1060SHOP PAINTING STRUCTURAL STEEL

1060.1DESCRIPTION —This work is the preparation and application of a three coat paint system for

structural steel using an approved paint system listed in Bulletin 15. Painting operations are to take place in a Bulletin 15 approved coating or fabrication shop. The primer coat is to be applied in the shop while the intermediate and top coats may be applied in the shop or in the field. Any field painting will be covered as specified in Section 1070.

that are certified by the AISC under its Sophisticated Paint Endorsement (SPE) qualit y program or by the Society for Protective Coatings (SSPC) under its QP3 quality program. Use Shops certified to the “enclosed shop” category. Use shops that are fully certified for the duration of time they are performing surface preparation and coating application. Apply complete coating system in an “enclosed shop” except for touch up painting. For shop removal and disposal of hazardous coating, including but not limited to lead based paint, use only shops certified to SSPC-QP3 and listed in Bulletin 15 as approved paint shops.

1060.2MATERIAL—

system, from a manufacturer listed in Bulletin 15, consisting of a self-curing, inorganic zinc primer, an epoxy or urethane intermediate coat, and an aliphatic urethane top coat. Do not mix components or coats from different systems. Use the products from the same manufacturer for the entire system. When new steel is to be connected to existing steel in the field, the coating system applied in the shop must be the same system applied in the field to ensure compatibility.

for Bulletin 15 evaluation and approval:

• 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 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

• Percent of metallic zinc by mass (weight) in the cured zinc primer coat, dry film

• Percent of metallic zinc by mass (weight) in the zinc pigment component

a minimum of 21 calendar days before beginning the coating. Begin coating after the Representative accepts the submittals. • Top coat color chips, of the color indicated for approval by the District Bridge Engineer; and

• Technical data sheets, safety data, and specific application instructions for all coats. If a conflict occurs between the data/instruction sheets and these Specifications, the Chief Structural Materials Engineer will determine the governing specification. Work will not be allowed to proceed until this information is received.

from the paint manufacturer at the beginning of operations and when required.

steel shop drawings that describes the procedures and protective materials to be used to prevent damage to paint coats. Have the plan cover the period of time from when paint coats are applied in the shop until erection is completed in the field. Submit the manufacturer's recommended surface preparation methods, coating material, application methods, and application conditions. Include the manufacturer’s recommended methods for correction of damage to one or more coats, including correction of damage caused in handling, shipping, and erection; correction of deficient or excessive coating thickness; correction of runs, sags, peeling, and poorly adhered coating; and removal of zinc salts and other contaminants that would be detrimental to succeeding coats. The Contractor is responsible for performing the proper repair of damage to the coating system caused by handling, shipping, erection, and bridge construction.

in Bulletin 15 omitting the primer coat and applying the intermediate and top coats. Select contrasting colors for the intermediate and top coat before fabrication. Do not mix components from different systems. If a wash primer is used, provide the manufacturer’s certification of compatibility with the selected paint system.

• Furnish submittals as specified in Section 1060.2( b) and 1060.2(c) for intermediate and top coats. Furnish technical representation as specified in Section 1060.2( d). Furnish damage prevention and repair procedures as specified in Section 1060.2(e).

coating system consisting of an 85/15 zinc/aluminum alloy wire, sealer, and top coat when a duplex system is specified. Use an approved thermal spray coating system consisting of an 85/15 zinc/aluminum alloy wire and a sealer when only a metalizing system is specified.

• Furnish submittals as specified in Section 1060.2( b) and 1060.2(c) for sealer and top coats. Furnish technical representation as specified in Section 1060.2( d). Furnish damage prevention and repair procedures as specified in Section 1060.2(e).

1060.3CONSTRUCTION—

and environmental health and safety rules and regulations.

1.a Edge Preparation. Before blasting, round edges to be painted, to a radius of 1/16” ± 1/32”.

1.b Weld Preparation. Before blasting, remove slag and weld spatter.

2.a Solvent Cleaning. Where oil, grease, lubricants, cutting compounds, petroleum products, and other contaminants are present remove according to the SSPC Surface Preparation Standard No. 1 Solvent Cleaning (SSPC-SP1). Perform cleaning before blasting. If contamination remains after blasting, reclean with solvent and reblast. SSPC-SP1 is a prerequisite to all other SSPC-SP surface cleanliness standards.

2.b Other Cleaning. Remove soil, concrete spatter, drawing compounds, salts, or other foreign matter by brushing with stiff fiber or wire brushes; by scraping; by cleaning with solutions of biodegradable cleaners, provided such cleaners are followed by a fresh water rinse, or by a combination of these methods. Satisfactorily remove detrimental deposits from new weld areas. When directed remove chlorides and other

water soluble salts according to NACE WJ -4/SSPC-SP WJ4 , by low-pressure water cleaning (gage pressures less than 5000 p ounds per square inch) or high-pressure water cleaning (gage pressures from 5000 to 10,000 pounds per square inch).

above the dewpoint. Determine the dewpoint with the use of a psychrometer and psychrometric tables or Electronic Psychrometer. Check environmental conditions before blasting operations begin and at four hour intervals thereafter.

Determine the near-white blast condition by use of SSPC-VIS 1 visual guide. Blast clean to leave an anchor pattern, from 1 1/2 mils to 3 1/2 mils deep, in a dense, uniform pattern of depressions and ridges. Determine the anchor pattern depth by using replica tape, according to ASTM D4417, Method C. The required number of replica tape tests and frequency are outlined below. Grind laminations raised by the blasting operation to a flush surface and restore the ground area to the specified anchor pattern.

4.a Centrifugal Blast Cleaning using Recyclable Abrasives. Abrasives must be clean, dry, free of oils, grease and other harmful materials as determined by the test methods SSPC-AB1, SSPC-AB2 and SSPC-AB3. Perform anchor pattern depth testing, using replica tape, as follows:

• Three random replica tape readings on each main member.

• Three random replica tape readings on 20% of all secondary members, but not less than t hree per shift.

• Two random replica tape readings on 5% of all miscellaneous items.

4.b Hand Blasting. Utilize clean and dry compressed air. Conduct blotter test(s) according to ASTM D4285, at the start of each shift and every four hours during blasting operations. Conduct the tests in the presence of the Inspector. When hand blasting, perform anchor pattern depth testing, using replica tape, as follows:

• Five random replica tape readings on each main member.

• Three random replica tape readings on 30% of all secondary members , but no t less than six replica tape readings per shift.

• Three random replica tape readings on 10%of all miscellaneous items.

High spots and rough edges must be smoothed to avoid paint film gaps as directed according to SSPC - SP2 and SSPC -SP3. Prepare surface for galvanizing by applying a wash primer treatment that is compatible with galvanizing and selected paint system, or by brush-off blasting the entire surface according to SSPC-SP 16. Do not use steel shot for brush-off blast. Use a blast media with a low level of aggressiveness, such as crushed walnut shells, corn cobs or bi-carbonate of soda for example, but not inclusive.

coatings according to the AASHTO/NSBA Steel Bridge Collaboration’s Specification for Application of Thermal Spray Coating Systems to Steel Bridges (S8.2-2017/SSPC-PA 18) except the following:

• Perform thermal spray coatings applications at a fabrication shop approved according to SSPC QP 6 qualification program.

• Apply Thermal Spray Coating to a coating thickness of at least 8 mils.

• Perform bend test according to Appendix A of the SSPC-CS 23.00/AWS C.2.23/NACE No. 12

• Perform hammer and chisel cut test according to Appendix B of the SSPC -CS 23.00/AWS C.2.23/NACE No. 12

• Companion coupons are allowed for use according to SSPC-CS 23.00/AWS C.2.23/NACE No. 12

• Slip critical faying surfaces requiring a slip B coefficient must remain unsealed and the thermal spray coating thickness must not exceed more than 16 mils per element.

intact. Minor damage may be accepted if container is not punctured.

and thinners in well ventilated areas not subject to temperatures in excessive 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.

overspray, and other contaminants.

4.a Primer. Mix the primer with a high shear mixer (such as a jiffy mixer), according to the manufacturer's recommendations to a smooth, lump free consistency. Do not use paddle mixers or paint shakers. Mix in the original containers. Continue mixing until the metallic powder or pigment is in suspension. Ensure that the coating solids that might have settled to the bottom of the container are thoroughly dispersed. Strain the mixture through 30 mesh to 60 mesh screen openings to remove large particles. Equip paint containers with a mechanical agitator so the mixture is in motion throughout the application period.

4.b Subsequent Coats. Mix each subsequent coat to achieve and to maintain a homogeneous mixture.

application has begun.

temperature of the air, paint, or metal is below 40F, and at no time above or below that described in the technical data sheet; when the air is misty; or when conditions are otherwise unsatisfactory. Do not paint when relative humidity is above the limit according to the manufacturer’s recommendations. Do not paint damp or frosted surfaces or surfaces hot enough to cause the paint to blister, to produce a porous paint film, or to cause the vehicle to separate from the pigment. Paint only when the surface temperature is at least 5F above the dewpoint. Determine the dewpoint with the use of a psychrometer and psychrometric tables or Electronic Psychrometer. Check environmental conditions before painting operations begin and at four hour intervals. If the dewpoint begins to rise and comes within 10F of the surface temperature, check environmental conditions every 15 minutes. Allow each coat of paint to cure before applying the succeeding coat. Follow the manufacturer's recommendations for drying time, unless a longer drying time is required. In damp or cold weather, keep the shop work under cover until thoroughly cured, or until weather conditions allow exposure.

the surface. Apply primer within 8 hours of blast cleaning. If the metal is not painted within 8 hours following blast cleaning; the surface temperature of the metal falls below the dewpoint temperature; or the metal shows signs of flash rust, blast clean it again before priming.

Apply inorganic zinc-rich primer according to the manufacturer's recommendations. Stripe any areas that are inaccessible, by spray, with inorganic zinc-rich primer. For application of the intermediate and top coats, wet stripe all edges, bolts, welds, rivets, corners, crevices, and other irregularities either by brush or by a separate and distinct spray operation, before the application of the full coat. Extend the stripe coat a minimum of 1” from edges, bolts, welds, rivets, corners, crevices and other irregularities. Provide safe access for inspection, as requested by the Representative, before application of the full coat over the striped areas. Do not apply the full coat until approval of the stripe coat is provided. Apply intermediate and final coats to areas of steel that will be inaccessible before the stage of construction that prevents access. Other types of prime coats may be substituted for the galvanized coating only if prior approval is received from the Department. Submit the written approval request at the preconstruction conference. Follow the paint manufacturer's recommendations to ensure comp atibility between the prime coat and the intermediate coat and to ensure adhesion when the surface of the prime coat has been contaminated, for example, by bolt/nut lubrication.

shipment. Do not apply primer to galvanized surfaces. Paint field contact surfaces and surfaces to be in contact with concrete with primer only, except in the unpainted area of weathering steel unless indicated. Do not paint within 2 inches of location of design field welds. Coat machine -finished metal surfaces, subjected to movement, with either corrosion -preventive compound, conforming to the requirements of Military Specification MIL -C-16173D, Grade 2, or other acceptable material, as soon as possible after acceptance and before removal from the shop. Paint other surfaces of metal, either milled or finished, with primer. Cer tify the coating material as specified in Section

106.03(b)3

Paint or stencil the required dates, weight markings, and erection markings only on previously primed or painted surfaces. Use a suitable paint that does not react with other primer or paint coats, and one that is not visible after the final field paint coat. Allow the paint to dry completely before loading and shipping. Protect the paint from damage and contamination. Use coverings and proper storage, handling, shipping, and erection techniques. Repair damaged and contaminated coatings according to the manufacturer's recommendations. Repair each coat according to manufacturer’s recommendations if more than one coat is damaged.

8.a Spray Painting. 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 paint application begins. Mix paint thoroughly by continuous agitation when applying primer.

8.b Roller Painting. Use rollers that do not leave a stippled texture in the paint film. Use rollers only on flat, even surfaces to produce a paint film of even thickness with no skips, runs, sags, or thin areas.

8.c Brush Painting. Use flat brushes, not wider than 4 1/2 inches, or round or oval brushes. Manipulate the paint under the brush to produce a uniform, even coat. Work the paint 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 paint film has an even thickness. Mix paint thoroughly by continuous agitation when applying primer.

8.d Painting Inaccessible Areas. Thoroughly cover surfaces inaccessible to normal painting methods by use of sheepskin daubers, spray, or other means to ensure thorough coverage. Mix paint thoroughly by continuous agitation when applying primer. 8.e Stenciling. After the final coat of paint has dried, stencil the following information on the outside face of the fascia members at the near and far abutment ends 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 manufacturers name

Examples:

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

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

according to SSPC-PA2 Appendix 2 For all other f abricated items perform dry film thickness measurements according to SSPC-PA2. For three coat systems, perform dry film thickness measurements after the application of each coat. Determine the dry film thickness of the intermediate and top coats by subtracting the average dry film thickness of the underlying coat(s) from the cumulative reading. Increase the thickness of coating, if directed, to ensure a finish that is uniform in color and appearance. Apply the three-coat system as follows:

9.a Primer. Spray apply, according to the manufacturer’s recommendations, in a single application, employing multiple spray passes, to the dry film thickness according to the paint manufacturer’s product data sheet above the anchor pattern. A dense and uniform appearance is required after the applied coating has cured. For areas deficient in coating thickness and areas exhibiting mudcracking, repair, according to the manufacturer’s recommendations.

9.b Intermediate Coat. Apply the intermediate coat, above the prime coat to the dry film thickness according to the paint manufacturer’s product data sheet. Use a color that contrasts with the colors of the zinc and top coats.

9.c Top Coat. Apply the top coat, above the intermediate coat, to the dry film thickness according to the paint manufacturer’s product data sheet.

lifts, blisters, wrinkles, has excessive coating thickness, has excessive runs or sags, or shows evidence of application under unfavorable conditions; the workmanship is poor; impure or unauthorized paint has been used; or for other reasons determined. Remove unsatisfactory paint, clean the metal, and repaint, as directed.

1060.4MEASUREMENT AND PAYMENT —Painting structural steel is incidental to the items of work

painted.