1044AESTHETIC COATING FOR CONCRETE SURFACES

1044.1DESCRIPTION—This work is the cleaning and coating of new concrete surfaces with a coating

system for aesthetic purposes only . Do not use this specification if protective performance is required against chlorides, water infiltration and/or concrete and rebar corrosion . A coating system may be paint, stain, or penetrating stain.

1044.2MATERIAL—

documents, and from a manufacturer listed in Bulletin 15. Do not mix components or coats from different systems. Use the products of one manufacturer for the entire system.

are not limited to surface preparation, surface preparation method(s), coating application method(s) , and application conditions. Include the recommended method(s) for correction of damage to one or more coats, including correction of damage caused during handling, shipping, and erection; correction of deficient or excessive coating thickness: correction of runs, sag s, peeling, and poorly adhered coating; and removal of contaminants that would be detrimental to succeeding coats.

21 calendar days before beginning the coating. Begin coating after the District Executive accepts the submittals. Include the following:

• Infrared curves, in microns, for each component of each coat and for mixed coat(s);

• Weight per gallon, at 75F, for each component of each coat;

• Viscosity in Krebs Units, at 77F, for each component of each coat; and

• Percent solids by weight of each component of each coat.

test data, Safety Data Sheets (SDS), and specific application instructions for all coats. If there is a conflict between the data/instruction sheets and this Specification, the Chief Structural Materials Engineer will determine the governing specification. Do not proceed with work until this information is received.

preparation, cleaning, and the application methods; including the inspection hold points.

that describes the procedures and protective material to use to prevent damage to coated items , method to remove coating from surfaces not designated for coating and method to clean -up a major spillage.

1044.3CONSTRUCTION—

occupational and environmental health and safety rules and regulations. When applying or repairing coating damage, protect pedestrians, vehicles, and other traffic, upon or under the structure; and surrounding property surfaces, buildings, and grounds. Protect against damage or disfigurement from surface preparation media and spatters, splashes, overspray, and smirches of coating or material . As necessary, furnish adequate canvas or other suitable containments materials, for protection. Remove coating dropped on surfaces not designated for coating. Remove debris from cleaning operations, empty coating containers, and other refuse. Use scaffolding and rigging conforming to OSHA regulations and providing safe and ready access to work areas for inspection purposes.

coating (spray and/or chips), dust, or other harmful materials. Provide documentation to ensure all work be in conformance with Pennsylvania Code -Title 25 Environmental Protection Chapters 121 -145 “Air Resources”. Comply with Co unty and local ordinances before the start of work. All DEP permits and notifications, for fieldwork, are required before any in-stream work that may be necessary. Adhere to all Special Provisions as required.

that each batch of the coating system meets specifications. Include in the certification the product name for each coat of the supplied system and the production lot number of the certified batch.

Representative) from the coatings manufacturer at the beginning of operations and when required by the Department.

prepare a 2-foot by 2-foot test panel that is representative of the concrete surface with the specified coating material(s). Prepare the panel using the same cleaning, surface preparation, and application techniques that will be utilized during production. Submit the test panel to the Representative for initial color acceptance.

application meeting with the Structural Materials Engineer, the Representative, and/or any other applicable representatives. Determine, during this meeting, the maximum repair limits for repairing unsatisfactory coating as specified in Section 1044.3(e)10. Provide a full size mock-up sample for review and acceptance, unless otherwise directed.

other surface conditions before and after surface preparation according to coating manufacture r’s recommendations. Recondition repair areas before coating.

1.b. Potential Surface Contamination. When directed based on age and condition of surface, perform pH testing before surface preparation according to section 5.2 of ASTM F710. Remove contamination to levels recommended by the coating manufacture r. Perform another pH test after removal to verify manufacturer’s cleaning method achieved the recommended level.

form oil, and other contaminants are present, remove according to manufacturer’s recommendations. If the coating manufacturer recommends water jetting, perform work according to SSPC SP WJ 1, WJ 2, WJ 3, or WJ 4. Perform cleaning before surface preparation. If contamination remains after surface preparations,

clean the surface again as recommended by the coating manufacturer. Perform water bead test according to ASTM F22, as directed by the Representative, to verify contaminant removal.

2.a Other Cleaning. Remove soil, concrete spatter, or other foreign matter by brushing with stiff fiber or wire brush, by scraping or by cleaning according to the coating manufacturer’s recommendations.

recommended by the manufacturer. Prepare surface to provide an anchor pattern to meet minimum adhesion requirements according to Section 1 044.3(e)9.a. Determine the anchor pattern depth by using International Concrete Repair Institute (ICRI) comparator plates according to Technical Guideline No. 310.2-1997 (formerly No. 03732).

of dust, dirt, grease, oil moisture, overspray, and other contaminants. All concrete must cure a minimum of 28 days before coating.

labels intact. The Representative may accept containers with minor damage, if containers are not punctured.

and thinner in well-ventilated areas not subjected to temperatures in excess of the manufacturer’s maximum storage temperature. If necessary, store in heated storage areas to maintain material temperature at or above the manufacturer’s minimum storage temperature, listed on the product data sheet.

4.a. Primer. Mix the primer with a high shear mixer (such as a jiffy mixer), according to manufacturer’s recommendations to a smooth, lump free consistency. Do not use paddle mixers or paint shakers. Mix in the original containers. Ensure that all of the coating solids that might have settled to the bottom of the container are thoroughly dispersed.

4.b. Subsequent Coats. Mix each subsequent coat, according to manufacturer’s recommendations, to achieve and maintain a homogeneous mixture.

application has begun.

moisture using the plastic sheet method according to ASTM D4263 or by using electronic moisture meters according to ASTM F2170. Moisture acceptance criteria will be based on manufacturer’s recommendations and as approved by the Representative. Do not apply coating when the temperature of the air, coating, or concrete is above or below that described in the technical data sheet ; if not specified in the technical data sheet do not exceed 100F or go below 35F. Do not apply coatings when the air is misty or when conditions are otherwise unsatisfactory. Do not apply coating when relative humidity is above that described in the technical data sheet. Do not apply coating on damp or frosted surfaces or surfaces hot enough to cause the coating to blister, to produce a porous coating film, or to cause the vehicle to separate from the pigment. Apply coating only when the surface temperature is at least 5F above the dew point. Determine the dew point with the use of a psychrometer and psychometric tables or electronic psychrometer. Check environmental conditions before coating operations begin and at 4-hour intervals. If the dew point begins to rise and comes within 10F of the surface temperature, check environmental conditions every 15 minutes.

12 hours of final moisture content and surface profile/cleaning acceptance. If the coating application does

not occur within 12 hours of final moisture content acceptance or the surface temperature of the concrete falls below the dew point temperature, recheck the moisture content of the concrete surface. When the approved system contains a primer, apply according to manufacturer’s recommendations. Apply the coating after fabrication, inspection , acceptance, and once the concrete has had a chance to cure according to the coating manufacturer’s recommendations, but not less than 28 days. Protect concrete surface from direct sunlight during coating application and curing, if required, to prevent exceeding manufacturer’s temperature limits for air or concrete. Verify that each coat has cured before applying the succeeding coat. Follow the manufacturer’s recommendations for time to topcoat, unless a longer curing time is required. In damp or cold weather, keep the shop work under cover until thoroughly dry or until weather conditions allow exposure. For shop applied coatings, allow the coating to cure completely before loading and shipping. Apply finish coats from the same lot number or batch number when possible.

7.a. Spray Application. If conventional (air) spray is used, provide suitable traps or separators to exclude oil and water from the air. Conduct blotter test(s) according to ASTM D4285 before coating application begins. Keep the coating thoroughly mixed by continuous mechanical agitations, when required by the manufacturer.

7.b. Roller Application. Use rollers that do not leave a stripped texture in the coating film. Use rollers only on flat, even surfaces to produce a coating film of uniform thickness with no skips, runs, sags, or thin areas.

7.c. Brush Application. Only use brushes if recommended by coating manufacture r. Manipulate the coating under the brush to produce a uniform thickness. Work the coating into corners and crevices. Move the brush in a series of small circles to thoroughly fill irregularities in the surface, then brush out and smooth by a series of parallel strokes until the coating film has an even thickness.

7.d. Coating Areas Not Readily Accessible. Thoroughly cover surfaces inaccessible to normal coating method by use of sheepskin daubers, spray, or other means to ensure thorough coverage.

pattern, according to manufacturer’s recommendations. Verify coating thickness using coverage rate calculations and Wet Film Thickness (WFT) gauges. Perform WFT measurements every 300 square feet , or three per concrete sound panel. When WFT measurements and/or coverage rate is not acceptable, p erform nondestructive DFT measurements according to SSPC-PA 9; take and record a minimum of five spot measurements for each 108 square foot of coated surface area. Measure DFT using an ultrasonic thickness gage or other approved measuring device according to ASTM D6132. For multiple coat systems, perform DFT measurements after the application of each coat. Determine the DFT of subsequent coats by subtracting the average DFT of the underlying coat(s) from the cumulative readings. Increase the thickness of coating, if directed by the Representative, to ensure a finish that is uniform in color and appearance.

8.a. Primer (When Applicable). Apply primer to the DFT above the anchor pattern, according to the coating manufacturer’s recommendations . A dense and uniform appearance is required after the applied coating has cured. For areas deficient in coating thickness, repair as recommended by the coating manufacturer.

8.b. Subsequent Coats (When Applicable) . Apply subsequent coat(s), above the underlying coat(s) to achieve the DFT, according to the coating manufacturer’s recommendations.

Certificate of Analysis to the BOPD’s LTS, when directed by the Representative. Provide unopened sample kits for testing, when unopened sample kits are not practical sampling will be done using ASTM D3925 as a guide.

9.a. Adhesion Acceptance Testing. Perform adhesion testing, on 10% of the coated items, according to Method A of ASTM D3359 when directed by the Representative. Adhesion ratings meeting condition 2A or better are acceptable. Perform adhesion test on formed or finished (flat) surfaces. Adhesion testing on textured surfaces is not required. Increase testing frequency, as directed by the Representative, if results are unacceptable.

9.b. Visual Acceptance Testing. Inspect 100% of coated surface for color consistency from a distance of 30 feet, unless otherwise specified. Determine color consistency by comparing an approved mock-up sample to each coated surface. Use the same color consistency for the mock-up as the approved test panel, as determined by the Representative.

• the coating lifts, blisters, wrinkles, or has excessive runs or sags,

• the adhesion is rated 1A or worse,

• evidence shows application was under unfavorable conditions,

• the workmanship is poor or impure,

• an unauthorized coating has been used,

• the ∆ E color variation is 2.0 or more,

• the visual acceptance testing is unacceptable, or

• for other reasons determined by the Representative.

recommendations for any repair . Submit r epair procedures for approval by the Representative before starting repair application. Remove unsatisfactory coating, clean surface, prepare surface, and recoat according to the manufacturer’s specifications. The Representative will approve the completed repair. Evaluate repaired areas at 30 feet for color acceptance.

information to provide uniform block lettering using suitable contrasting paint.

and proper storage, handling, shipping, and erection techniques. Install padding or other acceptable material on dunnage to protect coated surfaces from damage and staining. Before shipping, display in a manner that will allow the Representative access to all sides of the coated items for inspection and acceptance.

1044.4MEASUREMENT AND PAYMENT—Square Yard

Construction of the test panel and mock-up is incidental to this work.