1045PROTECTIVE COATINGS FOR CONCRETE SURFACES

1045.1DESCRIPTION—This work is the preparation and coating of new concrete surfaces with a coating

system for protective purposes. Use this specification if protective performance is required against chlorides, water infiltration, concrete deterioration and/or rebar corrosion. A coating system may consist of paint, stain, or penetrating sealer and be a single coat or a primer coat followed by a topcoat. After application the system must be opaque and uniform in color.

1045.2MATERIAL—

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, sags, peeling, and poorly adhered coating; and removal of contaminants that would be detrimental to succeeding coats.

Bulletin 15 evaluation and approval. Include the following:

• Attenuated Total Reflection – Fourier-Transform Infrared (ATR-FTIR) curves for each component of each coat and for mixed coat(s); according to ASTM E1252 as modified by AASHTO National Transportation Product Evaluation Program Concrete - Coatings Systems (NTPEP CCS) workplan Section 5.14.

• Weight per gallon, at 75F, for each component of each coat; according to ASTM D1475.

• Viscosity in Krebs Units, at 77F, for each component of each coat; according to ASTM D562.

• Percent solids by weight of each component of each coat; according to ASTM D2369.

• Water Absorption. The final average percent water absorbed, for concrete coated with the protective coating, not greater than 25.0% of the final average percent water absorbed by the uncoated reference concrete; according to AASHTO T 384.

• Moisture Vapor Transmission. The final average percent moisture loss, for concrete coated with the protective coating, not less than 50.0% of its final average percent water absorption; according to ASTM E96.

• ChlorideIon Penetration . The final average absorbed chlorideion content, for concrete coated with the protective coating, not greater than 25.0% of the final average absorbed chlorideion content of the uncoated reference concrete, according to AASHTO T 384.

• Color Fastness by UV Resistance. Conducted according to ASTM D4587, Cycle 2 for 2,500 hours. Evaluate every 500 hours. Change must be delta E < 4.0 after final weathering cycle.

as follows:

• Composed of 100% reactive constituents (condensation products of the reaction of epichlorohydrin with bisphenol A).

• Essentially pure, diglycidyl-ether of bisphenol A, containing no more than trace amounts of hydrolyzable chlorine.

• Epoxide equivalent between 465 and 530.

• Reacting system consisting of a blend of condensation polymers of dimerized and trimerized unsaturated, fatty-acids and an aliphatic polyamine.

• Pigmentation added so the cured coating conforms to the Federal Color Standard 595, and as indicated.

• Nonskid material added, if directed.

• Viscosity. 300 centipoises to 700 centipoises at 72F

• Pot Life. A minimum of 7 hours at 75F

• Minimum solids content. 48%

• A cured system that does not exhibit amine blushing or sweating.

When the pigmented finished coats are tested for abrasion, according to ASTM D968, a minimum of 25 L of sand is required to abrade a one-mil thickness of coating. A 2 1/2-mil dry film thickness of the coating, tested by ASTM D522, is required to pass a 1/8 -inch diameter mandrel test, without splitting the film or causing loss of bond.

from a well-blended bulk lot, before packaging or by withdrawing thief samples from no less than 5% of the containers comprising the lot or shipment. Unless the samples show evidence of variability, they may be blended into a single composite sample to represent that component. Packaged materials may be sampled by random selection of containers or each component from each lot. The entire lot of both components may be rejected if samples fail to meet any specified requirements.

with the contained materials. If directed, provide a container size so the recommended final mixture proportions can be obtained by combining one container of a component with one or mo re containers of the other component. Have containers marked as base polymer and reacting system, showing the mixing directions and usable temperature range. Have each container marked with the name of the manufacturer, the lot or batch number, the date of packaging, pigmentation, if any, and the quantity in pounds and gallons. Indicate the potential hazards on the package, according to the Federal Hazardous Products Labeling Act.

dated test report or a statement, accompanied by a copy of the dated test results, showing the system has been sampled and tested.

a minimum of 21 calendar days before beginning the coating. Begin coating after the Representative accepts

the submittals. Include the following:

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 CSME 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.

1045.3CONSTRUCTION—

Protection of Structure, Persons, and Property. Conduct work in compliance with applicable 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. Furnish canvas or other containment 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, dust, or other harmful materials. Provide documentation to ensure all work is being performed according to Pennsylvania Code -Title 25 Environmental Protection Chapters 121-145 “Air Resources”. Comply with County 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.

coating manufacturer at the beginning of operations and when required by the Department.

provide a full- size mock-up, unless otherwise directed. Prepare a mock -up that is representative of the concrete surface with the specified coating material(s). Prepare the full-size mock -up using the same cleaning, surface preparation, and application techniques that will be utilized during production. Provide a mock-up meeting the following requirements:

• Precast items, one complete unit

• Prestressed beams, 10% of the length of the beams with a minimum 5 feet and a maximum of 10 feet

• Cast-in-place concrete, 10% of the square footage with a minimum size of 25 square feet and a maximum 50 square feet A production piece can be used as the mock -up. Use the mock-up to verify moisture testing acceptance criteria. When only color acceptance is required, submit a 2-foot by 2-foot panel 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. During this meeting a review of the mock-up or test panel will be evaluated for acceptance.

defects, physical damage, chemical damage, and contamination. Remove/repair all laitance, efflorescence, bug holes, voids, and other surface defects before and after surface preparation according to coating manufacturer’s recommendations. Recondition repair areas before coating.

1.a. Potential Surface Contamination. When directed based on age and condition of the surface, perform pH testing before surface preparation according to Section 5.2 of ASTM F710. Remove contamination to levels recommended by the coating manufacturer. If no manufacturer recommendations exist, provide pH levels greater than or equal to 7.0 and less than or equal to 10.0. Perform another pH test after removal to verify manufacturer’s cleaning method achieved the recommended level.

drawing compounds, form oil, and other contaminants are present, remove according to manufacturer’s recommendations or at a minimum according to ASTM D4258. 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.

preparation required to achieve an anchor profile of CSP 2, CSP 3 or CSP 4; unless a greater CSP is required by the manufacturer. Determine the anchor profile by using International Concrete Repair Institute (ICRI) comparator plates according to Technical Guideline No. 310.2-1997.

dust, dirt, grease, oil, moisture, overspray, and other contaminants. 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 exceeding 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, according to manufacturer’s recommendations to a smooth, lump free consistency. Mix in the original containers. Ensure that 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.

coating application has begun.

moisture using the plastic sheet method according to ASTM D4263 or by use of an electrical impedance moisture meter according to ASTM F710 using the concrete scale. When using an electrical impedance moisture meter perform calibration verification in the presence of the Representative before taking any measurements. Moisture acceptance criteria will be according to manufacturers and the moisture meter manufacturer’s recommendations and as approved. If not specified in the technical data sheet, then moisture content must not exceed 2.5 %. If 2.5% is exceeded, then correlate the electrical impedance results with use of the plastic sheet method to obtain approval from the representative to continue use of the electrical impedance meter. The moisture acceptance criteria to be evaluated as part of the full size mock-up. 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 coati ngs when the air is misty. Do not apply coating when relative humidity is above that described in the technical data sheet or above 85 % if not specified. 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 manufacturer. 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.

according to manufacturer’s recommendations. Perform nondestructive DFT measurements according to SSPC-PA 2; take and record a minimum of five spot measurements for each 100 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, 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 LTS, when directed. Provide unopened sample kits for testing, when unopened sample kits are not practical sampling will be done according to ASTM D3925.

9.a. Adhesion Acceptance Testing. Perform adhesion testing, on 10 %of the total number of coated items, according to Method A of ASTM D3359 when directed. 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, 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.

• 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 as determined.

recommendations. Submit repair procedures for approval 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 from a distance of 30 feet for color acceptance.

following information on the outside face of the fascia members at the near and far abutment ends (two in total) unless directed otherwise:

• Line 1: Month and year of completion and ECMS number

• Line 2: BR Key

• Line 3: BMS Number

• Line 4: Type of coating system, and cleaning method

• Line 5: NEPCOAT number listed in Bulletin 15, and the manufacturer’s name

Examples:

08-2018, ECMS 88335 BR KEY: 712 02-0051-0110-0000IZEU, SSPC-SP10 SSC(12)-03, Carboline

Stencil using indelible black paint compatible with the coating system and approved by the coating manufacturer. Provide uniform block lettering 2 inches to 3 inches high.

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.

1045.4MEASUREMENT AND PAYMENT—Square Yard

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