly dispose of the waste material. Comply with all Federal, State, and local environmental protection laws, regulations, and ordinances including, but not limited to, air quality, waste containment, and waste removal. The Contractor is advised that various governmental bodies are involved with solid waste and hazardous waste disposal and the Contractor is responsible for complying with laws enforced by the various governmental bodies. To prevent contamination of the pavement or soil, park all equipment on ground covers free of cuts, tears, and holes. Clean equipment of spent abrasives or debris before bringing equipment to the project, moving equipment from one bridge site to another, and removing equipment from the project. Store debris cleaned from equipment with the debris from the structure that generated the debris. Erect an enclosure to completely surround (around, under and over the top on truss type bridges) the blasting operations. The Contractor may use the ground as the bottom of the enclosure if the ground is completely covered with plastic or tarps. Construct the enclosure of flexible materials such as tarpaulins (specifically designed for blasting containments), or construct the enclosure of rigid materials such as plywood. Maintain all materials free of tears, cuts, and holes. Overlap all seams a minimum of 6 inches (150 mm) and fasten the seams together at 12-inch (300 mm) centers or in a manner that ensures a seal that does not allow openings between the edges of the containment material. Extend the vertical sides of the enclosure completely up to the bottom of the deck on a steel beam bridge and use bulkheads between beams to enclose the blasting area. Collect all debris from blasting operations, equipment, or filters, and all debris that fell to the ground. Store the debris in steel containers/drums with lids that are locked at the end of each workday. Store the debris in these locked drums while in the storage location and when hauled from the storage location to the disposal site. The storage location shall be at the bridge site unless, the Engineer and Contractor agree on an alternate storage location. Secure the storage location by surrounding the site with a 5 foot (1.5 m) high dumpster or a 5 foot (1.5 m) high chain link fence fabric supported by traffic sign drive posts 10 feet (3 m) apart. Drive the traffics ignposts into the ground at least 2 feet (0.6 m) deep. Secure the dumpster or fencing with padlocks at the end of each day. The location of centralized cleaning stations for recyclable steel shall also be agreed by the Engineer and the Contractor. Test and evaluate the debris for disposal. Obtain the services of a testing laboratory to obtain directly from the project site and evaluate a composite representative sample of the abrasive blasting debris for each bridge site. The person taking the sample must be an employee of the testing laboratory. Take composite sample in the presence of the Engineer or Inspector, comply with the requirements of U.S. EPA Publication SW 846 and take individual samples from all containers that are on the site at the time of the sampling. Blend individual samples of equal size together to comprise one composite sample. Take one individual sample from each drum and four randomly spaced individuals amples from each container other than drums. Take individual samples and place into clean glass or plastic containers. Prepare a chain of custody record (Chain of Custody) for all composite samples. The Chain of Custody must include the name of the person taking the sample, the name of the testing laboratory for which the person works, the date and time the sample was take n, the bridge sampled, the Township and Municipality where the bridge is located, and the signatures and dates of all persons in possession of the sample in the Chain of Custody. 388 Sample the abrasive blasting debris within the first week of production blasting at each bridge. Cease all blasting and painting operations on the bridge from which waste was generated, if sampling is not performed within the first week of production blasting. Test composite samples for lead, chromium, cadmium and arsenic according to the U.S. EPA Publication SW 846 Method 1311 (TCLP). Provide the Chain of Custody and test results to the District Regulated Waste Engineer (DRWE) immediately after the test results are available. If the DRWE determines the blasting debris is hazardous, as defined below, provide the Engineer with the names of the hauler and treatment facility. Perform all sampling and testing required by the hauler, treatment facility, or disposal facility. The existing paint removed from bridges may contain lead, chromium, cadmium or arsenic. The Contractor is responsible for taking the proper safety precautions to ensure workers in this environment are properly protected.

exceed any of the regulatory concentration limits shown below: SW 846 Analyte Regulatory Concentration Limit Lead 5.0 mg/l Chromium 5.0 mg/l Arsenic 5.0 mg/l Cadmium 1.0 mg/l Label all the containers of hazardous blasting debris “HAZARDOUS”. Post hazardous waste warning signs at obvious locations on the fenced enclosure. The Office of Construction Administration will obtain a generator number assigned to the State. After the Office of Construction Administration obtains the generator number, arrange for the hauling, treating, and disposing of the hazardous waste. Use a firm licensed by EPA to haul and dispose of the hazardous waste. This firm is also responsible for providing the completed Uniform Hazardous Waste Manifest (EPA Form 8700-22, or current version). In every case, properly dispose of all hazardous waste within 60 days after it is generated. If hazardous waste is not properly disposed of within 60 days, the Department will consider the Contactor in breach of its Contract and the Department will take the following actions:

until hazardous waste is properly disposed.

The Contractor is responsible for fines or liens assessed by any governmental agency that has jurisdiction over the disposal of this hazardous waste material. Decontaminate or dispose of all collection and containment equipment according to EPA guidelines. The Contractor shall inform the Department when all hazardous waste has been removed from the Project so the EPA Site ID Number (Hazardous Waste Generator Number) can be deactivated.

Waste by the DRWE, the Contractor is required to: 389

disposal facility is licensed by the EPA to accept non-hazardous solid waste.

disposal of waste material at the licensed disposal facility.

514.14Washing Shop Primer (QCP #7). Wash shop primed structural steel after it is erected

and the concrete deck is placed and within 30 days of applying the intermediate coat. Wash the steel with potable water. Use equipment capable of delivering the water at a nozzle pressure of at least 1000 pounds per square inch (7 MPa) and at a rate of not less than 4 gallons (15 L) per minute. The Contractor shall provide the Engineer with equipment specifications that verify both the delivery pressure and rate. Provide gauges on the equipment to verify the pressure during operation. Hold the nozzle a maximum of 12 inches (300 mm) from the surface being washed. The surface is clean when clear rinse water runs off the structure. After rinsing the surface, inspect for remaining dirt and rewash dirty areas until clean.

514.15Handling. Deliver all paint and thinner in original unopened containers with labels intact

The Engineer or Inspector will accept containers with minor damage provided the container is not punctured. Thinner containers shall be a maximum of 5 gallons (19 L). Before use, provide the Engineer with shipping invoices for all painting materials used on the Project. Supply containers of paint and thinner with labels clearly marked by the manufacturer to show paint identification, component, color, lot number, stock number, date of manufacture, and information and warnings as may be required by Federal and State laws. Store paint at the temperature recommended by the manufacturer and in a storage facility that prevents theft. Provide thermometers capable of monitoring the maximum high and low temperatures inside the storage facility. Before opening paint or thinner containers, check the labels to ensure the proper container is opened and the paint has not been stored beyond its shelf life. Do not use paint that exceeded its shelf life. Do not open containers of paint and thinner until required for use and then open the oldest paint of each kind first. Solvent used for cleaning equipment is exempt from the above requirements. Do not use paint that has livered, gelled, or otherwise deteriorated during storage. Properly dispose of unused paint and paint containers.

514.16Mixing and Thinning. Thoroughly mix all ingredients immediately before use with a

high shear mixer (such as a Jiffy Mixer). Do not mix paint using paddle mixers, paint shakers, or an air stream bubbling under the paint surface. After mixing, carefully examine the paint for un iformity and to ensure that no unmixed pigments remain on the bottom of the container. Before use, strain the paint through strainers that remove skins or undesirable matter but not pigment. Except for primer, mix paint as necessary during application to maintain a uniform composition. Continuously mix primer using an automated agitation system. Do not use hand-held mixers for primer paints. Do not add thinner to the paint without the Engineer’s or Inspector’s approval, and only add thinner if necessary for proper application as recommended by the manufacturer’s printed instructions. In the Engineer’s or Inspector’s presence, slowly add the amount of thinner recommended and supplied by the manufacturer to the paint during the mixing process. Do not mix other additives into the paint. 390 Add catalysts, curing agents, or hardeners that are in separate packages to the base paint only after thoroughly mixing the base paint. With constant agitation, slowly pour the proper volume of catalyst into the required volume of base. Do not pour off liq uid that has separated from the pigment before mixing. Use the mixture within the pot life specified by the manufacturer and dispose of unused portions at the end of each workday.

514.17Coating Application

exposed steel piling, drain troughs, and other areas as shown on the plans. Paint galvanized or metalized surfaces if shown on the plans. Unless otherwise shown on the plans or specified below, apply paint to provide the specified coating thickness by brush and spray methods. Apply primer and intermediate paint per 708.01 and 708.02 to cover all visible steel surfaces. If gaps or crevices remain between adjacent coated steel surfaces after applying the intermediate coat, caulk according to 514.19. If brush and spray are not practical to paint places of difficult access, the Contractor may use daubers, small diameter rollers, or sheepskins. Use daubers, small diameter rollers, or sheepskins to paint the following areas:

beam seat.

intermediate, and final coats. If the Engineer or Inspector discovers defects, adjust the method of application to eliminate the defects then continue applying the coat.

structural steel surfaces except for the top surface of steel beams and girders by brush or spray methods, including insides of holes, behind stiffener clips, areas that are to be embedded in concrete and contact surfaces of connection, and splice material that is to be fastened with bolts in the shop or field. Apply a mist coating from 0.5 to 1.5 mils on the top surface of steel beams and girders. For ASTM A709 Grade 50W and 70W steel embedded in concrete diaphragms, apply a prime coat to the entire surface area encased within the diaphragm and extending at least 12 -in outside the diaphragm. Apply a mist coating from 0.5 to 1.5 mils on surfaces within 2 inches o f field welds other than those attaching intermediate or end cross frames to beams or girders. Apply one coat of primer to pins, pin holes, and contact surfaces of bearing assemblies, except do not paint those containing self -lubricating bronze inserts. Once the prime coat is dry, apply erection marks, using a thinned paint of a type and color that is completely concealed by, and compatible, with the second coat. Do not handle or remove coated structural steel from the shop until the applied paint has met the requirements as specified by the paint manufacturer’s printed instructions. Reduce the thickness of thick films of inorganic zinc primer by screening, sanding, or sweep blasting. If the primer paint cured longer than 24 hours, apply a re-coating of primer paint according to the paint manufacturer’s printed instructions. Abrasive b last and re -apply the primer to the affected area if “mud cracking” occurs. If “checking” occurs, abrasive blast and reapply the primer or remove the “checking” by screening and evaluate the area by adhesion testing. If specified in the plans,furnish all necessary labor, materials and equipment to apply a three - coat paint system to Item 513 Structural Steel in the shop and touch up areas in the field. 391 Repair damage to the paint system caused during storage, transportation, erection, bolting, welding, forming, concrete placement, and form removal operation, according to C&MS section

514.22. Repair damage to the galvanized coating on the nuts, bolts and washers, in the field due to the

bolt tightening or welding operations. Exercise extreme care while handling the steel during erection, and during subsequent construction of the bridge. Insulate the steel from the binding chains by softeners and pad all hooks and slings that are used to hoist/erect the steel members. Coating of Bolted Faying Surfaces Treat the surfaces indicated below as described in this specification

Coat the faying surfaces of bolted splices with inorganic zinc primer in the shop. After erection is complete, field apply the final coatings of epoxy intermediate coat and urethane protective coats to overlap the shop coatings shown in Figure 1 with the f ield coats shown in Figure 2. For bolted crossframes, leave a minimum of one inch step back from faying surfaces, for epoxy intermediate and an additional one inch for urethane top coat. Remove and reassemble all shop bolted connections and shop bolted cross frames prior to the blasting and coating of the girders or beams. Separately blast and prime the parts, then reassemble and fully tighten the bolts using the turn of the nut method. After bolting is complete, shop apply the epoxy intermediate and urethane protective coats. 392 After installation, solvent clean all galvanized nuts, bolts, and washers. Remove any contaminants on the nuts, bolts and washers, prior to the application of paint. Repair any damaged galvanized coating and remove any corrosion prior to the application of organic zinc by brush. Then apply the epoxy coat and the urethane coats. Erection marks added by the fabricator to highlight or enhance the required steel stamped erection marks must be made without damaging the paint system. Apply Erection marks only after the finish coat is cured and remove at the end of the project. Erection marks may be applied to the faying surfaces. These marks to the inorganic coating need not be removed but must be of a paint supplied by the IZEU system manufacture. Remove any oil, grease, asphalt cement, concrete or other contaminants from the surface of the IZEU system painted structural steel.

overspray, and other contaminants. If the surface is degraded or contaminated, restore the surface before applying paint. In order to prevent or minimize degradation or contamination of cleaned surfaces in the field, the prime coat of paint shall be applied within 12 hours of the beginning of the abrasive blasting operation as required in surface preparation above, for steel which is cleaned and painted in the shop, the prime c oat of paint shall be applied within 24 hours of the beginning of the blasting operation. Schedule cleaning and painting when dust or other contaminants will not fall on wet, newly painted surfaces. Protect surfaces that do not receive paint or have already been painted from the effects of cleaning and painting operations. Before applying the next coat, remove overspray and bird droppings with a stiff bristle brush, wire screen, or a water wash with sufficient pressure to remove overspray and bird droppings without damaging the paint. Before applying the next coat, remove all abrasives and residue from painted surfaces with a vacuum system equipped with a brush type cleaning tool. Remove all visible abrasives on the finish coat that came from adjacent work.

stripe coats using brushes, daubers, small diameter rollers or sheepskins to all edges, outside corners, crevices, welds, rivets, bolts, nuts and washers in addition to the spray app lication of each individual coating. Apply stripe coat of organic zinc primer and intermediate coat either before or after spray application of respective coats. Tint intermediate stripe coats another color that is applied after spray application. Apply stripe coats of the finish coats before spray application of the finish coats. Apply additional paint as necessary to produce the required coating thickness. 393

Keep spray equipment clean so that dirt, dried paint, solvents, and other foreign materials are not deposited in the paint film. Remove solvent left in the equipment before using the equipment. Apply paint in a uniform layer with overlapping at the edges of the spray pattern. Paint the border of the spray pattern first, followed by painting the interior of the spray pattern. Complete painting a spray pattern before moving to the next spray pattern area. Within a spray pattern area, hold the gun perpendicular to the surface and at a distance that will ensure a wet layer of paint is deposited on the surface. Release the trigger of the gun at the end of each stroke. Each spray operator shall demonstrate to the Engineer or inspector the ability to apply the paint as specified before the operator sprays paint. If mud cracking occurs, the affected area shall be cleaned to bare metal in accordance with surface preparation above and repainted. Use spray equipment recommended by the paint manufacturer and suitable for use with the specified paint. Provide adequately sized traps or separators to remove oil and condensed water from the air. Periodically drain the traps during operations. To ensure that the traps or separators are working properly, test by blowing air from the spray gun for 30 seconds onto a white cloth or blotter held in a rigid frame. The Engineer or Inspector will verify the test results by inspecting the white cloth or blotter. If the cloth or blotter retains oil, water, or other contaminants, suspend painting until retests verify the problem was corrected. Perform this test at the start of each shift and at 4-hour intervals. This is not required for an airless sprayer. Do not use spray application unless the operation is totally enclosed as required for abrasive blasting, to prevent overspray damage to the ground, public and private property, vegetation, streams, lakes, and other surfaces not to be painted.

continuous film of uniform thickness, free of all defects such as holidays, pin holes, mud cracking, checking, drips, runs, and sags. The Contractor is responsible for applying the manufacturer’s paint as necessary to satisfy the above requirement. Repaint all thin spots or areas missed before the next coat of paint is applied. Ensure that the paint manufacturer’s printed instructions for the minimum times to handle, recoat and cure the individual coats for specified conditions and thicknesses are followed for each coat of paint before applying the next coat. Comply with the manu facturer’s written instructions for the time interval between coats and apply the next coat when an additional coat will not cause detrimental film irregularities, such as lifting, wrinkling, or loss of adhesion of the undercoat. Do not exceed the following time intervals. If the prime coat is organic zinc, the maximum time between the prime and intermediate coats is 30 days. There is no maximum time between the prime and intermediate coats for an inorganic zinc primer. The maximum time interval between intermediate and finish coats is 13 days. These maximum recoat times include adverse weather days and the Engineer will not extend the times. The recoat windows begin with the initial application of each coating type inclusive of stripe coats. Additional applications of the same coat do not reset the recoat windows. The time interval ends with the application of the next full coat. The stripe coat does not end the time interval. If the next type of coating is not applied within the times stated above, remove the coatings and re-blast the steel according to SSPC-SP 10. If requested by the engineer, perform one or both of the following test to determine the hardness and or the adhesion of an individual coating or the coating system:

Hardness Test according to ASTM D3363. Meet or exceed scale of hardness HB for the coating. 394

adhesion between coats or between the paint system and the substrate, or 400 psi cohesion within paint coats. Stencil the Completion Date (month and year) of the finish coat and the letters of the applied paint system on the steel in 4 inch (100 mm) letters with black urethane paint. The appropriate letters for the paint systems are as follows: System Comprised of Letters Inorganic zinc prime coat, epoxy intermediate coat, and urethane finish coat IZEU Organic zinc prime coat, epoxy intermediate coat, and urethane finish coat OZEU Apply the date and paint system at four locations near the end of each outside beam on the outside web visible from the road or as directed by the Engineer.

514.18Removing Fins, Tears, or Slivers (QCP #6). Use a grinder to remove all fins, tears,

slivers, or any other burred or sharp edges that become evident after applying the prime coat. Retexture ground surfaces to produce a profile from 1.5 to 3.5 mils (40 to 90 μm) and reprime ground surfaces before applying the intermediate coat. The Contractor may begin removing fins, tears, and slivers after blasting and before priming. Temperature and weather restrictions do not apply to removing fins, tears, and slivers, but do to applying the prime coat.

514.19Caulking (QCP #9). After the intermediate coat cures and before applying the finish coat,

caulk gaps or crevices up to 1/2 inch (13 mm) wide. Follow the manufacturer’s recommendations for curing before applying the finish coat.

514.20Dry Film Thickness (QCP #5, #8, and #10). Determine prime coat thickness; prime and

intermediate coat thickness; and prime, intermediate, and finish coat thickness using a Type 2 magnetic gage as follows: Measure paint thickness at separate, evenly spaced, spot measurement locations over each 100 square feet (9 m²) of area of structural steel. Locate five spot measurements on each of the following locations: top flanges; bottom flanges; webs; cross bracing; stiffeners; etc. At each spot location, take three gage readings of either the substrate or the paint. Move the probe 1 to 3 inches (25 to 75 mm) for each new gage reading. Discard an unusually high or low gage reading that is not consistently repeated. The spot thickness measurement is the average of the three gage readings. The average of five spot measurements for each location in the 100 square foot (9 m²) area shall not be less than the specified thickness. No single spot measurement area shall be less than 80 percent of the specified minimum thickness nor greater than 150 percent of the maximum specified thickness when organic zinc is applied and 120 percent of the maximum specified thickness when inorganic zinc is applied. Any one of three readings which are averaged to produce each spot measurement, may under run or overrun by a greater amount. Take five spot measurements per location for each 100 square foot (9 m²) area as follows:

foot (9 m2) area within each 300 square foot (27 m²) unit of surface area that is painted.

area. 395

three 100 square foot (9 m²) areas.

m²) as stated in section C and for each additional 1000 square feet (90 m²), or increment thereof, randomly select and then measure one 100 square foot (9 m²) area.

with the requirements of this subsection, then measure each 100 square foot (9 m²) area.

Each coat of paint shall have the following thickness measured above the peaks: Min. Spec. Thickness Max. Spec. Thickness Min. Spot Thickness Max. Spot Thickness (Inorganic Zn) Max. Spot Thickness (Organic Zn) Prime 3.0 mils (75 µm) 5.0 mils (125 µm) 2.4 mils (60 µm) 6.0 mils (150 µm) 7.5 mils (188 µm) Intermediate 5.0 mils (125 µm) 7.0 mils (175 µm) 4.0 mils (100 µm) 10.5 mils (263 µm) 10.5 mils (263 µm) Subtotal 8.0 mils (200 µm) 12.0 mils (300 µm) 6.4 mils (160 µm) 16.5 mils (413 µm) 18.0 mils (450 µm) Finish 2.0 mils (50 µm) 4.0 mils (100 µm) 1.6 mils (40 µm) 6.0 mils (150 µm) 6.0 mils (150 µm) Total 10.0 mils (250 µm) 16.0 mils (400 µm) 8.0 mils (200 µm) 22.5 mils (563 µm) 24.0 mils (600 µm) Remove paint with a film thickness greater than the maximum specified thickness unless: The paint does not exhibit defects such as runs, sags, bubbles, or mud cracking, etc. The manufacturer provides a written statement to the Engineer that the excessive thickness is not detrimental. For any spot or average of five spots at any location of a 100 square foot (9 m²) area that exceeds the maximum spot thickness, either remove and replace the coating according to 514.22 or prove to the Office of Construction Administration that the excess thickness will not be detrimental to the coating system. In order to prove to the Office of Construction Administration that the excess thickness will not be detrimental to the coating system, the Contractor must provide the Office of Construction Administration with the following information. Certified test data proving that the excessive thickness will adequately bond to the steel when subjected to thermal expansion and contraction. The thermal expansion and contraction test shall take place over five cycles of a temperature range from -20 to 120 °F ( -49 to 49 °C). After the thermal contraction and expansion cycles have taken place, the tested system shall be subjected to pull off tests and the results compared to the results of pull off tests that have been performed on a paint system with the proper thicknesses. Perform the adhesion tests according to ASTM D4541 Type IV. Document the preparation methods for the panels, including profile and level of cleanliness. Document the application methods, conditions and if any thinner, (percentage), was used. Test the panels according to the following: 396

Document the type of adhesive.

the primer-substrate interface or pressure at failure is less than 400 pounds per square inch (2.8 MPa).

etc. have been applied including the adhesive Y which secures the dolly Z to the topcoat.

percent of each.

and the percent of each. In addition to the certified test results, the Contractor shall provide the Office of Construction Administration a written statement from the paint manufacturer stating that the excessive thickness is not detrimental. If the Office of Construction Administration does not approve the excessive coating thicknesses or the Contractor elects not to provide the required written statement from the paint manufacturer and the certified test results when required, the Contractor shall remove and replace the coating. The removal and replacement of the coating shall be done as specified in 514.22.

514.21Final Inspection

dry film thickness. For all structures in which the supporting members are rolled beams or girders, remove a minimum of one location per 300 linear feet of beam line for webs and flanges and 2.5 percent of all cross frame assemblies and other secondary structural members shall be selected for destructive testing. For all other bridge types with structural steel, remove one location for every 2400 square feet of steel surfac e for destructive testing. Do not perform destructive testing on areas that have been painted with an inorganic zinc prime coat.

magnetic gage. If the dry film thickness for that spot does not meet the requirements of 514.20, additional measurements will be taken to determine the extent of the deficient coatings.

inches (58 cm²) of the new coatings by methods that will not damage the surface of the steel. Approved removal methods are scraping, sanding, or the use of solvents. Do not use power tools. Perform removal while in the presence of the Engineer. The Engineer will document and photograph the selected areas after removal of the new coatings. If work is found not to be in conformance with the specifications and pertinent contract documents, additional locations may be selected for testing.

be deficient. Make repairs according to 514.22. If the final destructive testing according to 514.21.C, reveals greater than 15 percent of the areas inspected are not in complete conformance with the specifications and pertinent contract documents, the Department will require that surface preparation and painting of the structural steel be completely redon e to meet the requirements of the Contract Documents at no additional cost to the Department. 397

film thickness measurements obtained from the final inspection. Final Acceptance will also take into consideration acceptable progressive project documentation and progressive field measurements in determining the final acceptability of the Bridge Paint System. Inspection access to the test locations to perform the required final inspection measurements shall conform to the requirements of 514.10.

Repair Procedures. Remove paint and correct defects or damaged areas, including areas

damaged by welding, and in areas that do not comply with the requirements of this specification. Correct defects and damaged areas using the same paint as originally applied except the Engineer may approve using organic zinc to repair inorganic zinc in the field. Retexture the steel to a near white condition and a profile between 1.5 to 3.5 mils (40 to 90 μm). Measure the profile immediately before applying the prime coat to ensure the profile i s not destroyed during the feathering procedure. See

Feather the existing paint to expose a minimum of 1/2 inch (13 mm) of each coat. During the reapplication of the paint, apply paint as follows:

feathering. Do not apply the prime coat to the adjacent intermediate coat.

by feathering. Do not apply the intermediate coat to the adjacent finish coat.

feathered or lightly sanded. Do not apply the finish coat beyond areas that were feathered or lightly sanded. At the perimeter of the repair area, apply the prime and intermediate coats using a brush. Apply the finish coat using either brush or spray. The Contractor may need to apply several applications to obtain the proper thickness for each coat. During the application of the prime coat, the paint shall be continuously mixed. Perform all surface preparation and painting according to this specification. Instead of abrasive blasting, the Engineer may allow alternate methods of preparing the surface. Blend repair areas with the adjacent coating and provide a finished surface in the patched areas that is smooth and has an even profile with the adjacent surface. Submit, in writing, the method of correcting areas with runs to the Office of Construction Administration for approval.

514.23Method of Measurement. The Department will measure Surface Preparation of Existing

Structural Steel and Field Painting of Existing Structural Steel Prime Coat by the number of square feet (square meters) of structural steel painted or on a lump sum basis. The Department will measure Field Painting Structural Steel, Intermediate Coat and Field. Painting Structural Steel, Finish Coat by the number of square feet (square meters) or pounds (kilograms) of structural steel painted, or on a lump sum basis. The Department will determine the number of pounds (kilograms) of new structural steel painted by the accepted pay weight of the new structural steel. For steel beam and steel girder bridges, the Department will determine the surface area by taking a nominal measurement of the beams (i.e., two times the beam depth plus three times the flange width). 398 In addition to this nominal measurement, the Department will add a percentage to account for incidentals such as cross frames, bearing assemblies, stiffeners, expansion joints, scuppers, etc. It is not necessary for the Engineer or Inspector to field measure every detail of the bridge to verify quantities. If there is a quantity dispute, exact field measurements of all painted surfaces and calculations will govern over the above percentage to account for incidentals. For extremely complex bridges, such as trusses, the Department will pay for painting on a lump sum basis. The Department will measure grinding fins, tears, slivers on existing structural steel by the number of man hours expended by the workers actually doing the grinding and will include the time when the workers are performing grinding and repairing prime coa t and not limited to only the actual grinding duration (i.e., the Department will include all hours of the workers when assigned to grinding regardless of actual grinding time). The Department will not measure grinding fins, tears, and slivers on new steel but will consider it incidental to unit price for the new steel.

514.24Basis of Payment. The Department will pay for accepted quantities at the Contract prices

as follows: The Department may consider paint as eligible for payment for material on -hand as specified in

109.10, however, only paint that the Contractor can prove to the Engineer will be used during the

construction season is eligible for payment. The Contractor shall provide the Engineer calculations indicating the total square feet (square meter) of steel to be painted during the construction season. The Contractor shall also provide calculations showing the total number of gallons (liters) required. If the Contractor causes damage or injury to public or private property, the Department will not pay for restoring the property to its original condition. The Department will not pay for repairing adjacent coatings damaged during the blasting operation. The Department will not pay for removing and replacing an area of coating because a spot or maximum average thickness exceeds the maximum spot thickness. The Department will not pay for additional testing required by any hauler, treatment facility, disposal facility or landfill. The Department will pay for caulking under Field Painting Structural Steel, Intermediate Coat. The Department will pay for final inspection access, test area preparation and test area repair at each selected area under Final Inspection Repair. The Department will not pay for accessing, inspecting, and repairing areas that are not found to be in conformance with the specifications and pertinent contract documents. All other requirements of this specification are considered incidental to the work. Item Unit Description Square Foot Surface Preparation of Existing Structural Steel (Square Meter) Lump Sum Square Foot Field Painting of Existing Structural Steel, Prime Coat (Square Meter) Lump Sum Square Foot Field Painting Structural Steel, Intermediate Coat (Square Meter) 399 Lump Sum, Pound (Kilogram) Square Foot Field Painting Structural Steel, Finish Coat (Square Meter) Lump Sum, Pound (Kilogram) Man Hour Grinding Fins, Tears, Slivers on Existing Structural Steel Each Final Inspection Repair Square Foot Shop Painting and Field Touch-Up of Structural Steel (Square Meter) Lump Sum Pound (Kilogram)