SECTION 843 — GALVANIZED STRUCTURAL STEEL 800-203 — GALVANIZED STRUCTURAL STEEL
843.01 Description.
This work includes cleaning, preparing surfaces, and applying a hot-dip galvanized coating to the surfaces of new structural steel and its components at the required locations.
843.02 Materials.
Use materials that conform to Subsection M05.06. Submittals. Submit a Shop Drawing with all specified documentation, including working drawings, QC plan, test data, supporting details, and method of application to the Engineer for approval. Provide the manufacturer/supplier with the following information:
a.Analysis of Galvanizing. Submit an assay of the galvanize bath constituents and state how often the bath is tested.
b.W arranty . Provide the galvanizer’s standard warranty that the galvanized substrate shall be free from 10 percent or more visible red rust for 20 years.
c.C ertificate of Compliance for Items Coated by Galvanizer. Submit a notarized Certificate of Compliance for galvanization, signed by the galvanizer and indicating compliance with the requirements of these specifications. Include the scope of services provided, an itemized description of items processed, and their quantities.
d.I tem Identification by Galvanizer . The galvanizer shall mark all lots of material with a clearly visible tag indicating the name of the galvanizer, the type and weight of the coating, and the applicable ASTM standards.
e.Q uality Control (QC) ― Testing and Certification. The manufacturer shall certify that every batch or lot of material conforms to this specification and shall submit test results for every batch or lot of materials. Galvanizers using the wet kettle process shall show how their QC program addresses the potential for flux inclusion. Provide a QC plan for the coating process, including: ● Qualifications and responsibilities of the QC manager ● Qualification and training for workers, including the frequency of checks on quality of work ● How environmental conditions for the various stages of the process are monitored and maintained ● Any pretreatment of the steel before the galvanizing and how these processes are monitored and maintained
Part 800 — Bridge Structures August 2025
800-204 SECTION 843 — GALVANIZED STRUCTURAL STEEL ● How the zinc dipping and prep bath(s) are monitored and maintained ● How the adhesion of the coating systems is verified and at what frequency. Ensure that testing conforms to ASTM D4541. ● How the dry film thickness (DFT) of the galvanize thickness will be measured for verification of values according to the specification ● Documentation of any equipment used for QC operations and calibration records as applicable ● Methods to protect all items to be galvanized from damage during storage and shipping ● Method to mask areas not receiving galvanizing, such as the top of bridge beams and around edges to be welded ● Format of QC documentation records and how they are maintained Ensure that each item references the relevant standards. Provide documentation of all testing. Any destructive testing shall be the Contractor ’s responsibility at no additional cost to the Department. Do not initiate work until the QC plan is approved by the Engineer.
843.03 Construction Methods.
Surface Preparation for Hot Dip Galvanize. Prepare the steel before galvanization according to ASTM A385. Hot Dip Galvanize.
a.Masking of Areas not to be Galvanized. When masking the tops of bridge beams, do not mask the outer perimeter of the top surface of each beam for a distance of 1 in. from the edge. For areas to be welded, provide an ungalvanized surface to the masked area at least 1 in. beyond the anticipated heat affected zone.
b.A pplication of Galvanize. Ensure that the application and minimum thickness are according to AASHTO M111 or AASHTO M232, as applicable.
c.G alvanize Thickness. Measure the galvanize thickness using the methods described in the Steel Structures Painting Council Paint Application Specification No. 2 - Measurement of Dry Paint Thickness with Magnetic Gauges (SSPC - PA2).
d.A ppearance and Condition of Galvanize. Strip any items with defects or damage to the final condition of the galvanize that expose the steel substrate or with thicknesses below the applicable AASHTO standard completely of the zinc using the standard preparation methods and regalvanized.
e.Fi eld Touchup. Verify that all surfaces to be touched up in the field are cleaned of dirt, grease, oil, chalk, bird droppings, lubricants, and other surface interference material. Use
Part 800 — Bridge Structures August 2025
SECTION 843 — GALVANIZED STRUCTURAL STEEL 800-205 hand tools, power tools, or blast cleaning to remove rust and for spot repair of localized damage to the galvanizing and coating system. Do not touchup or paint until the Engineer has accepted the surface cleaning and dry surface condition. Make all field repair to the galvanized exposed steel by a field application of a zinc rich paint (minimum 92 percent zinc) according to the repair material supplier’s recommendations and these Specifications, which must be approved by the Engineer. Strip pieces with damage exceeding 2 percent of the steel substrate of all galvanize and other coatings using the standard preparation methods and regalvanized. Subsequent Coatings. Ensure that any top coating over the required galvanize is compatible with the galvanization and is applied according to the applicable Specifications. Prepare hot dip galvanize according to ASTM D7803, Section 5.1.1. Approval Requirements.
a.Qualification/Certifications. Provide proper training for each worker and any certifications to ensure that the final product meets the specifications.
b.Q uality Control (Process Control). In addition to the general process control requirements, provide technical supervision for all applications. Maintain daily logs of air and surface temperature, dew point, and relative humidity for at least five years after Project completion and provide to the Engineer upon request.
c.S afety and Health. Instruct all employees required to enter confined spaces where the work may be conducted on the nature of the hazards involved, the necessary precautions to be taken, and in the use of protective and emergency equipment required. Conform to all pertinent OSHA regulations.
843.04 Method of Measurement.
Galvanized Structural Steel will not be measured for payment.
843.05 Basis of Payment.
Galvanized Structural Steel will not be paid separately and will be considered incidental to the cost of items being galvanized.
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Source: Standard Specifications for Road and Bridge Construction (Blue Book), 2022 (Aug 2025 compilation) Edition. Pages 572–574 of 951. View official source ↗