SECTION 825 — PAINTING STRUCTURAL STEEL — PAINTING STRUCTURAL STEEL
825.01 Description.
This work includes the thorough cleaning, preparation of surfaces, painting or repainting of new or existing steel, galvanized, and metalized structures, its components or other steel materials at the required locations. Submittals. Submit the items listed below to the Department for approval before performing any work. This list does not include required submittals that are a part of other related Specifications: • Contractor applicator qualifications and material certifications. Refer to Subsection 825.01.5 and SECTION M06 • Topcoat color samples • Product Data Sheets (PDS) and Safety Data Sheets (SDS) according to SECTION M06 • Quality Control Plan according to Subsection 825.03.8 • Scaffolding/work platforms • Removal/repair procedures for unsatisfactory material (if required) Toxic Substances. Existing paint systems on the Department’s bridges may contain toxic substances such as lead, chromium, or cadmium, and these substances are considered hazardous to personnel, the environment, and the public proximate to the Project. P lan and take appropriate precautions during the painting operations and for waste disposal to meet the State and Federal requirements for the protection of workers, the public, and the environment. See SECTION 826 for a thorough discussion. Protection of Personnel, Public, Environment, and Structure. This provision addresses the requirements for removal and containment of paint and/or corrosion products from any steel bridge or other specified appurtenances during surface preparation and painting operations . Conduct all activities associated with the coating work specified herein according to all applicable Federal, State, and local regulations, SECTIONS 107 and 826, the Contract Special Provisions and the SSPC-PA Guide 10, “Guide to Safety and Health Requirements for Industrial Painting Projects.” Protect pedestrians from injury, vehicular, and/or other traffic on or under the bridge or structure, surrounding property, surfaces, buildings, grounds, etc., against damage or disfigurement from surface preparation media, or spatters, splashes, overspray , and smears of paint or material . Furnish adequate containment materials for protection. Remove paint drips, spills, or overspray from concrete or other surfaces not designated to receive coatings. Remove and dispose of debris from cleaning operations, and empty paint containers and other refuse at no additional cost to the Department.
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-151 Pollution Controls. Prevent environmental pollution of air, soil, and water caused by surface preparation media, paint spills or overspray, paint chips, dust, or other harmful materials. See SECTION 107. Contractor Applicator Qualification. Ensure that all painters are SSPC certified or AISC certified. Demonstrate that the Contractor(s) performing coating application has qualifications by obtaining either the Society for Protective Coatings (SSPC) QP 1 “Standard Procedure for Evaluating Painting Contractors (Field Application to Complex Industrial Structures) ” for field painting or SSPC QP-3 “Certification Standard for Shop Application of Complex Protective Coating Systems” as appropriate, or the American Institute of Steel Construction (AISC) Sophisticated Paint Endorsement (SPE). Demonstrate that the Contractors involved in the removal of paint containing lead or other toxic metals are certified SSPC QP2, “Standard Procedure Evaluating the Qualifications of Painting Contractors to Remove Hazardous Paint. ” For field work involving abrasive blast cleaning and painting , follow the requirements of the SSPC CAS QP1 Implementations Schedule as defined on the SSPC Web site (www.sspc.org) . Maintain the qualification throughout the painting portion of the Project. If the qualification expires or is revoked for any reason, notify the Engineer, who may require that a qualified Contractor complete the coating portion of the Project.
825.02 Materials.
Provide materials that conform to SECTION M06 and to the manufacturer’s recommendations as applicable. If there is a conflict between the manufacturer ’s recommendations and the requirements of this Section, comply with this Section unless the requirements of the manufacturer are more restrictive. In these cases, advise the Engineer of the discrepancies, in writing, and comply with the Engineer’s written resolution. Paint Supplier. Provide all paint material products including primer, intermediate coat, topcoat, and thinners from the same paint supplier and ensure compatibility of components . Use the same paint manufacturer throughout all work. Provide paints that are lead and chromium free. Use a coating system that is an approved NEPCOAT Qualified Product from List A or B according to SECTION M06. Topcoat Color. Provide a semi-gloss topcoat in the color specified. Provide color chips and the Munsel and/or Federal Standard color designation for verification of the color of the topcoat . Ensure that t he color of the primer does not affect the color of the topcoat.
Part 800 — Bridge Structures August 2025
800-152 SECTION 825 — PAINTING STRUCTURAL STEEL VOC Compliance. Ensure that all paint products conform to all Federal, State, and local requirements at the point of application as determined using EPA Method 24.
825.03 Construction Methods.
Surface Preparation.
a.General Requirements. Perform the surface preparation according to the manufacturer’s recommendations, most recent edition of the “ Society of Protective Coatings Specifications” and additional requirements contained in the Contract Documents , whichever is more stringent, as determined by the Engineer.
b.E ngineer ’s Access. Provide access for sampling and testing paint material components. Samples may be subject to chemical and physical testing. Materials that are of unsatisfactory quality will be rejected. Also, see SECTION 107.
c.S urface Anomalies . ● Corner Condition – Remove all sharp corners of steel created by flame cutting or shearing using a grinder. For zinc-rich primers, stripe-coat all corners resulting from sawing, burning, or shearing operations. ● Preparation of Thermal Cut Edges – Soften thermal cut edges before blast cleaning as necessary to achieve proper blast profile. ● Base Metal Surface Irregularities – Remove all visually evident surface defects according to ASTM A6 before blast cleaning steel. When material defects exposed by blast cleaning are removed, restore the blast profile by either blast cleaning or by using mechanical tools according to SSPC-SP 11 “Power Tool Cleaning to Bare Metal.” ● Weld Irregularities or Spatter – Remove or repair all sharp weld prominences, weld deficiencies (overlap, rollover, excessive concavity, convexity, or roughness) , and all heavy, sharp, or loose weld spatter. Occasional individual particles of rounded tight weld spatter may remain if fully covered or encapsulated, but remove widespread, sharp, or clustered particles of tight weld spatter. Remove the weld irregularities and spatter to form a flush surface.
d.Pre-Cleaning. Remove all oil, grease, and other adherent deleterious substances from areas to be painted according to SSPC -SP 1 “Solvent Cleaning” before abrasive blast cleaning.
e.A brasive Blast Cleaning. Abrasive blast -clean the entire surface according to the cleanliness and profile required by the manufacture’ s Product Data Sheet . Assess the profile per ASTM D 4417. Clean all new structural steel according to SSPC SP-10, “Near White Blast Cleaning.” Ensure that t he abrasive blast media meets SSPC-AB1 “Mineral & Slag Abrasives,” SSPC-AB 2 “Cleanliness of Recycled Ferrous Metallic Abrasives,” or SSPC-AB3 “Ferrous Metallic Abrasives.” If the material for the Project is heavily rusted or pitted, measure the non -visible contaminant and remove according to SSPC-Guide 15 “Field Methods for Retrieval and Analysis of Soluble Salts on Steel and Other Nonporous
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-153 Substrates” to ensure that detectable chloride levels are less than 10 micrograms per square centimeter. Equip compressed air supply lines with oil traps and moisture separators. Conduct a white blotter test according to ASTM D 4285 to verify the cleanliness of the compressed air. Conduct the test at least once per shift for each compressor system . Sufficient freedom from oil and moisture is confirmed if no soiling or discoloration is visible on the paper. Paint Application.
a.General Requirements . Apply coatings according to SSPC- PA 1, “Shop, Field, and Maintenance Painting of Steel ” and the manufacturer ’s recommendations . Apply the coating to provide a coating that is: ● A continuous, uniform film of the specified thickness that is well bonded to the substrate or previously applied coating ● Free of laps, streaks, sags, separation, unevenness, discoloration, and other visually evident defects ● Applied within the manufacturer’s specified pot life Repair areas that fail any required test as outlined in Para. j “ Removal/Repair of Unsatisfactory Material.”
b.Coating Material Storage. Store paint according to SSPC- QP3, SSPC-PA 1, and the manufacturer’s recommendations. Record the daily storage temperature range for coating materials and verify conformance with the coating manufacturer ’s recommendations . Inventory the components to ensure that they are used within the shelf life prescribed by the manufacturer. Record the coating batch numbers from each mixed component, the amount and type of thinner used, and the date of application. Do not expose paint in storage to temperatures lower than those recommended by the paint manufacturer . Paint exposed to temperatures higher or lower than specified is subject to rejection or retesting. When paint is rejected, cease painting operations until the rejected paint is removed from the Project site.
c.Conditions for Application. Apply the paint material to clean dry surfaces . Comply with the atmospheric conditions specified below or the written recommendations of the manufacturer, whichever is more stringent. Do not apply materials when: ● The temperature of the air or substrate is below 40° F or greater than 1 00°F or is forecasted to drop below 40°F before the coating dries according to the dry times specified in the manufacturer’s recommendations. ● The surface temperature is less than 5°F above the dew point. ● The relative humidity is above 85 percent.
Part 800 — Bridge Structures August 2025
800-154 SECTION 825 — PAINTING STRUCTURAL STEEL ● There is or will be rain, mist, fog, or snow during application and/or cure. ● The manufacturer’s requirements for reaction time after mixing are not satisfied.
d.Methods of Application. Use brushes, rollers, spray equipment, or any combination of equipment recommended by the manufacturer and authorized by the Engineer that provides a finish acceptable to the Department.
e.S tripe Coats . Apply a stripe coat of primer to corners, weld seams, around nuts and bolts, or as otherwise directed in the Contract Documents. Do not apply the full coat of primer any sooner than 15 minutes after the application of the stripe coat or any later than the manufacturer’s recommended recoat times . Notify Inspection personnel and provide ample time to verify and approve the stripe coat application. Do not apply the full coat of primer until the Engineer has approved the striping in writing. The coating material used for the stripe coat is typically the intermediate coat but , for painting, metalizing, or galvanizing surfaces, the approved finish coat is striped.
f.I ntermediate and Topcoat . Ensure that the intermediate coat color contrasts with both the primer and topcoat. Stripe coats may be tinted as necessary to ensure proper coverage. Ensure that coating materials used to apply piece marks are compatible with the existent and any subsequent coats.
g.R ecoat Interval . Comply with the coating manufacturer’s minimum and maximum recoat interval for each coating layer. Ensure that each coating layer is sufficiently cured before applying the next scheduled coating layer.
h.Fi eld Applied Coatings -Touchup of Primer and Intermediate Coat(s). Before applying field touch-up coatings, verify that all surfaces, including installed bolts, nuts , and zinc-rich primer around connection plates , are thoroughly cleaned of grease, oil, chalk, bird droppings, lubricants, and other adhesive interference material. Use pressure washing or solvent cleaning, as appropriate, to remove the interference material . Use hand and power tool cleaning for spot repair of localized damage to the coating system . Pressure wash using 1500 psi water pressure all surfaces primed w ith zinc-rich primer to remove zinc salts. Do not proceed with touchup and painting until the Engineer has accepted the surface cleaning. Repair any damaged areas of coating and reapply all affected coating layers. Perform field touchup in areas around bolts, nuts, connection plates, and other areas that had not previously been painted according to the manufacturer ’s recommendations. Comply with Paras. c and d for application.
i.Fi eld Applied Coatings Topcoat Application. Apply topcoat in the field after the Engineer has accepted the touch up (primer and intermediate) and after the structure has been erected on the Project site. Verify that the amount of time between the application of the intermediate and the topcoat is within the coating manufacturer’s recommended maximum recoat time. Verify that the surface is clean and dry before the application of the topcoat. If grease, oil, or other contaminants become deposited on the intermediate coat, remove it according to SSPC-SP1 before the application of the topcoat. Comply with Paras. c and d for application.
j.R emoval/Repair of Unsatisfactory Material . The coating system is unsatisfactory if any of the following defects are observed:
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-155 ● Abrasion damage ● Peeling ● Blistering ● Wrinkling ● Excessive runs ● Sags ● Evidence of application under unfavorable conditions ● Poor workmanship ● Use of unauthorized coating material ● Other defects as determined by the Engineer Submit repair procedures for unsatisfactory material to the Department for approval in writing before performing related work. Remove and replace unsatisfactory coating layers at no additional cost to the Department as specified below: ● Bare Steel Exposed Less Than 4 in. × 4 in. Area. When the defective paint or damage extends to the bare steel or if bare steel is exposed in areas less than 4 in. × 4 in. in size, clean the surface by power tool cleaning according to SSPC-SP11. Feather the surrounding paint to expose a minimum of ½ in. of each coat a round the entire perimeter of the repair area and to provide a smooth transition into the surrounding intact, adherent material. Select a primer recommended by the manufacturer for the intermediate and topcoat. For new steel, apply a spot coat of zinc -rich primer to the prepared surface. Follow with a spot coat of the intermediate and topcoat. ● Bare Steel Exposed Greater Than 4 in. × 4 in. Area. When the defective paint or damage extends to the bare steel in areas greater than 4 in. × 4 in. in size, blast clean the area according to SSPC SP10, feather the surrounding paint , and repair as described above. ● Primer or Intermediate Coat Exposed. When the damaged or defective paint extends to the primer or intermediate coat, and for primed areas around and on connection plates, clean the surface by hand or power tool cleaning. Clean according to SSPC SP2 or SSPC SP3 to remove oxidation, zinc-salts, and contamination from the surface. Do not burnish or polish the surface. Supplement hand and power tool cleaning with pressure washing (1500 psi minimum) accompanied by scrubbing with stiff bristled brushes or other means as necessary. Feather the surrounding material to expose a minimum of ½ in. of each coat and to provide a smooth transition into the surrounding intact, adherent coating material. ● All Repairs. For all repairs, roughen the paint in overcoat areas with 80 grit sandpaper to ensure good adhesion of the overcoat material to the underlying paint. Also, solvent clean according to SSPC SP1 and repaint the affected areas with the intermediate and topcoat.
k.S caffolding. Use rubber rollers or other protective devices to prevent damage to the finished coatings. In particular, use sufficient support pads for bracing on fascias. Do not allow temporary supports or attachments for scaffolding or forms to damage the coating system. Repair areas damaged by scaffolding according to Para. j above.
Part 800 — Bridge Structures August 2025
800-156 SECTION 825 — PAINTING STRUCTURAL STEEL
l.Technical Supervision. The Contractor/fabricator is responsible for securing the services of the technical representative, the services of which will be at no additional cost to the Department. New Steel Structures. Work under this paragraph only applies to structures being built new or structures whose superstructure is being replaced in its entirety. For new steel used in partial replacement or rehabilitation, see Subsection 825.03.4.
a.General. Use a three-coat system approved by the Northeast Protective Coating Committee (NEPCOAT), or as described in Subsection 825.03.5, and that conforms to SECTION M06 and the following: ● Exterior Steel Surfaces . Use a system that consists of a prime coat, intermediate stripe coat, intermediate coat, and topcoat. ● Interior Steel Surfaces. Use a coating system for the interior surfaces, such as open box girders, arch ribs and ties , and tubular wind bracing, that consists of a two-coat NEPCOAT exterior system and contrasts with the primer. This system contains a zinc- rich primer and intermediate coat. Select the same primer and intermediate coat for application to both interior and exterior surfaces of the same steel member . Interior surfaces require no topcoat. Use white for t he intermediate coat applied to interior surfaces.
b.P riming Faying Surfaces. Ensure that the coatings applied to contact surfaces of bolted connections between primary members comply with the AASHTO LRFD Bridge Construction Specifications. Use a coating system for faying surfaces that has a slip coefficient of Class B . Before shop bolting, verify that the coating on faying surfaces is applied at the recommended dry film thickness and that the temperature adjusted cure time for shop and field slip critical bolted faying surfaces is within the range previously validated through testing by the applicator’s QC person or as given by NEPCOAT. Verify the cure according to ASTM D 4752 or the manufacturer’s requirements. Apply the zinc-rich primer to all surfaces. Do not apply intermediate and topcoats to faying surfaces, connection areas, or within 2 in. of a connection area that will be welded. Mask or otherwise protect these surfaces to prevent the application of intermediate and topcoats. Zinc-rich primer is not allowed on flange surfaces that will be embedded in concrete, although overspray is allowed on the flange surfaces. Apply the topcoat to the same surfaces coated with the intermediate coat, except those surfaces that will be embedded in concrete.
c.Bolts (Fasteners). Prepare bolts installed and final tightened before priming as necessary so that, after the steel is abrasive blast cleaned, exposed bolt surfaces will satisfy the requirements in the Table below. Black bolts, nuts, and washers, including flat faces of nuts and bolt heads facing adjacent material, may require spot blast cleaning or other surface preparation before general blast cleaning to ensure that the proper surface profile to obtain adhesion of the primer has been achieved.
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-157 Surface Preparation Requirements for Fasteners and Bolts Item Fasteners Installed Before Cleaning & Primer Application Fasteners Installed After Primer Application Coating System Surface Preparation Coating System Surface Preparation Black Iron Bolts OZ or IOZ, I, T SSPC-SP10 IOZ, OZ, I, T SSPC-SP 1 & 10 Galvanized (Mechanical or Hot Dip) OZ or IOZ, I, T SSPC-SP 1 I, T SSPC-SP 1 & 2/3 Key: • OZ = Organic Zinc-Rich Primer • IOZ = Inorganic Zinc-Rich Primer • I = Intermediate Coat • T = Topcoat If the zinc coating on shop- installed galvanized bolts is damaged during shop abrasive blast cleaning or tightening, the coating may remain as is only if the entire coating system (including the zinc-rich primer) will be applied over the fasteners. Remove the lubricant from bolts . Obtain from the fabricator the identity of solvents and methods needed to remove the lubricant. Consult with the coating supplier to assess the compatibility of the coating with any lubricant residue. Supply to the shop and field painters, the Engineer, and other interested parties the information concerning the lubricant removal and the cleanliness necessary for satisfactory adhesion of the subsequent coat as described in the Table above. Use a white cloth wipe test with no color transfer to confirm that all lubricant and non - absorbed dye has been removed; only residual stain is permitted to remain on the surface.
d.Shipping, Storage, and Erection of Steel. When handling, storing, shipping, and erecting the steel, avoid damage to the coating system. Do not move coated steel in the shop until sufficient cure time has elapsed to ensure that no damage will be done to the fresh coating. Do not ship the steel from the shop to the field until the last coating has fully cured. Install padding on hooks and slings used to hoist the steel , and use softeners approved by the Engineer to insulate the steel from binding chains. Place small structural pieces in so that no rubbing will occur during shipment. Store the steel at the job site on pallets or by other means to prevent members from resting directly on the ground or from falling onto each other.
Part 800 — Bridge Structures August 2025
800-158 SECTION 825 — PAINTING STRUCTURAL STEEL Existing Steel Structures. Work under this section is only applicable to structures that are not addressed under Subsection 825.03.3.
a.Protection of Painted Surfaces . Protect freshly coated surfaces and those surfaces not scheduled for painting from over blast and stray abrasive during blast cleaning operations. Clean any previously coated surfaces damaged by subsequent blast cleaning operations according to SSPC SP10 and recoated according to this specification.
b.S urface Preparation. Obtain the Engineer’s approval of the preparation of all surfaces to be painted before applying any paint. Surface preparation and coating requirements are dependent upon the scope of work and the type and condition of the existing coating system. The Table below provides the required surface preparation methods for four scenarios. Use the specific coating material requirements for each surface preparation method in SECTION M06. Surface Preparation Methods for Spot, Zone and Overcoating1 Scope of Work Surface Preparation Existing Coating System Spot Prime and Overcoat Method 1 Alkyd Coatings Spot Prime and Overcoat Method 2 Zinc-rich or Metalizing/Galvanizing with Topcoat Zone Painting Method 3 Alkyd Coatings Zone Painting Method 3 or Method 4 Zinc-rich or Metalizing/Galvanizing with Topcoat
1.Ensure that the surface preparation methods are according to the paint manufacturer ’s recommendations, unless the requirements in this T able exceed the manufacturer ’s recommendations. In case of conflict, use the more stringent surface preparation methods as determined by the Engineer.
c.Method 1: Spot Prime and Overcoat an Existing Alkyd Coating System. Spot clean localized areas of corrosion or coating breakdown using vacuum shrouded power tools according to SSPC-SP3, “Power Tool Cleaning.” Feather the edges of the power tool cleaned areas. Prepare the intact alkyd coating for overcoating by cleaning according to Low-Pressure Water Cleaning (LP WC) of SSPC-SP12. The minimum acceptable water pressure is 1500 psi. Use low pressure water cleaning to remove chalk, pigeon droppings, dirt, and other deleterious materials from the surface.
d.M ethod 2: Spot Prime and Overcoat an Existing Coating System. Spot clean localized areas of corrosion or coating breakdown using vacuum shrouded power tools according to SSPC-SP11, “Power Tool Cleaning to Bare Metal, ” or using vacuum blast cleaning equipment according to SSPC-SP10, “Near White Blast Cleaning.” Feather the edges of the repaired area. Prepare the intact topcoats (epoxies or urethanes) for overcoating by hand sanding to roughen the surface.
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-159
e.Method 3: Abrasive Blast Clean. To remove all coating material from a well-defined zone (portion of the structure). B last clean steel according to SSPC SP10, “Near White Blast Cleaning.” Ensure that the surface area of the steel to be blast cleaned is no greater than the surface area of steel that can be primed during the same day. Ensure that the maximum time lapse between surface preparation and application of the prime coat is not greater than eight hours, unless atmospheric controls are used to prevent “ rust back.” If any “rust back” occurs before priming, reclean surfaces to provide the specified degree of cleanliness. Ensure that the abrasive blast profile meets the manufacturer’s requirements as stated on the product data sheets.
f.M ethod 4: Water Wash and Ultrahigh Pressure Water Clean. Use in a well -defined zone (portion of the structure). Pressure wash all surfaces in the zone that will be coated, including areas of limited access such as crevices between back to back angles. Use low pressure washing to remove the loose debris, followed by ultrahigh pressure water cleaning to remove all existing coating and corrosion from the steel surfaces scheduled to be coated. Comply with the requirements of SSPC- SP 12, “ Surface Preparation and Cleaning of Steel and Other Hard Materials by High- and Ultrahigh-Pressure Water Jetting Before Recoating.” Ensure that cleaned steel surfaces that will be painted conform to the Visual Surface Preparation Definitions of the surface condition WJ-3 in SSPC SP12. Do not use rust inhibitors. Reclean steel surfaces not primed within 72 hours by water jetting. Collect all water and paint chips dislodged by the water cleaning process. Use potable filtered water for the washing to achieve a surface that is free of paint, corrosion, and other visible contaminates. Measure the non- visible contaminant and remove according to SSPC-Guide 15 to ensure that detectable chloride levels are less than 10 micrograms per square centimeter.
g.Li mited Access Areas . The design of the structure may create areas of limited access that cannot be cleaned to the specified degree of surface preparation across every square inch of the surface. In these cases, provide surface preparation as follows. Clean all areas that can be viewed without the use of mirrors to the specified degree of cleanliness. Localized areas of limited access due to the configuration of the structure may prevent the specified degree of cleanliness from being achieved. At a minimum, remove all loose coatings in these areas. Inspect the surfaces by touch, using a putty knife and inspection mirrors, optical or digital scopes. Cleaning and painting of these areas may require the use of specialized equipment. If the limited access area is a crevice or gap from which pack rust cannot be removed such as between mating plates, between back-to-back angles, or between structural members, apply sealants/caulks to seal the top and side surfaces to prevent moisture intrusion. Do not caulk the bottom crevice. Use sealants/caulks compatible with the coating system and p rovide written verification from the coating manufacturer on the compatibility of the sealant/caulk with the coating. Painting Metalized or Galvanized Surfaces. Use a coating system that is an approved NEPCOAT system and conforms to SECTION M06 . The zinc-rich primer is not required for metalized or galvanized surfaces.
Part 800 — Bridge Structures August 2025
800-160 SECTION 825 — PAINTING STRUCTURAL STEEL Prepare galvanizing according to SSPC SP-16 before painting. Remove white corrosion deposits, such as wet storage stains , before coating. Overcoat with any of the NEPCOAT approved intermediate coats followed by applying the compatible NEPCOAT-approved topcoat. The natural profile of metalized surface will not require any surface preparation. For any process that reduces the metalized or galvanized thickness below the specification limit, remove and re-apply the metalize or galvanize, as applicable, to meet the specification. Apply the intermediate coat to the surface as soon as possible after the Engineer has accepted the metalizing or galvanizing surface preparation and no later than eight hours after the preparation. If more than eight hours elapses, provide written recommendations from the intermediate coat manufacturer that identify the required steps to compensate for any oxidation and make the surface suitable for the intermediate coat application. Do not implement the steps without written approval from the Engineer. Apply a stripe coat of urethane to all edges of bolted connections and other areas followed by a full approved finish coat of urethane. Stenciling of Topcoat. After the topcoat has fully cured, provide stencil information on the inside surface of the fascia member at each abutment location. Use suitable black paint or other color as approved by the Engineer to contrast with the topcoat for visibility. Stencil uniform block lettering on the surface, 2 in. to 3 in. in height, with the following information: • The bridge identification number as shown on the Plans • The month and year of completion of the coating system (MM/YYYY) • The SSPC identification of the cleaning method • Identification of the coating system (for example: IOZ/OZ, E, U) with the name of the manufacturer; use the following designations: ○ IOZ = Inorganic Zinc Rich Primer ○ OZ = Organic Zinc Rich Primer ○ M = Metalized ○ G = Galvanized ○ E = Epoxy ○ U = Urethane Lighting. Provide adequate lighting for all surface preparation, paint application, and inspection work. Maintain a minimum of 10 ft-candles for surface preparation and painting, and a minimum of 30 ft-candles of general area lighting for inspection. Increase the lighting if workers or other personnel have difficulty seeing. Use explosion-proof lighting. Quality Control. Document and conduct an on-going Quality Control plan for the process and for the inspection of the materials, surface preparation, coating applications storage, and shipping of components as
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-161 necessary to ensure that all work is performed in compliance with the Contract Documents and the manufacturer’s recommendations. At a minimum, address the following: • Qualifications, authority, and responsibilities of the QC Manager • Qualifications, responsibilities, and training for workers (Include the frequency of checks on the quality of work) • Documentation of the proposed equipment and calibration records • How the QC documentation and supporting records are maintained • How the surface preparation of the steel before the application of the paint system, especially the profile, is verified and monitored (e.g., frequency). For galvanized steel, include the method of profiling • How the environmental conditions (e.g., ambient temperature, dew point, relative humidity) for various stages of the paint process are monitored and maintained throughout the duration of the Project • How the coating materials and abrasives are verified and monitored for receipt, storage, and control • How the coating materials are verified and monitored for batch numbers, mixing, pot life, mix reaction time, dry time, curing, recoat time, and cleanliness of each coat before the application of the subsequent coat • How the coating materials, including galvanize and metalize, are inspected and accepted for appearance, film thickness, adhesion, etc. For galvanized surfaces, include the galvanize thickness after the surface preparation. • How the coating films are inspected for defects • How the faying surfaces are treated and protected • How the coatings of steel components are protected from damage during storage, shipping, and erection Equipment and Standards. If requested by the Engineer, f urnish the following equipment and standards , which will be returned to the Contractor when the Engineer is finished with the inspection: • Magnetic contact surface thermometer • A portable instrument capable of measuring and digitally displaying the temperature, humidity and dew point • SSPC VIS Standard appropriate for the specified degree of cleaning: ○ SSPC VIS 1, “Visual Standard for Abrasive Blast Cleaned Steel” ○ SSPC VIS 3, “Visual Standard for Power- and Hand-Tool Cleaned Steel” ○ SSPC VIS 4/NACE ○ SSPC VIS 4/NACE VIS 7, “Guide and Reference Photographs for Steel Surfaces Prepared by Waterjetting”
Part 800 — Bridge Structures August 2025
800-162 SECTION 825 — PAINTING STRUCTURAL STEEL • Wet film thickness comb or combs of a suitable scale for the coatings being applied • A digital display dry film thickness gauge with a scale suitable for the coatings being applied and probes suitable for the surface to be measured • NIST (NBS) Calibration Standards • SSPC Surface Preparation Standards appropriate for the surface preparation requirements of the Contract Documents • A microscope with an illuminated graduated scale suitable for the dry film coating thicknesses to be measured; provide suitable cutters to create scratches of the geometry needed to take measurements with the microscope. Provide current certificates of calibration for the instruments. Pre-Painting Meeting. Arrange a meeting at the site where the surface preparation and painting will be performed at least one month in advance of starting the work to discuss the P roject requirements with the Department and the manufacturer’s technical representative and for an examination of the surface preparation and paint application equipment. The meeting will address: • Methods of operation • Weather-related concerns • Health and safety • Proper storage of material and equipment • Location of recycling, dust collection, and storage equipment • Treatment of inaccessible areas • Visual standards to be satisfied Provide the QCP to the Engineer for review at least two weeks before this meeting. Do not proceed with the work until this meeting has been completed to the satisfaction of the Engineer.
825.04 Method of Measurement.
Painting Existing Structural Steel. Painting Structural Steel will be measured by the number of square feet of steel painted. Cleaning, surface preparation, and paint systems on new steel will be considered as incidental to the painting work and, therefore, will not be measured separately. Surface Preparation for Existing Steel. Surface Preparation for Existing Steel will be measured by the number of square feet of steel surface prepared. Separate levels of surface preparation necessary to accomplish the final specified surface preparation will not be measured separately for payment but will be considered included in the single square foot measurement.
Part 800 — Bridge Structures August 2025
SECTION 825 — PAINTING STRUCTURAL STEEL 800-163 Lump Sum Alternative. In some cases, any or all of the above items of work may be paid on a lump sum basis. In these cases, no measurement will be required. Personnel and Environmental Protection. Personnel and environmental protection will be measured according to SECTION 826.
825.05 Basis of Payment.
The Department will pay for the completed and accepted quantities as follows. Pay Item Pay Unit Painting Existing Structural Steel SF Surface Preparation for Existing Steel SF Painting Existing Structural Steel. The price constitutes full compensation for all labor, materials, and equipment including cleaning, surface preparation, selection of paint system, painting, and all incidentals required to finish the work, complete and accepted. Surface Preparation for Existing Steel. The price constitutes full compensation for all labor, materials, equipment, and all incidentals required to finish the work, complete and accepted.
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Source: Standard Specifications for Road and Bridge Construction (Blue Book), 2022 (Aug 2025 compilation) Edition. Pages 519–532 of 951. View official source ↗