00594.01 613 Section 00594 - Preparing and Coating Metal Structures
Description
00594.00Sc ope - This Work consists of preparing and Coating new metal Structures and features
in the shop and in the field, and preparing and C oating existing metal Structures. This includes all:
• Interior and exterior steel surfaces • Steel railings, bridge bearings, and bridge expansion joint assemblies • Other miscellaneous steel • Galvanized and aluminum surfaces
00594.01Abbreviations, Definitions, and References :
AAMA - American Architectural Manufacturers Association DFT - Dry Film Thickness FTMS - Federal Test Method Standard WFT - Wet Film Thickness
Apparent Magnetic Surface - The magnetic surface that a magnetic gauge senses, somewhere between the peaks and valleys of the profile, after the steel is roughened by abrasive cleaning.
Cleaning - Removing detrimental material in Preparation for C oating.
Coat - An application, or applications, of Paint or other protective material to a Substrate , resulting in a layer of specified thickness .
Coating - Protectiv e material after it is applied to a Structure .
Coating Material - Protective material in the liquid state before application. Coating System - All specified Coats applied separately in a predetermined order. Field Coating - The on-site coating of new or existing metal Structures before or after erection. Hold Coat - A brush augmented Coating that completely covers the Substrate, including all complex details as described in the definition of “Stripe Coat”. Applied prior to the full prime C oat to prevent flash rusting of the cleaned steel surfaces. Hold Point - A time at which the Contractor is required to stop a partic ular activity until a phase of Work is inspected or tested. If the Engineer finds this phase conforms to the Specifications, the subsequent phase of Work may proceed.
Maintenance Coating - The Coating of existing steel Structures that have been previousl y coated and need recoating. Maintenance Coating is not considered Rehabilitation Work. Manufacturer's Recommendation - The written specifications and instructions provided by a manufacturer of a Coating Material concerning the handling, mixing, and appl ication of the Coating Material. 00594.01 614 Pack Rust - A localized form of crevice corrosion that is typical of built -up members or layered steel components. Corrosion product is formed between or along the edges of the steel components and pushes the steel compon ents apart to form crevices, the resulting pressure from the deforming steel and the corrosion buildup compresses the corrosion product.
Paint - A pigmented liquid, applied as a thin layer, which is converted to a solid colored film after curing. This fi lm provides a decorative and protective Coating to the Substrate. The binder is a resin that may or may not be modified with natural vegetable oils, fish oils, or other ingredients.
Phase - An activity or step of the Preparation and Coating procedures to be inspected or tested. The transition from one Phase to another represents a H old Point.
Preparation - Measures taken to provide a suitable surface ready to C oat.
Rehabilitation - Work performed on a Structure to restore or improve load carrying capacity, serviceability, or maintenance and inspection access.
Rust -Back - Rusting that occurs when freshly exposed bare, dry, steel is exposed to conditions of high humidity, moisture, or a corrosive atmosphere. Rust Bloom - Discoloration indi cating the initiation of rusting.
Shop Coating - The Coating of steel surfaces in the fabrication shop before the metal is transported to the erection site.
Skin - A solid or semi -solid membrane that forms on P aint in a container. Skimming - The process in which a film forms over a liquid Coating, either during storage or after application.
Stripe Coat - Separate, independent C oating that is applied to complex details and irregular surfaces.
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 previ ous Coating.
Surface Profile - Roughness of a cleaned metal surface. The height of the profile is measured from the bottom of the valleys to the top of the peaks in mils. Thinner - Volatile liquids used to thin compatible Coating Materials. Thinners may be a blend of solvents.
Wet Film Thickness - Coating layer dimension determined with a Wet Film Thickness gauge immediately after application and before curing.
Volume 2, Systems and Specifications , of SSPC's Painting Manual .
In these Specifications, references are made to FTMS 141, Paint, Varnish, Lacquers, and Related Materials: Methods of Inspection, Sampling and Testing, which is distributed by the U.S. General Services Administration.
00594.10 615 00594.03 Precoating Conference and Submittals - Before beginning any Preparation and Coating Work , meet with the Contractor's supervisory personnel and quality control manager, any Preparation or Coating Subcontractors' supervisory personnel, a representative from the C oating manufacturer, and the Engineer at a mutually agreed upon time. At least 21 Calendar Days before the precoating conference, submit a plan for accomplishing all phases of the Preparation and Coating Work , including the following:
Ventilation Containment Surface Preparation Painting Coating Materials Quality Control Plan Waste handling and disposal All other pertinent information
If the Contractor's key personnel change, or if the Contractor proposes a significant revision to the plan for accomplishing the P reparation and Coating Work , the Engineer may require additional precoating conferences.
Do not begin any Prepar ation or C oating Work before the plan for completing the Work has been approved.
00594.04Notice - Notify the Engineer, in writing, at least 7 Calendar Days in advance of the date
that Preparation and Coating operations are to begin.
00594.05Waste Handling and Disposal - Dispose of waste material according to 00290.20, and
the requirements of SSPC Guide 7 that do not conflict with 00290.20.
00594.06Access and Containment for Field Preparation of Coating - Provide access and
containment according to Section 00253.
Materials
00594.10Materials - Furnish Materials meeting the requirements of this Section, the Special
Provisions, and the applicable portions of SSPC -PA 1, Shop, Field and Maintenance Painting, when not in conflict with eit her this Section or the Special Provisions.
requirements:
For shop Coating of steel or iron surfaces, furnish a three -coat system with organic or inorganic zinc primer. For Maintenance Coating of steel or iron surfaces, furnish a three- coat system with organic zinc primer. For field Rehabilitation of coated steel or iron surfaces, furnish a three- coat system with surface tolerant organic zinc primer . For shop C oating or M aintenance Coating of non- ferrous surfaces, furnish a two-coat system. For shop pile C oating of steel pile, furnish a three -coat system with tar.
00594.11 616 Do not apply Coating Materials until certifications required by 00165.35(a) and 00165.35(b) have been provided and the M aterials are accepted for use by the Agency.
SAE AMS-STD -595 color #24272 for ODOT Green top C oat. SAE AMS-STD -595 color #30059 for weathering steel top C oat. SAE AMS-STD -595 color #26357 for miscellaneous metal on concrete Bridges.
00594.11Coating Materials:
• Prepared by the manufacturer. • For multi -component Coatings, be manufactured in separate, properly portioned containers and ready for field mixing. Do not field mix multi -component Coatings unless approved by the Engineer. • Homogeneous, free of contamination, and of a consistency suitable for the specified use. • Does not require a pretreatment chemical or material prior to application of the prime Coat, except as stipulated in the Specifications. • Includes required tinting and coloring materials at the time of manufacturing. Do not use gray for the first prim e Coat. • A sufficiently different shade for each individual C oat from the manufacturer, so that skips and holidays can be easily detected. Do not tint the C oating Material in the field unless approved by the Engineer. • Does not vary in composition without prior notice by the manufacturer and approval of the Engineer. • Has sufficient time remaining on the manufacturer's recommended shelf life to allow for application before expiration of that shelf life.
requirements:
• Constructed of new and unused materials. • Not have a capacity of more than 6 gallons. • Meet U.S. Department of Transportation's Hazardous Material Shipping Regulations. • If necessary, constructed with an interior lining to prevent attack by the Coating Material. The lining shall not delaminate from the container wall so as to contaminate the C oating. • Labeled with a quality compliance certificate according to 00165.35, showing the following: • Manufacturer's nam e • Exact title of C oating Material • Manufacturer's batch number • Date manufactured • Identification of all toxic substances • Handling and application precautions
ODOT Materials Laboratory : 00594.13 617 • One unopened 1 quart container from each batch of each C oating . For multi -component Coatings, pre-proportion components to mix approximately 1 quart of Coating . The Agency may, at its discretion, place an Inspector at the site of manufacture and obtain check samples at the Project Site . • Test results certification according to 00165.35 for each batch of each C oat, and if the C oating Material is specified for use on steel -to-steel contact surfaces, certification that the C oating Material meets the requirements of 00594.11( d). • A product data sheet for each type of C oating Material. • A material safety data sheet or safety data sheet with the initial sample of each ty pe of C oating Material.
Agency testing may include the following tests necessary to ensure that the C oating Materials conform to Specifications, manufacturer's product data sheet, and other testing as the Agency deems appropriate.
Test Test Method Density of Liquid Coatings, Inks, and Related Products ASTM D1475 Determination of Zinc in Dry Films of Paints and Coatings ODOT TM 614 Coarse Particles in Pigments, Pastes, and Paints ASTM D185 Consistency of Paints Using the Stormer Viscometer ASTM D562 Fineness of Dispersion of Pigment -Vehicle System ASTM D1210 Drying, Curing, or Film Formation of Organic Coatings at Room Temperatures ASTM D1640 Volatile Content of Paints ASTM D2369 Pigment Content of Solvent -type Paints ASTM D2371 Volume Nonvolatile Mat ter in Clear or Pigmented Coatings ASTM D2697 Vehicle Solids (Ordinary Centrifuge) FTMS 141, Method 4051 Nonvolatile vehicle Content FTMS 141, Method 4053 Agency testing is not to be construed as determining or predicting the performance or compatibility of the individual Coating Material or the total C oating System.
slip-critical structural bolted connections 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.
00594.12Caulking - Furnish structural steel caulking from the QPL and approved for use by the
Coating manufacturer. The caulking color shall be clear, approximate the color of the top C oating, or be over coated. 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.
00594.13Chloride Remover - When used, furnish a chloride remover from the QPL that is fully
compatible with the C oating System according to the recommendations of the C oating System manufacturer.
00594.30 618 Labor
00594.30Quality Control Personnel - Provide an on -site quality control manager who shall be
responsible for managing quality control related to all Preparation and C oating quality control activities. The quality control manager shall not be employed in a supervisory role for any Preparation or Coating Work .
Construction
00594.40General :
as provided in the Specifications, perform all required Preparation and C oating at the fabrication shop after completion of fabrication and before transporting to the Project Site.
Special Provisions.
Structures impacted by erection according to 00594.60. This includes all existing steel surfaces uncovered by the removal of existing steel, wood, and concrete members. Impacted areas include areas where rivets or bolts are removed, and existing steel surfaces damaged during erection or other Contractor operations. Except as provided in the Specifications, p erform all required Preparation and C oating of new steel members at the fabrication shop after completion of fabrication and before transporting to the Project Site. Perform Preparation and Coating of steel Structures impacted by erection in the field.
Except as provided in the Specifications, perform all required Preparation and C oating at the fabrication shop after completion of fabrication and before transporting to the Project Site. Prepare and Coat existing non- steel Substrates described in the Special Provisions.
to SSPC -Guide 12, Guide for Illumination of Industrial Painting Projects .
00594.41Special Fabrication, Preparation and Coating :
inaccessible to Preparation and C oating after fabricati on.
Prepare and C oat contact surfaces within slip-critical joints, constructed as part of the Work under
not damaged by the welding or fabricating process. 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 Coating System and as required in 00594.42. Do not apply C oating within 4 inches of the weld before the welding operation is complete.
00594.42 619 00594.42 Preparation of Surfaces:
to SSPC -SP 10 / NACE No. 2 Near White Metal Blast Cleaning , except as modified by this Section. The appearance of the final blast -cleaned surface shall closely approximate Pictorial Standard SP 10 of SSPC -Vis 1.
according to SSPC -SP 10 / NACE No. 2 Near White Metal Blast Cleaning with the appearance of the blast -cleaned surface to closely approximate Pictorial Standard SP 10 of SSPC -Vis 1, or clean to SSPC -SP WJ-2 Waterjet Cleaning of Metals - Very Thorough Cleaning with the appearance of the water -jetted surface to closely approximate Pictorial Standard WJ -2 of SSPC -Vis 4.
which is not receiving a Maintenance Coating outside the immediate area of the Rehabilitation details, prepare all existing steel surfaces to be coated according to SSPC -SP 15, Commercial Grade Power Tool Cleaning . Provide a cleaned surface with a minimum Surface Profile of 1 mil. Prepare all existing coated surfaces exposed by the removal of the existing components involved in the R ehabilitation, all areas in which rivets, bolts, or plates are to be removed, and areas damaged by erection or other Contractor operations . Completely clean all existing lead -based Coatings exposed by the removal of any structural or miscellaneous member to SSPC -SP 15 Commercial Grade Power Tool Cleaning requirements. Extend all prepared areas at least 2 inches into tightly adhering, intact paint. Overlap the subsequent C oating and the still intact C oating by a minimum of 2 inches. Lightly sand the overlap area of the intact Coating to provide a profile for the subsequent repair C oating to adhere to.
• Solvent clean surfaces to be coated according to SSPC -SP 1, then follow 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. • 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:
disch arge the abrasive:
• A stream of high -pressure air • A rotating centrifugal paddlewheel • A stream of high -pressure water Surfaces shall be dry before C leaning unless a wet blast C leaning method is used. Use methods specified in SSPC -SP 1, Solvent Cleaning, SSPC -SP 2, Hand Tool Cleaning, SSPC -SP 3, 00594.42 620 Power Tool Cleaning, and SSPC -SP 15 Commercial Grade Power Tool Clean, as necessary to augment blast -cleaning.
produce an angular Surface Profile of at least 1 mil, but not more than 4 mils, as measured according to ASTM D4417 using replica tape on the prepared surface. The blast -cleaning shall result in a roughened steel surface comparable to a Keane- Tator Surface Profile Comparator for sand or grit using ASTM D4417.
When removing C oatings with lead or chromium, use a mineral slag abrasive combined with an approved additive to render the removed Coating Material non-hazardous. Obtain approval for the specific abrasive blast additive before use. If a centrifugal wheel with a grit mixer is used for blast -cleaning, inspect each member and for those members not meeting the comparator or profile requirements, perform a final blast - cleaning with high -pressure air with an abrasive to obtain the specified profile.
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 . The conductivity results from ASTM D4940 shall not exceed 100 microsiemens per c entimeter. Wet abrasives are allowed if wet sa ndblasting methods are used.
any other material detrimental to the Coating System. Provide adequate separators and traps. Test compressed air cleanliness daily according to ASTM D4285, or as directed.
than 75 milligrams per liter of chlorides or 200 milligrams per liter of sulfates. Filter, recycle, and dispose of water when surface soluble salt levels cannot consistently be kept below 70 microsiemens per centimeter, measured with a conductivity meter capable of reading to 1 microsiemen per centimeter.
Use a rust inhibitor that is recommended by the C oating man ufacturer. Use the rust inhibitor to prepare a test panel at least 14 Calendar Days before beginning Work , to show that the inhibitor does not cause loss of bond between the steel Substrate and the primer. Do not use the rust inhibitor product if the tes t panel does not meet the adhesion requirements of 00594.43(g).
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 material 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, accor ding to SSPC PA-1. • Repairing all damaged galvanizing according to ASTM A780. • Obtaining approval from the Engineer. 00594.43 621
Mechanically, in combination with saturating the Pack Rust with water at 3,000 psi and heating to a minimum of 250 °F and a maximum of 400 °F. Blast with ultra -high pressure water jet ting at 35,000 psi.
00594.43Coating Metal Structures:
Coating application 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 .
• The material does not arrive at the application site in the original, unopened manufacturer's containers. • The container is punctured or has a break in the lid seal. • The Coating Materials have begun to polymerize, solidify, gel, or deteriorate in any other manner. • The recommended shelf life, as stated in the manufacturer's product data sheets, has expired.
composition. Do not mix Coating Materials by means of air stream bubbling or boxing. Mix in the original container and continue until all pigment or metallic powder is in suspension. Ensure that all solid Coating Material that may have settled to the bottom of the container is thoroughly dispersed. After mixing, inspect the C oating Materials for uniformity and to ensure that no unmixed pigment or lumps are present.
Add separately packaged catalysts, curing agents, hardeners, initiators or dry metallic powders to the base Coating Material only after the base Coating Material is thoroughly mixed to achieve a uniform mixture with all particles wetted. Add the proper volume of curing agent to the correct volume of base with constant agitation. Use the mixture within the pot life specified by the manufacturer. Discard unused portions at the end of each workday.
Engineer. If allowed, furnish the amount and type of T hinner conforming to the Manufacturer's Recommendations.
pigment or metallic powder.
during application by using paint pots equipped with mechanical agitators.
00594.43 622 (6) Storage - Store the C oating Material and solvents in original containers. Store the containers in a weather -tight space where the temperature is maintained between 40 °F and 100 °F or according to the manufacturer recommendations, whichever is more restrictive.
other substances that would prevent the bonding of succeeding applications. Protect freshly coated surfaces from contamination by abrasives, dust or foreign materials from any source. Do not apply succeeding C oats until the Engineer has approved the prepared surface.
combination of these methods, or as recommended by the C oating Material manufacturer, unless otherwise specified. If air is used for application, ensure that it is free of water, oil, or any other material detrimental to the Coating System. Provide adequate separators and traps and test air cleanliness daily according to ASTM D4285, or as directed. Regardless of which application method is used to apply the Coating, use brushes to push the Coating into complex details, crevices, gaps, areas difficult to access , and where spraying does not adequately cover or penetrate. All application techniques shall conform to Section 7 in SSPC -PA 1 and the applicable sections of SSPC Paint Application Guide N o. 11. Augment the initial primer application using brushes. Immediately upon transfer of the liquid Coating to the Substrate, work C oating by brush into all areas that are usually stripe coated as identified by SSPC Paint Application Guide No. 11.
If Rust Back, Rust Bloom, or rust stains are present on the surface after brush augmented primer application, re- prepare the surface according to 00594.42 and resubmit the primer application procedure to the Engineer. Apply subsequent C oats of Paint in sufficiently different shades so that skips and holidays can be easily detected.
Apply each C oat in a uniform layer, completely covering the preceding C oat. Correct runs, sags, skips or other deficiencies before application of succeeding C oats. Perform re -cleaning, application of additional Coating, or other measures, as directed by the Engineer, at no additional cost to the Agency.
For each applicator, perform at least one WFT test 15 minutes after beginning Coating application and one WFT test per hour thereafter. Test immediately after C oating application and report results.
in the manufacturer's product data sheet for the Coatings.
Apply the Coating System in the number of Coats specified in the QPL, with each Coat consisting of as many applications as necessary to cover the Work and achieve the minimum thickness specified for the C oat. On steel -to-steel contact surfaces, apply only zinc primer Coating . On steel -to-concrete contact surfaces, apply the full Coating System so that it extends 1 inch into the steel -to-concrete contact surface if accessible. On steel -to-wood contact surfaces, apply all Coatings specified.
00594.43 623 The dry film thickness of the primer on steel -to-steel contact surfaces shall not be less than 3 mils nor more than the manufacturer's class "B" certification allows.
Do not assemble coated joints before the coatings have cured for at least the time used in the qualifying test, or as recommended by the manufacturer.
prime Coat and apply an intermediate stripe C oat by brush before applying the full intermediate Coat. For two C oat Paint systems, except non-ferrous Coating Systems from the QPL, apply a top Coat stripe Coat prior to full top C oat application. Apply the stripe C oat by brush only. Use brushes to push the C oating around and into complex details and irregular surfaces identified as usually stripe coated by SSPC Paint Application Guide No. 11. Make each stripe Coat a different color than the preceding and subsequent full Coat, extending a minimum of 1 inch from the irregular surface, and completely hiding the Substrate. The stripe Coat shall be a different color and be approximately 3 mils thick. Each stripe C oat will have its own H old Point and shall not be used to correct deficiencies in the preceding or subsequent C oats. Apply stripe Coats according to the applicable sections of SSPC Paint Application Guide No. 11 that do not confl ict with this Section or the Special Provisions.
A prime stripe Coat may be applied prior to a full prime Coat without brush augmentation other than what is necessary to achieve full coverage provided both Coats are applied on the same Calendar Day as sur face Preparation.
thickness measurements after the application of each C oat and before application of the succeeding Coat. In addition to C oating thickness measurements , a visual inspection for complete coverage will be made by the Engineer after each Coat. Apply each C oat in sufficient 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 applicati ons, 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 metal Substrate.
The Engineer will take dry film thickness measurements with a type 2 gauge according to SSPC -PA 2. The minimum dry film thickness measurements and frequency of measurements will be according to SSPC -PA 2, modified as follows :
• A single gauge reading will be taken for each 10 square feet of surface area. • A spot measurement is onl y taken at locations where a gauge reading is less than 100 percent of the Project 's specified minimum DFT. • All spot measurements shall meet 100 percent of the Project 's specified minimum DFT. • Additional readings may be required to identify the limits of t he non-compliant areas.
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 C oat to be less than the specified minimum thickness, or revea ls a missing intermediate C oat, the total C oating System will be rejected even if the thickness of the total system equals or exceeds total specified thickness.
In areas where dry film thickness measurements are impractica ble, Wet Film Thickness measureme nts will be made according to ASTM D4414.
intermediate Coats exceed the specified thicknesses of the prime and intermediate C oats, apply 00594.43 624 the top C oat to at least the minimum required topcoat thickness, to provide uniform and complete coverage and appearance.
according to one of the following methods:
• Prime on the same Day that the surfaces are cleaned. • Apply an approved rust inhibitor to the entire surface on the same Day as cleaning, and prime within 48 hours after inhibitor application. • Reblast all surfaces prior to C oating.
Before priming surfaces prepared by waterjetting, ensure that the surfaces do not exceed "Light" flash rust as defined by the Wipe Test in SSPC -SP WJ-2. Ensure that all other surfaces are dry and free of flash rust before priming.
Apply each C oat over the preceding C oat as soon as possible, allowing for drying time of the preceding Coat, weather, temperature, and similar factors, as well as the M anufacturer's Recommendations. Re-prepare a primer Coat that exhibits freckle rust or is exposed to the weather for more th an 60 Days, according to 00594.42.
Allow each Coat to dry and sufficiently cure before recoating so the succeeding or additional Coat can be applied without delamination, blistering, wrinkling, or loss of adhesion or cohesion. C onform to the Manufacturer 's Recommendations for recoat times unless they conflict with this Section or any Coating problems develop. Do not revise recoat times without receiving approval from the Engineer.
opaque caulk cannot be supplied in a color that approximates the top Coat color, apply after intermediate Coat application, but before top C oat application following all manufacturer recommended curing schedules. Fill and seal crevices and gaps between structural shapes and plates, around bolt heads and nuts, weld terminations, and similar areas that would retain moisture, with the following:
• Caulk, if the crevice or gap cannot be filled 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.
Do not caulk the b ottom edge of vertical connections, horizontal built up members, or other connection details where caulking bottom surfaces may trap moisture.
Ensure that a m inimum pull -off strength of 650 psi is achieved for zinc -rich primers and tar based Coatings, and that a minimum pull -off strength of 1, 000 psi is achieved for all other C oatings, including those over a zinc -rich primer. When testing a C oating or C oating System with a DFT of more than 12 mils, score around the test fixture. Allow sufficient time for C oating to cure prior to performing adhesion tests.
Perform three adhesion tests in locations determined by the Engineer on the completed C oating system for e ach shift of Coating application. When C oating limits differ between C oats, determine test frequency by each shift of primer application. When Field Coating discrete locations on a 00594.44 625 structure where less than 1,500 square feet is to be coated in each location, perform a minimum of three adhesion tests per 3,000 square feet of applied C oating.
For shop applied Coatings, use of coupons of identical material prepared and coated at the same time as production parts is acceptable. Perform additional adhesion tests as warranted or at the direction of the Engineer. Repair adhesion test locations according to 00594.60.
apply Coating Materials only during periods when:
• Air temperature is above 45 °F • Steel surface temperature is: • Greater than 45 °F • Less than 115 °F • At least 5 ° F above the dew point • Relative humidity is within the manufacturer's recommended range
Do not apply Coating Materials if the Engineer determines that conditions are not favorable for proper application and performance of the C oating.
If fresh Coatings are damaged by the elements, replace or repair at no additional cost to the Agency.
If a Coating System allows application in environmental conditions different from those specified, submit a letter from the manufacturer stating the conditions under which the C oatings can be applied. Application under conditions other than specified is not allowed without the Engineer's written approval.
Cover and protect the metal if C oating is to be applied in adverse weather conditions. Heat the metal and s urrounding air to the temperature specified in this Subsection. Continue protecting the newly coated surfaces until the C oating achieves proper cure.
letters 2 inches high at a location on each end of each span on the Structure being coated. The exact location of stenciling will be determined by the Engineer. Use flat black color stenciling unless otherwise directed.
00594.44Inspecting - The Engineer will inspect each Phase of Preparation and Coating. Do not
proceed with succeeding phases until approved. Provide the Inspector timely access to areas where Work is being performed. Allow adequate time for inspection at each H old Point. Hold Points are the following:
• Before Cleaning operations begin • After Cleaning operations are completed and before application of any C oating Materials • After each stripe Coat • After each full C oat • After Cleaning in conjunction with C oating repairs • After application of each C oat in C oating repairs 00594.45 626 • After application of last C oat, before moving work platforms and containment structures
Repair Coating System damages resulting from Agency inspection and testing at no additional cost to the Agency.
Aspects of the Preparation and Coating process to be i nspected and tested may include:
Test Test Method Environmental Conditions for Coating .............................................. ASTM E337 Oil in the Abrasive Material ............................................................ ASTM D7393 Ionic Contamination of Abrasive Material ....................................... ASTM D4940 Cleanness of Compressed Air ........................................................ ASTM D4285 Pictorial Surface Preparation Standards ....................... SSPC -VIS 1, 3, 4, and 5 Surface Profile by Replica Tape ..................................................... ASTM D4417 Wet Film Thickness ........................................................................ ASTM D4414 Dry Film Thickness by Magnetic Gauge ............................ SSPC -PA2 (modified) Dry Film Thickness by Tooke Gauge ............................................. ASTM D4138 Pull-off Strength of Coating ............................. ASTM D4541 (Method D, E, or F) Nonvolatile Vehicle Content ......................................... FTMS 141, Method 4053
00594.45Protecting 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 00594.42 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.
Do not clean or C oat galvanized steel members such as ladders, safety rails and stanchions unless otherwise directed in the Special Provisions. Protect them from damage during Preparation and application operations. Repair damaged galvanizing at no additional cost to the Agency.
Protect navigation lights and conduits. If navigation lights or lenses are damaged by Preparation or Coating operations, immediately repair or replace at no additional cost to the Agency. Keep navigation lights operating and visible at all times .
shop, during shipping, and during erection. Do not move or handle coated metal until the Coating has cured. 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.
Preparation and Coating Work , including:
• Damage to marine or ve hicular traffic or harm to pedestrians in the vicinity of the Work . • Abrasive material or debris falling into an area which would create a traffic hazard. • Damage to the Bridge Substructure , Superstructure or motorized Equipment . 00594.75 627 • Damage to other property as a result of the Contractor's operations.
Maintenance
00594.60Repair of Damaged and Unacceptable Coatings - Repair damaged surfaces and
surfaces not in compliance with requirements of 00594.43 as follows:
Prepare areas exhibiting C oating defects down to the metal Substrate, whether exhibiting visible corrosion or not, according to SSPC -SP 10 / NACE No. 2 Near White Metal Blast Cleaning. If approved by the Engineer , prepare small areas according to SSPC -SP 15, taking care not to damage adjacent areas.
In areas exhibiting C oating defects that do not extend down to the metal Substrate , remove all loose, delaminating, non-intact, non -sound Coatings, or otherwise defective C oating, down to sound, still -performing Coating. Extend the prepared areas at least 2 inches into adjacent tightly adhering, intact Coating.
location. Feather the existing C oating for a distance of 1 to 2 inches to provide a smooth, tapered transition into the existing intact C oating. Verify that the edges of the Coating 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 C oats. Overlap the intact, still -sound surfaces at least 2 inches.
repair area apply all C oats of the Coating System , including stripe Coats where applicable, to the specified thicknesses.
When the damage does not extend to the bare metalS ubstrate, apply only the a ffected Coats. Maintain the thickness of the system in overlap areas within the specified total thickness tolerances and overlap the intact, sound existing Coating at least 2 inches.
Finishing and Cleaning Up
00594.75Coating System Warranty and Supplemental Warranty Performance Bond - When the
Special Provisions identify that a C oating System warranty and a supplemental warranty Performance Bond are required, provide them according to 00170.85(b)(1) and the following:
the Coating Systems, above deck and below deck, performed and applied on this Project are and shall be free of all defects for a period of 36 months. Provide a written 36-month warranty using the Agency -supplied Coating System warranty form that is included near the front of the Special Provisions booklet. Furnish the written warranty 30 Calendar Days before the precoating conference. "Unconditionally warrant" means that the warranty covers all defects, regardless of the source or cause of the defect, including, without limitation , whether the source or cause is or may be related to workmanship, inspection, or choice of materials.
For purposes of the warranty, Coating System defects are defined as any one or more of the following conditions: 00594.75 628 • Visible rust or rust breakthrough • Blistering, cracking or alligatoring • Chalking or fading • Loss of adhesion • Cohesive failure
The Agency inspection of any portion of the Work during the Contract and during the Coating System application, the Agency acceptance of the Work , corrections under the warranty, or expiration of the warranty shall not relieve the Contractor of its obligations under this warranty. Within 60 Calendar Days of written notification of defects, submit a repair plan to the Engineer. Within 120 Calendar Days of written notification of defects, or within such other time as the Engineer may agree in writing, corre ct all defects at no additional cost to the Agency.
The 36 month Coating System warranty will begin on the date of Second Notification. During this warranty period, the Agency will inspect the C oating System for defects three times; at approximately 12, 24, and 36 months after issuance of the Second Notification. The Contractor will be notified in advance of each inspection and will be permitted to accompany the Agency Inspector . Make repairs and correct all defects to the C oating System. Make all corr ections and repairs according to the Contract requirements.
Bond, in addition to the regular P erformance Bond for the Contract, executed by a Surety authorized to do business in the State of Oregon. Furnish the supplemental warranty Performance Bond 30 Calendar Days before the precoating conference. The supplemental warranty Performance Bond dollar amount will be listed in the Special Provisions.
The bond is to secure the performance by the Contractor of correction Work on any C oating System defects that the Contractor may be directed by the Agency to perform. Use the Agency -provided form included near the front of the Special Provisions booklet, except when the Surety is a multiple Surety , obtain a co-Surety execution form from the Agency. The supplemental warranty Performance Bond shall be signed by the Surety's authorized Attorney -in-Fact with the Surety's seal affixed to the bond. Attach a power of attorney for the Attorney -in-Fact to the bond, include the bond numbers, and affix the Surety's original seal to the power of attorney. If executed by co- Sureties, each Surety shall sign, seal, and attach the power of attorney.
The supplemental warranty P erformance Bond shall become effective on the date of Second Notification and continue, in full force and effect, until the Agency has advised the Contractor of either of the following:
• There are no Coating System defects at the end of the full warranty period. • The Contractor has been notified that there are Coating System defects, the defects have been repaired by the Contractor to the satisfaction of the Agency as specified under the Coating System warranty, and the full warranty period has expired.
Supplemental warranty Performance Bonds cannot be canceled nor be released due to possible claims.
00594.90 629 Measurement
00594.80Measurement - Except for Pack Rust removal, no measurement of quantities will be made
for Work performed under this Section. Pack Rust removal will be measured on the length basis.
Payment
00594.90Payment :
metal Work . Payment for this Work , including correction of damages, will be included in payment made for structural steel according to 00560.90 and metal sign supports according to 00930.90, as appropriate.
Structures will be paid for at the Contract unit price, per unit of measurement, for the following items:
Pay Item Unit of Measurement
Item (a) includes preparing existing metal surfaces and disposal of spent abrasives, Paint waste and other debris from the surface Preparation Work .
Item ( b) includes C oating existing metal surfaces. Item ( c) includes the C oating Material . Partial payments for items (a), (b), and (c) will be made only for portions of the Structure that have been prepared and coated with all C oats specified. The partial payment will represent an estimate of the Work completed as a percentage of the total C oating System Work to be done. No payment for Work will be made until the supplemental warranty Performance Bond and the written 36 month Coating System warranty, if required under 00594.75, have been furnished to the Agency. 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 00594.45 and 00594.60.