00593.01 605 Section 00593 - Powder Coating Metal Structures
Description
00593.00Scope - This Work consists of preparing and powder coating new metal Structures and
features in the shop, and preparing and C oating existing metal Structures at the Project Site. This includes all:
Interior and exterior steel surfaces Steel railings, bridge bearings, and bridge expansion joint assemblies Other miscellaneous steel Galvanized and aluminum surfaces
00593.01Abbreviations, Definitions, and References :
AAMA - American Architectural Manufacturers Association
DFT - Dry Film Thickness
Cleaning - Removing detrimental material in Preparation for C oating.
Coat - An application, or applications, of a protective material to a substrate , resulting in a layer of specified thickness.
Coating - Protective material after it is applied to a substrate . Coating Material - Protective material in the liquid state before application. Coating System - All specified Coats applied separately in a predetermined order. Maintenance Coating - An additional Coating applied to a previously coated existing Structure to prolong the protective capability of previous C oatings.
Manufacturer's Recommendation - The written specifications and instructions provided by a manufacturer of a Coating Material concerning the handling, mixing, and application of the C oating Material. Preparation - Measures taken to provide a suitable surface ready to coat.
Solvent - Liquid used to solvate or put materials into solution, or to clean Equipment and tools.
Substrate - A surface to which a C oating is to be applied. This may be the prepared surface of the metal Structure or a previous Coating.
Surface Profile - Roughness of a cleaned metal surface. The height of the profile is measured from the bottom of the v alleys to the top of the peaks in mils.
Volume 2, Systems and Specifications , of SSPC's Painting Manual .
00593.03 606 00593.03 Required Submittals :
operations are scheduled to begin, submit a Project -specific powder coating plan for the approval of the Engineer. Include the following:
The name, location, and contact information (mail address, phone, and e-mail) for the firm performing the powder coating operation. Quality assurance and quality control (QA/QC) programs established and followed by the firm performing the powder coating operation. A product data sheet and material safety data sheet of each type of C oating Material to be used, including the products to be used for field repair of damaged areas. A description of the Cleaning, surface preparation, pre- heating, application, curing, shop and field coating repair, handling, and storage processes to be followed for Structures and items to be coated. A letter from the firm performing galvanizing, if other than the Contractor, certifying that neither water quenching nor a chromate conversion coating will be used on the surfaces that are to be powder coated. Do not begin Preparation or C oating Work before the p owder coating plan has been approved.
and coating operations are scheduled to begin, submit a manufacturer's certification stating that each Coating Material in the C oating System:
Meets the requirements of this Section. Meets the specifications of the manuf acturer's data sheets. Is compatible, including Coating repair M aterials.
Materials
00593.10Coating Materials - Furnish Coating Materials meeting the requirements of the
Specifications and the applicable portions of SSPC PA 1, Shop, Field and Maintenance Painting , when not in conflict with the Specifications .
epoxy primer and a polyester topcoat , conforming to the following: Test Test Method Limit or Value Adhesion ASTM D3359, Method B B5 (no failure) Flexibility ASTM D522, Method B Pass 1/4" Mandrel Bend Pencil Hardness ASTM D3363 H Plus Specific Gravity ASTM D792 2.30 minimum Zinc in Dry Film Calculated Weight 50% minimum
galvanized and non-steel metallic substrates consisting of an epoxy primer and polyester topcoat , conforming to the following:
00593.41 607 Test Test Method Limit or Value Adhesion ASTM D3359, Method B B5 (no failure) Flexibility ASTM D522, Method B Pass 1/8" Mandrel Bend Pencil Hardness ASTM D3363 H Plus Specific Gravity ASTM D792 1.25 minimum
Architectural Manufacturers Association (AAMA) Specification 2604.
SAE AMS-STD -595 col or #20059 for weathering steel SAE AMS-STD -595 color #24272 for ODOT Green SAE AMS-STD -595 color #26357 for miscellaneous metal on concrete Bridges concrete gray SAE AMS-STD -595 color #27038 for black
bolted joints using high strength bolts shall conform to Class B (slip coefficient of 0.5) Coating requirements in Test Method to Determine the Slip Coefficient for Coatings Used in Bolted Joints , as adopted by the Research Council on Structural Connections.
00593.11Blasting Abrasives - Provide abrasives that have no corrosion products, water, oil, or any
other material detrimental to the application and adherence of the C oatings . Provide abrasives that conform to SSPC -AB 1. When directed, test cleanliness according to ASTM D7393 and ASTM D4940. Conductivity results from ASTM D4940 shall not exceed 100 microsiemens per centimeter.
00593.12Caulking - Furnish structural steel caulking from the QPL and approved for use by the
Coating manufacturer. Unless the caulking is to be over coated, the caulking color shall be clear or shall approximate the color of the top Coating. Furnish industrial grade polystyrene or polyurethane backing Material of sufficient diameter to fill the crevices or gaps as required.
Obtain the Engineer's approval of the caulking and backing Material before using.
Construction
00593.40General - Structures to be prepared and powder coated include new and existing steel,
galvanized, and non-steel metallic substrates.
00593.41Special Fabrication, Preparation, and Coating :
inaccessible to Preparation or to Coating after fabrication.
Protect from blast -cleaning, powder coatings, overspray, and drippings all contact surfaces within slip-critical joints that are not to be coated. Remove or repair unintended Coatings or other damage on these surfaces to the Engineer's satisfaction at no additional cost to the Agency.
not damaged by welding or fabricating processes.
00593.42 608 Neutralize weld areas and remove smoke stain and spills according to SSPC -SP 1. Remove weld slag and spatter by mechanical means before blast -cleaning. Supplement blast -cleaning by other treatment as recommended by the manufacturer of the C oating System and as required in
00593.42
Do not apply C oatings within 4 inches of the weld before the welding operation is complete.
Preparation of Surfaces:
SSPC -SP 10 / NACE No. 2 Near White Metal Blast Cleaning, except as modified by the Specifications . The appearance of the final blast -cleaned surface shall closely approximate Pictorial Standard SP 10 of SSPC -Vis 1 and have a 1.0 to 2.5 mil profile finish.
ASTM D6386, the approved powder coating plan, and the following:
• Newly Galvanized Steel - Smooth and clean surfaces according to ASTM D6386, Section 5 and prepare surfaces according to ASTM D6386, Section 5.4.1.
• Partially Weathered Galvanized Steel - Check and prepared according to ASTM D6386, Section 6, then smooth and clean surfaces according to ASTM D6386, Section 5, then prepare surfaces according to ASTM D6386, Section 5.4.1.
• Weathered Galvanized Steel - Prepare according to ASTM D6386, Section 7.
of the following methods:
• Solvent clean surfaces to be coated according to SSPC -SP 1, followed by a light brush blast according to SSPC -SP 16 Brush -Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels, and Non-Ferrous Metals with a maximum nozzle pressure of 75 psi. The prepared surface shall have a 1.0 to 2.5 mil profile finish. • Hand sand the surface, creating a minimum 1 mil profile. • Clean the surface according to the Manufacturer’s Recommendations.
edges according to SSPC Paint Application Guide No. 11. Clean all surfaces of material detrimental to the application of the C oating System as follows:
discharge the abrasive:
• A stream of high -pressure air • A rotating centrifugal paddlewheel
Surfaces shall be dry before Cleaning. Use methods specified in SSPC -SP 1, Solvent Cleani ng, SSPC -SP 2, Hand Tool Cleaning , SSPC -SP 3, Power Tool Cleaning, and SSPC -SP 15 Commercial Grade Power Tool Clean, as necessary to augment blast -cleaning.
an angular Surface Profile of at least 1 mil, but not more than 4 mils, as measured according to 00593.43 609 ASTM D4417 using replica tape on the prepared surface. Blast -cleaning shall result in a roughened steel surface comparable to a Keane-Tator Surface Profile Comparator for sand or grit using ASTM D4417. If a centrifugal wheel with a grit mixer is used for blast -cleaning, inspect each member after blast -cleaning, and for those members not meeting the comparator or profile requirements, perform a final blast -clea ning with high- pressure air with an abrasive to obtain the specified profile. Use abrasives conforming to 00593.11. Wet abrasives are allowed if wet sandblasting methods are used.
any other material detrimental to the Coating System. Test compressed air cleanliness daily according to ASTM D4285, or as directed.
required, without damaging partially or entirely completed portions of the Work . Do not blast -clean adjacent to areas being coated. Examine blast -cleaned and pressure washed surfaces for any traces of corrosion, water, oil, grease, soluble salts, and other mater ial deposited during the Cleaning operations. If present, remove any detrimental material by Solvent cleaning and blast -clean the surface again.
• Blowing down prepared surfaces using high -pressure air within the fully enclosed containment, with the specified ventilation operating, and supplemented by brushing if required. • Determining that the prepared surfaces are free of all residues per SSPC -PA 1. • Repairing all damaged galvanizing ac cording to ASTM A780. • Obtaining approval from the Engineer.
00593.43Coating Metal Structures:
according to the following:
• The applicable portions of SSPC -PA 1. The recommendations of the coating manufacturer. The best practices of the trade according to SSPC Painting Manual , Volume 1, Good Painting Practice .
following requirements:
rust, or other substance that would prevent the bond of succeeding applications. Prepare contaminated surfaces to the Engineer 's satisfaction before applying the Coating.
the powder coating Manufacturer's Recommendations, the approved powder coating plan, and the following: 00593.43 610 • Pre-heat surface. • Apply the epoxy primer coat, followed by a partial cure. • Apply the polyester finish coat, followed by the finish cure.
Apply each C oat in a uniform layer, completely covering the preceding coat. Furnish each individual Coat in a sufficiently different shade so that skips and holidays can be easily detected. Correct skips or other deficiencies before application of succeeding coats.
• Primer: 2.5 mils • Topcoat: 2.5 mils
applications as necessary to cover the W ork and achieve the minimum thickness specified. Apply each Coat in suff icient thickness to achieve uniform and complete coverage and appearance. If all thickness measurements are not within the specified minimum dry film thickness, or if the visual inspection does not satisfy the Engineer, make additional applications, as necessary, to meet the thickness and coverage required. Film thickness will be measured above the peaks of the profile of the anchor pattern in the substrate.
The dry film thickness will be measured for acceptance using a Type 2 gauge according to SSPC -PA 2. If a question arises about an individual Coat thickness or coverage, it will be verified using a Tooke gauge, according to ASTM D4138. If the Tooke gauge shows a prime Coat to be less than the specified minimum thickness the total C oating System will be rejected even if the thickness of the total system equals or exceeds the total specified thickness.
the prime coat specified thickness, apply the top coat to at least the minimum required topcoat thickness, to provide uniform and complete coverage and appearance.
visible rust forms.
and gaps between structural shapes and plates, around bolt heads or nuts, and similar areas that would retain moisture with the following:
• Caulk, if the crevice or gap cannot be fille d with C oating Materials. • Backing material and caulk to fill the crevices and gaps that exceed 1/4 inch. Apply caulk over the backing material to form a watertight seal. In areas that collect or channel water, apply caulk even if C oating fills the gap.
F", as warranted or at the direction of the Engineer. Ensure that minimum pull -off strength of 650 psi is achieved for zinc -rich primers and based C oatings, and minimum pull -off strength of 1000 psi is achieved for all other C oatings, including those over a zinc -rich primer. When testing a C oating or Coating System with a DFT of more than 12 mils, score around the test fixture.
00593.45 611 00593.44 Inspecting - Conduct or make arrangements for powder coating tests required in the approved powder coating plan.
Aspects of the Preparation and C oating process to be inspected and tested include, but are not limited to:
Test Test Method Ionic Contamination of Abrasive Material ....................................... ASTM D4940 Cleanness of Compressed Air ........................................................ ASTM D 4285 Pictorial Surface Preparation Standards ....................... SSPC -VIS 1 , 3, 4, and 5 Surface Profile by Keane-Tator Comparator .................................. ASTM D4417 Surface Profile by Replica Tape ..................................................... ASTM D 4417 Hardness ............................................................. AAMA 2604 and ASTM D3363 Dry Film Thickness by Magnetic Gauge ........................... SSPC -PA 2 (modified) Dry Film Thickness by Tooke Gauge ............................................. ASTM D 4138 Pull-off Strength of Coating ............................. ASTM D 4541 (Method D, E, or F) Provide access to the Engineer, at the powder coating facility, to visually inspect the assemblies for the presence of Coating holidays and other unacceptable surface imperfections, and to witness the Coating thickness testing, the hardness testing, and th e adhesion testing. Provide documentation of the QA/QC testing to the Engineer. Assemblies failing these tests will be rejected. Repair and recoat the rejected assemblies as directed. Do not ship assemblies to the Project Site without Engineer's approval. Repair Coating System damages resulting from Agency inspection and testing a t no additional cost to the Agency.
00593.45Protecting Against Damage:
than rust, clean the surface in a manner satisfactory to the Engineer before making the succeeding application. If the prepared surface becomes contaminated by rust, prepare the contaminated area again according to 00593.42 and recoat with all specified coats. Clean, re-prepare and recoat at no additional cost to the Agency.
overspray, and drippings. Remove or repair unintended Coatings or other damage on these surfaces to the Engineer's satisfaction at no additional cost to the Agency.
coated assemblies with multiple layers of bubble wrap or other protective wrapping materials specified in the approved p owder coating plan. During storage and shipping, separate each wrapped assembly with expanded polystyrene spacers and other spacing materials specified in the approved powder coating plan.
After erection, repair marred and damaged coated surfaces due to the Contractor's shipping, storage, handling, and erection operations according to 00593.60.
Repair marred or damaged coated surfaces at no additional cost to the Agency, with the same Materials and to the same condition as specified. At the completion of all Work , the Coating shall be complete and the surfaces undamaged and clean.
00593.60 612 Maintenance
00593.60Repair of Damaged and Unacceptable Coatings - Repair damaged surfaces and
surfaces not in compliance with requirements of 00593.43 as follows:
Prepare the surface according to SSPC -SP 1, SSPC -SP 2, and SSPC -SP 3. Use a Solvent that is acceptable to the C oating Material manufacturer. Extend the prepared area at least 2 inches into adjacent, tightly adhering, intact C oating. In areas exhibiting C oating defects that do not extend down to the metal substrate, remove all loose, delaminating, non-intact, non -sound or otherwise defective Coating down to sound, still performing Coating. Extend the prepared areas at least 2 inches into adjacent tightly adhering, intact Coating.
locati on for a distance of 1 inch to 2 inches to provide a smooth, tapered transition into the existing intact Coating. Verify that the edges of C oating around the periphery of the repair area are tight and intact by probing with a putty knife according to SSPC -SP 3. Roughen the existing C oating in the feathered area to ensure proper adhesion of the repair coats. Overlap the intact, still sound surface at least 2 inches.
repair area, apply all coats of the system to the specified thicknesses .
When the damage does not extend to the bare metal substrate, apply only the affected coats. Maintain the thickness of the system in overlap areas within the specified total thickness tolerances and overlap the intact, sound existing C oating at least 2 inches.
Measurement
00593.80Measurement - No measurement of quantities will be made for Work performed under this
Section.
Payment
00593.90Payment :
new metal Work . Payment for this Work , including correction of damages, will be included in payment made for furnishing and placing the new metal Structure or assembly .
existing metal Structures will be paid for at the Contract lump sum amount for the item "Prepare and Powder Coat Existing Structures". Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment , labor, and Incidentals necessary to complete the Work as specified.
No separate or additional payment will be made for correction of damages described in 00593. 60.