446Field Cleaning and Painting Steel

2.1 Paint Systems. Standard paint systems for painting new and existing steel include the following.

2.1.1 System I (Overcoating, One Coat). Provide paint in accordance with DMS -8105

, “Paint, One Coat Overcoat,” and the manufacturer’s specifications.

2.1.2 System II . Provide paint in accordance with DMS -8101 , “Structural Steel Paints —Performance.” Provide

organic zinc (OZ) prime coat and acrylic latex appearance coat meeting DMS -8101 .

2.1.3 System III -A. Provide paint in accordance with DMS -8101 . Provide organic zinc (OZ) prime coat, epoxy

intermediate stripe coat, epoxy intermediate full coat , and urethane appearance coat.

2.1.4 System III -B. Provide paint in accordance with DMS -8101 . Provide inorganic zinc (IOZ) prime coat, epoxy

intermediate coat , and urethane appearance coat. Provide epoxy zinc prime coat, as recommended by the IOZ manufacturer, for touchup of IOZ.

2.1.5 System IV . Provide paint in accordance with DMS -8101 . Provide IOZ prime coat and acrylic latex

appearance coat. Provide epoxy zinc prime coat, as recommended by the IOZ manufacturer, for touchup of IOZ.

2.2 Paint Inside Tub Girders and Closed Boxes . In accordance with Item 441, “Steel Structures.”

2.3 Paint over Galvanizing . In accordance with Item 445, “Galvanizing.”

2.4 Special Protection System (SPS) . Provide the type of paint system shown on the plans or in conformance

with special provisions to this Item. SPS paints must have completed AASHTO Product Evaluation & Audit Solutions Structural Steel Coatings (SSC) testing regimen as a complete system, with full data available f rom AASHTO unless specified otherwise.

4.1 Qualification . Certification of the cleaning and painting contractor, subcontractor, or fabricator is required as

follows. Submi t to the Engineer documentation verifying AMPP QP 2 Cat A certification . If the plans specify that the existing coating system does not contain hazardous materials, provide AMPP QP 1 certification. Maintain certifications throughout the project. No work may be performed without current and active certifications unless otherwise shown on the plans. The Engineer may waive certification requirements for minor, touch- up repair work and coating steel members repaired in accordance with Item 784, “Steel Member Repair.” The Engineer may waive certification requirements, when shown on the plans, for qualification in either contractor certification program if the project has been accepted as a qualification project as part of the process for obtaining AMPP QP1 certification. Submit certification applications and proof of acceptance before beginning work or provide AMPP QP 7 certification when shown on the plans . Inform the Engineer within 1 business day of all scheduled or unannounced inspections or audits by AMPP, OSHA, EPA, TCEQ, or other agencies or organizations. Furnish the Engineer a complete copy of all inspection and audit reports and any actions within 7 days of receipt.

4.2 Responsibility for Hazards. Comply with Article 6.10., “Hazardous Materials.” Handle all paints and

cleaning products in conformance with the information provided by the manufacturer and all applicable federal and state regulations.

4.3 Steel to be Painted . Clean and paint all structural steel except weathering steel that is to remain unpainted,

unless otherwise shown on the plans. Structural steel includes all main members, bearing apparatus, diaphragms, floor beams, rivets, bolts, and lateral bracing, where applicable. Paint the rolling faces of rockers and base plates, all surfaces of bearing plates, and all surfaces of iron or steel castings, regardless of whether the surfaces are milled, unless otherwise shown on the plans or exempted in accordance with this Item. Perform the initial cleaning and application of required prime coating on new steel before shipment of the steel to the jobsite, unless otherwise provided in the Contract or approved in writing. Areas deemed inaccessible by the Engineer will be cleaned and painted in conformance with the Engineer’s instructions.

4.4 SPS. Apply paint as shown on the plans.

4.5 Cleaning and Painting New Steel . Clean and prime new steel in accordance with Item 441 before erection

or installation of repair pieces. Clean and paint unpainted areas of newly erected steel, including bolts, nuts, washers, and areas where the shop- applied paint has been damaged or fails to meet specification requirements, in accordance with the method required under the paint system specified and Section 446.4. 6.3.1., “General Preparation.” Water blast exposed surfaces of all newly erected steel. Provide tool cleaning surface preparation to all repair areas. Prepare all unpainted areas by abrasive-b last cleaning. Repair prime coat and apply remaining coats after erection and maintenance work is complete. Prevent abrasive debris , paint , and overspray from contact ing passing traffic, private and public property, and areas of the bridge not designated to be painted. 666 4.6. Cleaning and Painting Existing Steel .

4.6.1 Hold Points . No work may proceed beyond the listed hold point until the Engineer has reviewed and given

provisional approval. Provide at least the following hold points:  at containment completion,  following any surface preparation,  immediately before each coating application,  after coating application,  after each coat has cured, and  after preparation of areas for repair.

4.6.2 Containment . Submit a plan that details the procedures and type and size of equipment proposed to keep

public property, private property, and the environment from being adversely affected by the cleaning and painting operations. Approval of the plan is required before cleaning and painting operations begin. Containment is not required for painting new steel erected under Item 441 that is not erected or installed onto an existing steel structure other than to comply with Section 446.4.5., “Cleaning and Painting New Steel.” When shown on the plans, include with the containment plan an engineering analysis showing that the loads added to the existing structure by the containment system and waste materials do not result in overstress of the members . Have a licensed professional engineer sign, seal, and date the submittal. Provide containment during all cleaning and painting operations of existing steel structures. Obtain approval of the constructed containment system before beginning cleaning and painting. Construct and maintain a structure meeting the following minimum requirements:  AMPP Guide 6, Class 1A, Level 1 emissions;  ability to withstand winds up to 30 mph;  enclosure of all sides of area with air -impenetrable walls;  illumination meeting AMPP Guide 12;  rigid and solid, watertight floor formed from minimum 20-gauge steel;  overlapping seams and entryways; and  exhaust air filtration system capable of creating negative pressure inside the enclosure, causing the sides of the containment to have a concave appearance and demonstrating minimum 100- ft. per minute cross- draft airflow and minimum 50- ft. per minute downdraft airflow in all areas within the cont ainment . In place of a full containment structure, a modified containment system may be proposed for the following situations:  when using abrasive blasting equipment with negative pressure able to contain all blast refuse. Demonstrate, for approval, the equipment’s ability to contain all blast refuse.  when tool cleaning and water blasting for spot cleaning only, provide a system that will contain all removed paint, rust, and other debris. Place an airtight membrane below the member being cleaned to collect all falling debris and wastewater .  when using power hand tools for spot cleaning only that are equipped with high- efficiency particulate air (HEPA) filter vacuums that will capture all removed paint, rust, and other debris. Otherwise, provide an airtight membrane below the member being cleaned to collect all falling debris. Provide a system meeting AMPP Guide 6, Class 1W, when using water blasting. Manage wastewater from water blasting in accordance with Section 446. 4.8.2. , “Wastewater.” Provide safe access to all parts of the work for proper inspection. When a temporary facility is proposed for inspection access, provide a plan for review. This facility requires a licensed professional engineer in accordance with Article 5.2, “Plans and Working Drawings,” T able 1. Do not place rigging or scaffolds in 667 contact with previously painted surfaces until the previously applied coating has fully cured. Protect previously painted and cured surfaces using an approved padding to minimize damage when rigging or scaffolds will be placed on or hung from those surfaces. Avoid and minimize coating damage to the extent possible. Repair all coating damaged by rigging or scaffolding as directed. Remove tree limbs, bushes, grass, and other items that will interfere with the cleaning and painting operations as directed. Remove vertical clearance signs, and erect and maintain temporary ground- mounted signs matching the content and letter size on the existing sign unless otherwise directed. Re- attach permanent clearance signs as directed. Use a skimmer when cleaning and painting over bodies of water. Remove any blast or paint material the skimmer collects the day the release occurs. Correct the containment problem that allowed the release before continuing work. Ensure air is clear of dust and remove all blast refuse from cleaned members before the I nspector enters the containment to inspect the cleaned surfaces. Remove all blast refuse from the containment before ending work for the day.

4.6.3 Preparation of Surfaces. Prepare surfaces before applying paint.

4.6.3.1. General Preparation . Ensure all surfaces to be painted are completely free of all visible contaminants including but not limited to oil, grease, moisture, dirt, sand, overspray, and welding contamination (slag or acid residue); loose or flaking mill scale, rust, or paint; weld spatter; and any other conditions that will prevent the paint from forming a continuous, uniform, tightly adhering film. Before other cleaning operations, remove grease- like contaminants using clean petroleum solvents or other approved methods. Contain solvents and removed material as approved. Dispose of properly or reuse solvents as approved. Remove all hackles, splinters , weld spatter, sharp edges, fins, slag, or other irregularities that may interfere with proper paint adhesion to the steel. Remove all steel splinters (hackles) raised or evident during cleaning. Round all corners and edges to a 1/16- in. radius. Abrasive blast areas from which hackles and irregularities are removed and edges t hat have been rounded to achieve a minimum 1.5- mil profile . Grind all flame -cut edges when necessary to produce a minimum 1.5- mil profile over the entire flame- cut surface to achieve adequate coating adhesion. Remove all pack rust and expansive rust between steel plates and in crevices using either abrasive blasting, ultra-high pressure waterjetting (UHP), heated water, or other approved methods. Ensure all surfaces to be painted meet the minimum non- visible contaminant level established by the coating manufacturer or in accordance with AMPP- SP 12, NV -2, whichever is more stringent. Perform soluble salt contamination tests in accordance with AMPP Technology Guide 15, “ Field Methods for Retrieval and Analysis of Soluble Salts on Steel and Other Nonporous Subs trates,” immediately before paint application of each coat to determine whether salt contamination has occurred. If a method other than Class A is used, then it must first be validated against the Class A m ethod before adopting structure- wide. Test at leas t four random locations every 1, 000 sq. ft. If soluble salt levels exceed maximum requirements , provide additional water blast cleaning to remove salt contamination (or recontamination) and retest the area. If additional water blasting does not reduce the concentration to the acceptable level, a surface treatment or water additive may be used. Use a surface treatment or water additive that is approved by the coating system supplier and the Engineer. All salt test results must be preserved and made accessibl e to the Engineer. Clean coated surfaces by an approved method that does not damage applied paint to remove all dirt, grease, concrete, overspray, and any other substance that may impair adhesion before the application of the next coat. Clean far enough into any shop- applied paint to ensure removal of all contaminants. 668 Feather edges of sound paint around spot -cleaned areas. Feather all sound, tightly adhered coating edges surrounding cleaned or repaired areas at least 1 in., and ensure a smooth, blended transition. Completely remove, as directed, the protective coating on machined surfaces and pins. Do not damage adjacent materials such as concrete during surface preparation or painting. 4.6.3.2. Classes of Cleaning . Water blast to remove contaminants before any mechanical or abrasive surface preparation. Water blast the steel and between coats when necessary to remove non- visible contamination. System I requires tool cleaning for defective areas of disbonded coating or rust. All other paint system s require abrasive blast cleaning unless otherwise shown on the plans. Prepare all surfaces of painted steel members subsequently exposed from structural operations, such as deck removal or steel repair, in accordance with this Item. Prevent loose or damaged paint from entering the environment . 4.6.3.2.1. Abrasive Blast Cleaning . Meet the surface preparation requirements in accordance with AMPP- SP 10 unless otherwise shown on the plans. Ensure a minimum profile of 1.5 mils. Do not add depth to existing profile when the surface profile exceeds 4.0 mils. Measure surface profile in accordance with ASTM D4417, Method C. Containment mounting points and other repair areas under 1 sq. ft. may be tool -cleaned to AMPP- SP 11 with at least a minimum 1.5 -mil profile when approved. For existing steel structures , use an abrasive recycling system with an approved recyclable abrasive unless otherwise shown on the plans . New steel erected under Item 441 that is not erected or installed onto an existing steel structure is excluded from t he recyclable abrasive requirement. Do not use steel shot. Abrasive will be considered recyclable if it is separated from the dust and paint debris before being reused. A non- recyclable abrasive may be used when the coating system has been identified as nonhazardous as shown on the plans. All abrasives must meet AMPP AB1, AB2, or AB3 as appropriate. 4.6.3.2.2. Tool Cleaning. Meet the requirements of AMPP- SP 11 unless otherwise shown on the plans. Probe the perimeter of peeled areas of paint using a putty knife to ensure remaining paint is tightly adhered. 4.6.3.2.3. Water Blasting . Meet the requirements of AMPP- SP WJ -4. Tight mill scale and tightly adhered rust and paint are permitted. Probe the perimeter of peeled areas of paint using a putty knife to ensur e remaining paint is tightly adhered. 4.6.3.3. Tape Test . Perform the tape test, as necessary to determine cleanliness, on any surface before painting as follows:  Press a strip of filament tape onto the surface by rubbing using moderate thumb pressure four times, leaving approximately 2 in. of one end of the tape free from the surface.  Grasp the free end and remove the tape from the surface using a sharp pull. The surface will be considered contaminated and not adequately cleaned if visible particles cling to the t ape.

4.6.4 Painting .

4.6.4.1. Paint Condition. Thoroughly mix and strain paints to be applied in conformance with the manufacturer’s recommendations . Mix by mechanical methods. Provide continuous mechanical agitation during painting operations to prevent settling. Ensure the paint is a completely homogeneous mixture free of lumps, skins, and agglomerates and contains all pigments, vehicle solids, and thinners required in the original formulation. Keep paint containers tightly covered and protected from weather when not in use. 4.6.4.2. Thinning. Adjust paint to the correct application consistency in conformance with the manufacturer’s recommendations . 669 4.6.4.3. Paint System Requirements. Ensure all coatings in the paint system, including shop- applied coats, are from the same manufacturer. 4.6.4.4. Stripe Coat . All stripe coat will be unthinned and worked in by brush to achieve a contiguous film over all edges, corners, bolts, nuts, threads, rivets, and weld seams, extending at least 1 in. onto adjacent steel and must be of a contrasting color to the coating over which it is being applied. Ensure the paint is mixed in the appropriate proportions by weight and is agitated continuously during the striping operation. 4.6.4.5. Paint Systems. Apply the paint system specified in accordance with this It em and in conformance with the equipment and coating materials manufacturer’s recommendations. Conflicts between this Item and the manufacturer’s recommendations will be resolved by the Engineer. 4.6.4.5.1. System I (Overcoating, One Coat) . Apply at least 4.0 mils dr y film thickness (DFT) overcoat to all surfaces to be painted. 4.6.4.5.2. System II .  Prime Coat . Apply at least 3.5 mils DFT of epoxy zinc primer.  Stripe Coat . Apply stripe coat of epoxy zinc primer to all edges, corners, bolts, nuts, threads, rivets, and weld seams, extending at least 1 in. onto adjacent steel.  Appearance Coat . Apply at least 2.0 mils DFT of appearance coat. 4.6.4.5.3. System III -A.  Prime Coat . Apply at least 3.5 mils DFT of epoxy zinc primer.  Stripe Coat . Apply stripe coat of epoxy zinc primer to all edges, corners, bolts, nuts, threads, rivets, and weld seams, extending at least 1 in. onto adjacent steel .  Intermediate Coat . Apply at least 2.0 mils DFT of epoxy intermediate coating.  Appearance Coat . Apply at least 2.0 mils DFT of appearance coating. 4.6.4.5.4. System III -B.  Prime Coat . Apply at least 3. 5 mils DFT of IOZ primer to new steel in accordance with Item 441. Spot - clean all damaged and unpainted areas in accordance with Section 446.4. 5., “Cleanin g and Painting New Steel.” Apply at least 3. 5 mils DFT of epoxy zinc primer to the spot -cleaned areas.  Stripe Coat . Apply stripe coat of epoxy zinc primer to all edges, corners, bolts, nuts, threads, rivets, and weld seams, extending at least 1 in. onto adjacent steel .  Intermediate Coat . Apply at least 2.0 mils DFT of epoxy intermediate coating.  Appearance Coat . Apply at least 2.0 mils DFT of appearance coat. Apply stripe, intermediate, and appearance coat to new steel after erection and repair of all damaged areas . Extend stripe coat at least 1 in. onto flat steel in all directions. 4.6.4.5.5. System IV .  Prime Coat . Apply at least 3. 5 mils DFT of IOZ primer to new steel in accordance with Item 441. Spot - clean all damaged and unpainted areas in accordance with Section 446.4. 5., “Cleaning and Painting New Steel.” Apply at least 3. 5 mils DFT of epoxy zinc primer to the spot -cleaned areas.  Appearance Coat . Apply at least 2.0 mils DFT of appearance coat. Apply stripe, intermediate, and appearance coat to new steel after erection and repair of all damaged areas. Extend stripe coat at least 1 in. onto flat steel in all directions. 4.6.4.6. SPS. Apply paint as shown on the plans. 4.6.4.7. Application . Do not apply paint when the steel or air temperature is below 50°F or when the steel or air temperature is expected to drop below 50°F within 2 hr. after application, unless otherwise approved. Do not 670 apply paint to any surface with discernible moisture. Do not apply paint to any surface when steel is within 5°F of the dewpoint. Do not apply paint when impending weather conditions might result in damage to fresh paint. Provide environmental controls such as dehumidification, heaters, or additional containment measures as needed to control and maintain favorable atmospheric conditions in all areas of the containment. Provide environmental controls at no additional cost to the Department. Apply each coat in two passes using a crosshatch pattern. Apply each coat of paint to clean, dry, firm surfaces in accordance with all specification requirements. Ensure each coat fully cures to form a smooth, continuous, tightly adhering film of uniform thickness and appearance and free of defects before applying the next coat. Apply all coats by spray, except brush- applied stripe coats. Obtain approval for alternative methods of application to paint inaccessible areas. Repair all runs, sags, and other defects in each coat of paint before application of subsequent coats. Measure the dry film thickness of coatings in accordance with AMPP PA 2, Level 3, “Procedure for Determining Conformance to Dry Coating Thickness Requirements.” If, in the opinion of the Engineer, there is an objectionable amount of dust in the atmosphere, discontinue painting or take necessary precautions to prevent dust and dirt from contact ing freshly painted surfaces or surfaces before the paint is applied. Provide full coverage of the steel with the concrete surface when painting steel that is in contact with concrete. Do not extend paint more than 4 in. onto the concrete surfaces or as directed. Ensure when painting is completed the only visible paint on concrete surfaces is the finish coat. Remove excessive or objectionable paint on concrete surfaces in an approved manner. Intermediate and appearance coats do not have to be applied to surfaces that will be in full contact with concrete. Before applying the appearance coat onto existing steel structures, caulk gaps or crevices greater than 1/16 inch. New steel erected under Item 441 that is not erected or installed onto an existing steel structure is excluded from the caulking requirement. Use a paintable caulk meeting the requirements of DMS -8142 , “Paintable Caulk for Concrete and Steel.” Use caulk that is compatible with the coatings to be applied, as determined by coating manufacturer. Apply caulking in a manner that does not trap moisture. 4.6.4.8. Workmanship . Perform all painting using skilled painters who can adjust equipment and application techniques as dictated by the type of paint, weather conditions, environment, and size and shape of the surface being painted. Painters who, in the opinion of the Engineer, do not adjust equipment to apply coatings in a uniform, full wet coat free of runs, sags, holidays, and overspray will not be considered skilled painters and may be removed from the project . Brush application for touchup is acceptable if the paint is mixed in the appropriate proportions by weight and is agitated continuously during the painting operation.

4.6.5 Handling and Shipping. Pad the blocks, chains, slings, braces, and clamps used for handling, moving,

storing, and shipping painted members so the paint will not be damaged.

4.7 Paint Improperly Appl ied. To uncover evidence of improperly applied paint, the Engineer may at any time

during construction explore underneath the surface of any paint coats already applied. Repair these areas of investigation at no additional expense to the Department. Whenever unsatisfactory conditions are found, the Engineer may require remedial measures. Repair or completely remove and replace all paint that has been applied improperly, has been applied to improperly cleaned surfaces, fails to dry and harden properly, fails to adhere tightly to underlying metal or other paint film, or does not have a normal, workmanlike appearance in accordance with this Item. When the final field coat does not have a uniform color and appearance throughout the structure, correct it using whatever additional coats or other corrective measures are required. Remove freshly applied paint that has 671 not yet set using suitable solvents. Remove dried paint films by blast cleaning, scraping, or flame torches, as approved.

4.8 Waste and Wastewater . Manage all waste and wastewater generated by cleaning and painting operations

as necessary to prevent unauthorized release into the environment.

4.8.1 Waste. At minimum, collect all waste before leaving the jobsite each day. Handle and store the waste as if it

were hazardous or Universal Waste until classification is made. Follow the requirements of 30 TAC § 335 for onsite handling of the waste. Store waste collected in containers that comply with 49 CFR Part 178. Seal containers containing waste each day before leaving the jobsite. Test a representative sample of waste in accordance with EPA Test Method 1311, “Toxicity Characteristic Leaching Procedure” (TCLP), to determine existing metal and organic content. Handle and dispose of nonhazardous waste as a “Special Waste” as defined in 30 TAC § 330.2 or as directed. Provide documentation showing disposal of the waste was in a suitable landfill holding permits to handle this type of material. Dispose of hazardous waste in conformance with applicable waste rules and regulations. Transport hazardous waste using a permitted transporter and dispose of it in an authorized hazardous waste facility. When the plans show the existing coating to be removed contains hazardous materials and steel grit is used as the abrasive, the waste generated is classified as hazardous or Universal Waste regardless of the results of the TCLP. For manifesting purposes, the Department is considered the waste generator for paint removal wastes generated from structures owned or controlled by the State. Dispose of this waste in conformance with applicable waste rules and regulations as specified above and in accordance with the Contract. Provide copies of all test reports and transportation manifests to the Engineer before shipping waste. Provide signed original manifests to the Engineer verifying all steps of the handling and disposal process were correctly handled.

4.8.2 Wastewater . Avoid unauthorized discharge of wastewater to streams or other surface waters. Contain and

dispose of all wastewater to a publicly owned treatment works (POTW), with written approval from the POTW, or at a permitted commercial disposal facility, unless authorization for reuse or discharge is obtained from TCEQ and approved. Wastewater from cleaning operations of ne w steel erected under Item 441 that meet s the TCEQ Texas Pollutant Discharge Elimination System (TPDES) Construction General Permit (CGP) TXR150000 guidelines for non- stormwater discharge may be discharged in accordance with best management practices described in the site Stormwater Pollution Prevention Plan (SW3P ).

4.9 Miscellaneous. Notify the Engineer of any condition that may require the repair or replacement of any

portion of the bridge.