532for at the contract unit price per linear foot for the type specified. This price shall include furnishing and installing materials designated above the bridge deck surface, including anchorage material, reinforcing steel, junction boxes, conduits, and/or raceways used for rail grounding. Payment will be made under: —————————————— ————————Pay Item Pay Unit—————————————— ————————Railing (Type) Linear foot Parapet (Type) Linear foot Bridge median barrier (Type) Linear foot—————————————— ———————— SECTION 411—PROTECTIVE COATING OF METAL IN STRUCTURES
411.01 Description
This work shall consist of preparing and coating ferrous metal surfaces on new and existing structures, including, but not limited to, main units, diaphragms, bearing assemblies, shop and field contact surfaces, surfaces in contact with concrete, parts designed to be embedded in concrete, railings, expansion joints, drainage systems, utility lines, and attachments in accordance with these specifications. Classification of Structures: Existing structures will be classified on the plans by the Department as follows: Type A: Steel structures that have no existing coatings. Type B: Steel structures that have existing coatings. Should the bid proposal involve a structure that requires application of a coating and no classification is specified in the bid documents, the bidder shall assume the structure to be Type B and bid accordingly. Galvanized surfaces and surfaces protected with other coatings shall not be coated unless spec - ified otherwise in the contract. Cast, ductile, and nodular iron castings need not be coated. Application procedures not specified herein shall be as specified by the coatings manufacturer and approved by the Engineer.
411.02 Materials
a.Coatings shall conform to Section 231.
b.Water used in cleaning operations shall be potable. If water is recycled, it shall be filtered prior to reuse. Recycled water shall be used only on the bridge from which it was generated and shall be subsequently tested after cleaning operations but prior to disposal in accordance with Section 411.04(a) and then properly disposed of.
c.Soluble Salt Remover shall be added to wash water in order to remove chlorides, sulfates and nitrates from surfaces when cleaning operations are performed. Soluble salt removers shall be submitted to the Engineer for acceptance prior to use.410.04 533(d) Abrasives used in cleaning operations shall be one of the following categories:
1.Expendable abrasives shall conform to SSPC-AB 1, Type I or Type II, Class A, except that the Engineer will not permit the use of silica and quartz sands. The abrasive shall not contain total levels of any of the heavy metals listed in 40 CFR 261.24, Table 1, in excess of 20 times the specified regulatory leachable limits. Expendable abrasives shall be selected from the VDOT Materials Division Approved Products List 18, and shall not contain chemi - cal additives that render the waste non-hazardous under the Toxicity Characteristic Leaching Procedure.
2.Recyclable abrasives, newly manufactured or re-manufactured steel, shall conform to SSPC- AB 3. Recycled abrasive shall be examined by the Contractor for oil contamination prior to start up and at least once per 8-hour shift in accordance with VTM-82. Recycled abrasive shall not contain non-abrasive residue in excess of that specified in SSPC-AB 2.
411.03 Certifications
a.SSPC QP-1 Requirement: The Contractor shall be certified to perform coating applications according to SSPC QP-1, Standard Procedure for Evaluating Qualifications of Industrial/Marine Painting Contractors, Field Applications in Complex Structures in order to perform coating operations on all new and existing steel structures except as noted below. The Contractor shall submit proof of such current certification to the Engineer before starting the Work. For existing steel structures, the requirement is not applicable for repairs or replacement of structural components where the area of applied coating is less than 100 square feet.
b.SSPC QP-2 Requirement: When contract work involves the removal of greater than 100 square feet of coating from a Type B structure, the Contractor shall be certified to perform coating removal operations according to SSPC QP-2, Standard for Evaluating Painting Contractors, Removal of Hazardous Coatings from Industrial/Marine Steel Structures in order to perform coating removal operations. The Contractor shall submit proof of this certification to the Engineer before starting the Work.The SSPC QP-2 certified contractor shall assign a SSPC QP-2 qualified Competent Person to oversee removal activities to protect the environment and workers safety and health while performing removal activities under the contract. For the purposes herein a Competent Person is an individual who meets the qualifications defined in the document SSPC-QP2 – Qualifications, Section 2. The Environmental Protection Plan and worker safety and health plan described in Sections 411.09 and
411.10 shall be prepared by the SSPC QP-2 certified organization. The SSPC QP-2 Competent
Person shall be present during startup, surface preparations, removal operations, and waste remov - al/disposal activities to ensure and verify environmental protection and worker safety and health practices and procedures comply with the prepared plans. The SSPC QP-2 Competent Person shall submit written certification that the Contractor’ s work operations are meeting the environmental and worker safety and health plans requirements each week. The SSPC QP-2 Competent Person shall submit written certification at the completion of the project that the environmental and worker safety and health plans fully complied with all applicable regulations and was fully implemented by the Contractor. If there are any emissions or discharges noted, the Competent Person shall submit in writing, within 24 hours of the time of the discharge, corrective actions taken by the Contractor to remedy the noncompliance.411.03 534If the project work involves the removal of less than 100 square feet of coating from a Type B structure for structural steel repairs and/or replacement of structural components, the SSPC QP-2 requirement is not required. All work performed for repairs and/or replacement shall be accom - plished in accordance with all applicable environmental and worker health and safety requirements for the type and scope of work specified. The 100 square foot requirement applies to each structure on the project.
c.Professional Engineer: If the project involves the erection of any waste or emissions containment structure with the bridge serving as the primary means of support, the Contractor shall describe such system as specified in Section 411.09(a) and provide certification by a Professional Engineer, holding a valid license to practice structural design engineering in the Commonwealth of Virgin - ia. The certification shall verify the structural integrity of the containment structure and that the containment system does not adversely affect any portion of the bridge. This requirement will not apply to any containment structure with a total weight-bearing capacity of less than 1,000 pounds.
411.04 General Surface Preparation and Application Standards
Prior to being coated, the Contractor shall ensure surfaces are clean and free from rust, loose or brittle paint, chalking, oil, grease, salt contaminants, dirt, and other substances that would prevent coatings from tightly adhering to the intended surfaces. Surfaces shall be prepared in accordance with SSPC specifications. Surface conditions and finished surface profiles shall conform to SSPC-Vis Standards or National Association of Corrosion Engineers (NACE) Comparators. When blast cleaning is specified for surface preparation, the Contractor shall use SSPC PA-17, Procedure for Determining Conformance to Steel Profile Requirements, including information in Appendix B, Determining Compliance Based on Process Control Procedure. Surface profile shall be measured in accordance with Section 411.04(c)6. Should an area of steel that has previously been cleaned become soiled, contaminated, or rusted, the Contractor shall reclean the area to the satisfaction of the Engineer prior to the application of coating at no additional cost to the Department. Regardless of the method of cleaning, surface imperfections described in the “Procedures Following Blast Cleaning and Immediately Prior to Painting Section” of SSPC-SP 10 and any other matter that will prohibit a smooth unobstructed surface for the application of the specified coating, shall be removed.
a.Application Conditions: Preparing Surfaces To Be Coated: The Contractor shall prevent contaminants coming in contact with surfaces during surface preparation and coating operations. Unsealed connections, small cracks, cavities, and depressed areas on flanges shall be filled in accordance with Section 407. Depressions found on flanges or other structural components where water can pond shall be filled using a material recommended by the coating manufacturer and approved by the Engineer. The Contractor shall prepare the surfaces scheduled to be coated in accordance with one or more of the following methods prior to the application of coating(s). Surfaces to be coated shall be cleaned in accordance with Method 1 followed by Method 7 prior to the use of other surface preparation methods, except as provided herein.411.03 535When surface preparation is performed in the field, the Contractor shall collect and contain solid and liquid wastes. Waste shall be characterized and properly disposed of in accordance with Section 411.09(c) for a T ype B structure or for galvanized surfaces, prepared using zinc phosphate treatments in accordance with 411.07(b). Any additional cost for surface preparation, waste collection, waste characterization, and disposal associated with the coating of quenched or chromate-treated galvanized material as authorized and directed by the Engineer will be made in accordance with the provisions of Section 109.05.
1.Method 1: Solvent, emulsion, or steam shall remove oil, dust, dirt, grease, concrete, chalking, and salt in accordance with SSPC-SP-1. The Contractor shall remove emulsions and/or contaminated solvent before they evaporate by wiping or rinsing with clean solvents to prevent a film of contaminants from remaining on the surface. The Engineer may require solvent wiping between coats. Solvents used in the work shall be those recommended by the coating manufacturer.
2.Method 2: The Contractor shall employ hand-tool cleaning shall remove loose coating, loose rust, and loose mill scale in accordance with SSPC-SP-2.
3.Method 3: The Contractor shall employ power-tool cleaning to remove loose coatings, loose rust, and loose mill scale in accordance with SSPC-SP-3. After cleaning, locations cleaned to bare metal shall have a minimum 1 mil profile.
4.Method 4: The Contractor shall employ power-tool cleaning to remove coating, rust, and mill scale to bare metal in accordance with SSPC-SP-11. Surface profile shall be a minimum of 1 mil with continuous pattern with no smooth unprofiled areas.
5.Method 5: The Contractor shall employ abrasive blast cleaning to remove visible coating, rust, and mill scale in accordance with SSPC-SP-10/NACE No. 2. When surface preparation involves less than 1,000 square feet per structure, expendable abrasives may be used, otherwise abrasives shall be recyclable unless otherwise specified or approved by the Engineer. The Contractor shall collect, remove and properly dispose of all expendable abrasives after use. The Engineer will not allow the use of recyclable abrasive containing rust that adversely affects the cleanliness of the blasted surface. After blast cleaning, the surface profile shall be an average from 2 to 4 mils with no individual readings below 1.5 mils or above 4.5 mils in a dense uniform pattern of depressions and ridges. Shop-blasted and field-blasted surfaces shall be coated within 8 hours. If rust bloom develops before coating, the Contractor shall repeat blast cleaning at no additional cost to the Department.
6.Method 6: The Contractor shall employ brush-off blasting to remove loose or brittle coatings, loose rust, and loose mill scale in accordance with SSPC-SP-7/NACE No. 4. Bare steel locations shall have a uniform 1 mil minimum profile.
7.Method 7: The Contractor shall use low-pressure water cleaning to remove dust, debris, and salt contaminants. A soluble salt remover shall be added to the wash water in accordance with the manufacturer’ s instructions for concentration, washing, and rinsing processes. Method 7 can be used exclusively (i.e., in lieu of Method 1) and without a soluble salt remover for the cleaning of new shop-primed or new field-primed steel provided that no salt, oil or grease is present or when oil and grease are removed separately by Method 1. However, tests shall be performed 411.04 536to verify no oil or grease is present and that chloride, sulfate and nitrate levels are at or below manufacturer’ s recommendations prior to coating application. The pressure washer shall be capable of achieving a minimum of 3,000 pounds per square inch at the nozzle when used prior to blast cleaning, and a minimum of 5,000 pounds per square inch at the nozzle when used to remove loose or brittle coatings. The Contractor shall maintain the nozzle no more than 10 inches from the surface, and consistently hold it at 90 degrees to each surface being cleaned. Any detergents or cleaners used in conjunction with this cleaning method shall be those allowed or recommended by the coating manufacturer and as approved by the Engineer. All water generated by this washing technique must be collected and tested in accordance with Section 411.09(c), and disposed of in accordance with Section 411.09(d). The exception to this requirement, provided no detergents or cleaners are used, is any water generated from cleaning new shop-primed or new field-primed steel by this technique may be directed to the bridge approaches or stream bank but shall not be directly discharged into any waterway. This exception does not apply to waste generated from surface preparation of galvanized steel.
8.Method 8: Commercial grade power tool cleaning shall remove rust, coatings, oxides, mill scale, corrosion products and other foreign matter in accordance with SSPC SP-15. After cleaning, locations cleaned to bare metal shall have a minimum 1 mil profile of continuous pattern with no smooth un-profiled areas.
9.Method 9: Commercial blast cleaning shall remove all mil scale, rust, coatings, oxides, corrosion products and other foreign matter in accordance with SSPC SP-6/NACE, No. 3. When surface preparation involves less than 1,000 square feet per structure expendable abrasives may be used, otherwise abrasives shall be recyclable unless otherwise specified or approved by the Engineer. After blast cleaning, the surface profile shall be an average 2 to 4 mils with no individual readings below 1.5 mils or above 4.5 mils in a dense uniform pattern of depressions and ridges. The waste material(s) generated from work performed on Type B structures shall be tested in accordance with EPA Method 1311, Toxicity Characteristic Leaching Procedure (TCLP), and corresponding EPA 6000 or 7000 series metals analytical method for, but not limited to, the following metals to determine if the waste material(s) requires management as hazardous waste: arsenic, barium, cadmium, chromium, lead, mercury, selenium, and silver. The exception to this testing protocol is that waste generated from abrasive blasting with recycled steel abrasives for Method 5 or Method 9 shall be tested for total concentrations of the aforementioned heavy metals in lieu of the TCLP analysis. Waste material(s) shall be properly disposed of in accordance with all federal, state, and local regulations.
b.Coating Application: The Contractor shall apply coatings in accordance with SSPC-PA 1. Coatings shall not be applied under any of the following conditions unless recommended by the manufacturer and approved by the Engineer:
1.When air, coating, or metal temperature is below 35 degrees F when applying solvent based coatings.
2.When air, coating, or metal temperature is expected to fall below 35 degrees F before the solvent based coating has cured.
3.When snow, sleet, or rain is falling.411.04 5374. When moisture is visible on metal.
5.When humidity is above 85 percent.
6.When the temperature of the steel or metal surface to be coated may cause blistering of the coating as indicated in the manufacturer’ s product data sheet.
7.When the steel surface temperature is less than 5 degrees F above the dew point or is expected to fall to that point before the coating has dried or cured. In no case shall System W as shown in Table IV -6 or other approved waterborne coatings be applied unless the air, steel surface, and material temperature is above and maintained above 50 degrees F and rising during application and curing. Prior to application of coatings, the surface shall be dry. The Contractor shall apply coatings in a neat and orderly manner by brushing, rolling, or spraying as recommended by the manu- facturer. The Engineer will not allow the Contractor to use rollers, daubers, or sheepskins to apply zinc- rich coatings. Zinc-rich coatings may be applied by brush, limited to isolated areas of 1 square foot or less and shall be re-stirred just prior application at each location. Coatings shall be applied in a manner to provide a tight film of specified uniform thickness well bonded to metal or underlying coating, including crevices and corners, and shall be free from laps, lint from rollers, bristles from brushes, streaks, sags, runs, overspray, dryspray, shadow- through, skips, pin holes, holidays, excessive film build-up, mud cracking, misses, and other defects. The Contractor shall apply a stripe coat prior to the full coat application on beams, girders, diaphragms, cross frame edges, bolts, washers, and nuts. If the Contractor has to apply a multicoat system, beams, girders, diaphragms, cross frame edges, bolts, and nuts shall be striped prior to each coat except that the application of a stripe coat will not be required by the Engineer for a zinc-rich primer. Stripe coatings shall dry or cured to touch before overcoating. Deficient, impaired, or damaged areas of each coat shall be repaired according to the coatings manufacturer’ s recommendations or by using appropriate material from the VDOT Materials Division’ s Approved Products List. Two-component, solvent-based, inorganic zinc shall have a minimum rating of 4 when tested in accordance with ASTM D4752. The Contractor shall not apply successive coatings until each preceding coat has dried and cured in accordance with the manufacturer’ s recommendations and has been approved by the Engineer. Coatings shall be applied in accordance with Table IV -6. Mixing: Coatings shall be mixed in strict accordance with the manufacturer’ s instructions. Zinc-rich coatings shall be applied from containers equipped with a mechanical agitator, which shall be in motion throughout the application period unless otherwise specified by the manufacturer. Coatings shall not be thinned beyond the volatile organic compound (VOC) limit or the manufacturer’ s recommendation, whichever is the most restrictive. Individual components of multicomponent coatings shall be mixed separately prior to mixing with other components of the kit. The Contractor shall use a power mixer to perform mixing. Multicomponent material shall not be mixed in proportions less than the packaged quantities.411.0 538(c) Quality Control Measurements:
1.Water and/or Oil in Compressed Air: The Contractor shall perform a Blotter Test in accordance with ASTM D 4285 with equipment at operating conditions, prior to the start of work and once per 8 hour shift. The Contractor shall perform this test daily in the presence of the Engineer, record the findings, and provide a copy to the Engineer for inclusion to the project records.
2.Illumination in containment: The minimum illumination in foot candles stated in SSPC Guide 12 shall be confirmed in the general work areas and task specific areas such as surface preparation, inspection, and coating application activities prior to start of each shift’ s operations when working in containment areas.
3.Presence of Oil or Grease: The Contractor shall check surfaces for oil and/or grease contamination prior to coating application by verifying surfaces using a water break test. A black light may also be used to confirm the presence of hydrocarbons.
4.Chloride, Sulfate and Nitrate Testing: Chloride concentrations shall be no greater than 7µg/ cm2 on new or existing structures. Sulfate and nitrate concentrations shall be at or below the coating manufacturer’ s recommended levels. The Contractor shall perform chloride, sulfate and nitrate tests at a frequency of three tests per span after surface preparation is completed. Sampling (retrieval) and analysis of chloride, sulfate and nitrate shall be performed using an acceptable method in accordance with SSPC Guide 15. The Engineer will select test locations on existing structures to represent the greatest amount of corrosion in the span. Should chloride, sulfate, and nitrate concentrations not be in compliance with 7µg/cm2 for chlorides or manufacturer’ s maximum levels for sulfates and nitrates, the location(s) of non- conformance shall be re-cleaned and re-tested along with two additional test locations. Should the re-cleaned location(s) or any additional test not meet the compliance requirements, the entire span shall be rewashed using a soluble salt remover and retested as stated above until411.0 System Coat Coating Color Min Dry Film (Approved List No.) Thickness (DFT) (Mil) B Primer Zinc-Rich As Specified (List 13) Intermediate Per List White As Specified Finish Per List As Specified* As Specified F Primer No. 14 Aluminum 5.0 (List 21) Finish No. 14 As Specified* 5.0 Alternate Finish Per List As Specified* As Specified W Primer No. 101 Brown 595-30045 2.0 – 4.0 (List 40) Intermediate No. 102 White 2.0 – 4.0 Finish No. 103 As Specified* 2.0 – 4.0** * Color as specified. If not specified, color shall be Federal No. 595-26307. ** DFT of finish coats shall be no less than the specified thickness and shall completely cover the intermediate coat. The Dry Film Thickness of any coat when Systems B, F or W is applied shall be in accordance with Restriction Level 3 of SSPC PA-2, these specifications and the manufacturer’ s instructions unless otherwise specified in the Contract.TABLE IV-6 Coating Systems 539the span is in compliance. New structures shall be tested in three random locations per span as chosen by the Engineer.
5.Blast Cleaning Process Control: When the contract or plans designate Method 5 or Method 9 surface preparation, the Contractor shall identify and document the processes used at the start of each shift, or blasting operation, in the presence of the Engineer in accordance with SSPC PA-17, including information in Appendix B. When establishing the blasting process, the Contractor shall inspect surfaces for surface profile produced and the degree of cleanliness as specified. This information shall be daily recorded into the project records.
6.Surface Profile Measurements: When the contract or plans designate Method 5 or Method 9 surface preparation, surfaces shall be measured in 3 locations per span using a compressible foam tape in accordance with ASTM D 4417, Method C and in accordance with the tape manufacturer’ s instructions. Should surface profile tests not conform to specification profile range, the Contractor shall measure the extent of non-conforming profile in accordance with SSPC PA-17. The Contractor shall correct any non-conforming location(s) at no additional cost to the Department. When measuring surface profile for methods other than Method 5 or Method 9, the Contractor shall take readings in accordance with ASTM D 4417, Method B at a sufficient number of locations to verify profiles conform to the specifications requirements.
7.Coating Preparation/Mixing: Procedures used for mixing coatings shall be included in daily project records. These records shall also include product name, batch number, material temperatures, ambient temperatures, relative humidity, time of day mixed, dwell times, pot life and product number of thinner and quantities, if used.
8.Film Thickness: The Contractor shall measure the dry film thickness (DFT) of each coating applied using a Type 2 film thickness gage. The Type 2 gage shall be calibrated according to the frequency and procedure specified by the manufacturer and in accordance with ASTM 7091. Prior to taking measurements, a verification of combined accuracy shall be performed in accordance with SSPC PA-2, Appendix 8. The combined accuracy shall be within the manufacturer’ s tolerance of the gage and the tolerance of the standard shim(s) used. If the gage does not meet the combined tolerance, it shall not be used. The Contractor shall furnish another gage which passes accuracy testing for use. Coatings shall be measured in accordance with SSPC PA-2 and comply with thickness Restriction Level 3 after they have dried or cured. In the event coatings are applied and individual coat thicknesses are not documented by the Contractor and confirmed by the Engineer, the undocumented surfaces shall be re-cleaned and coatings reapplied at no additional cost to the Department. When plans or contracts state work on an existing structure is designated as Prepare and Over - coat Existing Structure, the dry-film thickness of coatings will be determined by the Engineer or the Department’ s Representative with a Tooke gage when the thicknesses of previous coatings are not known.
d.Hold Point Inspections: : The following hold point inspections shall be required for all coating methods and all field surface preparation and coating applications performed. Before moving to 411.04 540the next phase of work, each of the following activities must be confirmed by the Engineer and documented by the Contractor’ s representative as it applies to the work specified per the plans or the Contract on new and existing structures (Confirmation will be as required by the paint process used to verify compliance):
1.Cleanliness of surfaces prior to surface preparation
2.Surface preparation and cleanliness prior to primer application
3.Full coat primer prior to intermediate stripe coat
4.Intermediate stripe coat prior to full intermediate coat
5.Full coat intermediate coat prior to finish stripe coat
6.Stripe coat finish prior to full finish coat
7.Full finish coat insp ection The Engineer will verify each of the seven step hold point inspections by means of visual and instrumentation methods. The Contractor shall be responsible for documenting the completeness of the work. The Contractor shall employ a Paint Quality Control Officer to accompany the Engineer during all hold point inspections. The Paint Quality Control Officer shall schedule and coordinate all hold point inspections with the Engineer and complete all required documentation. If deficiencies are detected during a hold point inspection, such deficiencies shall be corrected to conform to the Specifications requirements. All hold point inspections shall be signed by the Engineer and the Contractor’ s designated Paint Quality Control Officer.
e.Record Keeping and Protective Coating Identification: The Contractor shall maintain a record that establishes and describes the location and limits of the work area where protective coating removal or application of a protective coating has been performed. Such records shall be maintained and completed on a daily basis and shall provide, at a minimum, the following information: Contractor’ s name, date, time work began, time work completed, ambient air and structure temperatures, relative humidity ranges during coating and curing operations, all quality control measurements, signed hold point inspections, and manufacturer and name of coating system applied. The record shall include a map detailing work designated as Prepare and Spot Coat and Prepare and Over-coat Structures indicating areas where the protective coating has been applied as accurately located on the actual bridge structure. The Engineer must approve the daily record and map format prior to commencement of work. The Contractor shall maintain the daily records and maps in a three-ring binder throughout the duration of the project. Prior to final acceptance, the Contractor shall submit to the Engineer the completed three-ring binder and shall certify that all information contained therein is factual and correct. The Contractor shall stencil on the structure a legend indicating the coating system(s) applied per Table IV -6, using manufacturer’ s name, product names (abbreviated) or number of each coat, the month and year applied, and the Contractor’ s name after the final coat has cured on new steel and after recoating or over-coating of an existing structure. The legend shall be black in color, and 411.04 541placed inside a fascia stringer near an abutment at a location approved by the Engineer. The legend’ s location shall be shown on the bridge map.
411.05 Existing Structures
Coated steel structures built before 1978 and weathering steel structures may contain mill scale. Coatings applied to existing structures are qualified as systems and therefore shall be applied as listed. Mixing and matching of coatings is not allowed unless permitted in writing by the coatings manufacturer(s) and approved by the Engineer.
a.Bare Steel: The Contractor shall coat all weathering steel either indicated in the Contract or within 5 feet of a deck joint, including but not limited to cross frames, diaphragms, stiffeners, connector plates, girders, and beams with System B. All areas to be coated shall be thoroughly cleaned using Method 5 to no less than 6 inches outside the area to be coated before any coating is applied.
b.Steel Re-Embedded in Concrete: When concrete decks are removed, top flanges of beams or girders including edges and top surfaces of diaphragms, cross frames or other structural steel that is within 4 inches of the bottom of the deck after replacement shall be prepared using Method 1, Method 7 and Method 9 respectively. These surfaces shall be coated using the specified repair primer. If the bridge is designated as a Type B structure, Section 411.03 (b) shall apply to this work.
c.Coating Remaining: Coating application will be performed as follows: The Contractor shall test for chloride, nitrate and sulfate contaminants when preparing surfaces in accordance with Method 7. Chloride, nitrate and sulfate levels shall be tested on bare steel and/ or completely prepared surfaces in accordance with the manufacturer’ s test instructions for each contaminant.
1.Prepare and spot coat existing structure: The Contractor shall prepare surfaces being coated in accordance with Method 1 followed by Method 7 using a pressure of 5,000 pounds per square inch at the nozzle. Rust shall be removed in accordance with Method 4 or Method 5. Prepared areas shall be spot-primed with primer from the system specified. Intermediate and finish coats shall be applied to spot-primed areas only and shall be feathered into the existing finish coat to produce a uniform homogeneous appearance on the existing structure. The coating system shall be as specified on the plans. If no system is specified, the Contractor shall apply System W in accordance with Table IV -6.
2.Prepare and overcoat existing structure: The Contractor shall clean the entire structure in accordance with Method 1 followed by Method 7 using a pressure of 5,000 pounds per square inch at the nozzle. Areas to be primed and coated shall be prepared in accordance with Method 5 or Method 4. Prepared areas shall be spot-primed with primer from the system specified. Intermediate and finish coats shall be applied to the entire structure. The coating system shall be as specified on the plans. If no system is specified, the Contractor shall apply System W in accordance with Table IV -6.
3.Recoat existing structure: The Contractor shall clean the entire structure in accordance with Method 1 followed by Method 7 using a pressure of 3,000 pounds per square inch at the nozzle. The entire structure shall be cleaned to bare metal in accordance with Method 5 unless 411.05 542otherwise specified in the contract. The structure shall be recoated using System B in accor - dance with Table IV -6.
4.Coating new steel members used to repair existing structure: Unless otherwise directed on the plans or approved by the Engineer, the Contractor shall clean the newly installed steel members to bare metal in accordance with Method 5. Prepared areas shall extend 6 inches beyond new steel member into the existing structure at the point of repair and shall be spot-primed with primer from the system specified. Intermediate and finish coat shall be applied to spot-primed areas only and shall be feathered into the existing finish coat to produce a uniform homogeneous appearance on the existing structure. If the existing coating is a zinc- rich primer, the Contractor shall apply System B. The coating system shall be as specified on the plans. If no system is specified, the Contractor shall apply System W in accordance with Table IV -6.
5.Zone coating: Surfaces shown on the plans or in the Contract to be zone coated shall be cleaned in accordance with Method 1 followed by Method 7 using a pressure of 3,000 pounds per square inch at the nozzle. The entire area designated for zone coating shall be prepared in accordance with Method 5 unless otherwise specified in the Contract. The Contractor shall coat areas designated for zone coating using System B. If a winter season elapses between applications of coats, the Contractor shall prepare the structure again in accordance with Method 1 prior to resuming application of additional coatings at no additional cost to the Department. Existing steel on structures to be widened shall not be prepared and coated unless otherwise specified on the plans. When specified on the plans for coating, the Contractor shall clean the entire surface in accordance with Method 1 followed by Method 7. Coatings shall be removed in accordance with Method 5 and the existing structure shall be coated with the same system as required on the new steel portion of the structure.
411.06 New Structures
The Contractor shall coat non-stainless ferrous metal using System B, Group I coatings as specified in Table IV -6. System B coatings are qualified as systems and therefore shall be applied as listed. Mixing and matching of coatings is not allowed unless permitted in writing by the coatings manufacturer and approved by the Engineer.
a.Shop Coating: The fabricator shall abrasive blast clean metal surfaces to be coated in accordance with Method 5 prior to the application of primer. Material shall not be handled or shipped prior to the time(s) established by the coating manufacturer’ s handling and shipping instructions. Machine-finished surfaces and/or areas that are to bear on other surfaces of the structure in a sliding movement shall not receive an applied protective coating as specified in Table IV -6 but shall be coated with a multipurpose grease or other specified coating prior to shipment. The fabricator shall be careful not to get such grease or other specified coating on other painted surface areas. Unless otherwise specified on the plans or directed by the Engineer, the top surfaces of top flanges of beams and girders where shear connectors are to be field applied shall only receive a mist coat of zinc primer to prevent surface corrosion of subsequent shear connector application.411.05 543The fabricator shall stencil or paint erection and weight marks on structural steel subsequent to application of shop primer. The Department will not permit any other lettering. The fabricator shall correct deficiencies and nonconformities to the specification requirements prior to shipment.
b.Field Coating: The Contractor shall not perform field application of coatings until concrete work is completed and forms are removed. The Contractor shall remove concrete, concrete dust, zinc salts, chlorides, sulfates and nitrates or any other debris deposited on coated steel surfaces. Surfaces shall be cleaned in accordance with Method 7 as described in Section 411.04(a) using a pressure of 3,000 pounds per square inch at the nozzle. The Engineer will not require the use of a soluble salt remover when Method 7 is performed on new steel providing transportation of the steel unit has not occurred during winter months. However, confirmation of the level of chlorides is still required in accordance with Section 411.04(c)4. If a winter season elapses between the applications of coats, the Contractor shall prepare the structure again in accordance with Method 7 and test it in accordance with Section 411.04(c)4. at no additional cost to the Department. The Contractor shall clean uncoated surfaces and deficient or damaged areas in accordance with the coating manufacturer’ s instructions or recommendations and touch-up primed areas with a primer from the selected System B coating system. After installation and approval by the Engineer, galvanized bolts, nuts, and washers shall be cleaned and prepared to remove any coating or sealer that may be present in accordance with the coating manufacturer’ s instructions. The Contractor shall wire brush the galvanized bolts, nuts and washers followed by a potable water rinse. The galvanized bolts, nuts and washers shall then be coated with the identical intermediate and top coats being applied to the rest of the structure. All other erection bolts shall be prepared in accordance with Method 1 and abrasive blasted in accordance with Method 5. After preparation, the Contractor shall coat bolts, nuts, and washers using the zinc-rich primer, with intermediate and finish coats being applied to the rest of the structure. Suitable precautions shall be taken to mask off the surrounding primed area to prevent over-blasting. Cleaning agents and rinse water shall be collected and disposed of in accordance with applicable local, state, and federal regulations. Surfaces that will be inaccessible after assembly and erection shall be coated prior to assembly. When the superstructure is weathering steel, the topcoat shall be Brown, Federal No. 595-20059. The topcoat color for other structures shall be Gray, Federal No. 595-26307 unless otherwise specified on the plans. When only portions of a structure are designated for coating, the edges of proposed coated areas shall be masked to a straight line.
411.07 Metal-Based Coatings
a.Galvanizing Existing Uncoated Structures: The Contractor shall prepare the surface in accordance with Method 1 or Method 7. Rust shall be removed using Method 2 or Method 3. If no coating is specified, the Contractor shall apply an epoxy prime coat and urethane top coat selected from System F as specified in Table IV -6.
b.Galvanizing New Surfaces: When coating new galvanized steel is specified in the Contract or plans, galvanizing shall be accomplished in accordance with Section 233 and the following. 411.07 544 1. Galvanizing Facility: Prior to galvanizing operations, the galvanizing facility shall inspect and remove all sharp edges on rolled, pressed or forged steel, railings, tubing or other assemblies by grinding or filing edges to a radius of 1/8 inch. The galvanizer shall not quench or chromate treat surfaces that are to be coated. After galvanization, surfaces shall be uniform and smooth. Should any locations be found to have excessive liquid zinc run-off, dross, or zinc oxide particles, these locations shall be smoothed using hand or power tools until such locations are level with the surrounding area. The galvanizing facilities quality control personnel shall measure the applied galvanizing layer using a Type II film thickness gage as described in Section 411.04(c)8. The galvanizing facility shall prepare a report providing the gage manufacturer, model number, serial number, record of last calibration, verification of combined accuracy results. The report shall also include the specified coating thickness grade by material category for parts and/or assemblies shipped, the dates when work was completed and reported thicknesses of the galvanized layer in accordance with ASTM A123. The facility shall also include a written statement certifying the materials have not been quenched or chromate treated after the hot dip process. Copies of this report shall be sent to the Contractor, the Painting Contractor and the Department. After galvanizing and inspection, the facility shall protect materials from rain or moisture during storage and subsequent shipment. Precautions shall be taken when handling material by using appropriate straps and spacing material in shipping to minimize damage.
2.Painting Contractor: The painting contractor’ s quality control personnel shall inspect materials received for sharp edges, dross, excessive zinc run-off, damaged locations from shipping and zinc salts that may have formed during storage or transport. Painting personnel shall verify film thicknesses reported by the galvanizing facility, prior to performing surface preparation. The galvanized layer and subsequent application of coatings shall be measured using a Type II film thickness gage as described in Section 411.04(c)8. Galvanized surfaces shall be prepared using Method 1 followed by sweep blasting in accordance with SSPC SP-16, including all information noted in Appendix A. The resultant profile shall be from 1.0 to 1.5 mils in a uniform pattern with no smooth un-pro - filed areas. Surface profile shall be measured in accordance with ASTM D 4417, Method C. After sweep blasting the painting contractor’ s quality control personnel shall measure the gal - vanized layer in 3 random locations per shift, for a total of 9 readings, to ensure thicknesses are at or above the specified coating thickness grade by material category reported by the galvanizing facility. Locations found to have insufficient coating thickness shall be repaired in accordance with ASTM A780 and prepared in accordance with the coating manufacturer’ s instructions. Coatings shall be applied as soon as possible within 8 hours after the start of sweep blast preparation. The painting contractor’ s quality control personnel shall measure each coating applied in accordance with SSPC PA-2. The painting contractor shall submit, in a report, information of the Type II gage manufacturer, model number, serial number, record of last calibration, verification of combined accuracy tolerance and thickness readings of the galvanized layer prior to and after sweep blasting. The report shall also include all surface profile measurements, air, surface, material temperatures, relative humidity’ s during preparation and painting, dry film thickness of coating(s) applied with dates and times each phase of work was performed. If new galvanized material is supplied to the project and no written documentation exists that it has not been quenched, chromate treated, or other passivating treatment has been used, surfaces 411.07 545must be tested in accordance with SSPC SP-16 to confirm no chromates or other oxidizing treatment is present. If present, surfaces shall be tested after sweep blasting to ensure chromates or other oxidizing treatments have been removed prior to coating application. Surfaces shall be prepared by sweep blasting as stated above. If treated members or materials have been erected and it is deemed sweep blasting is inappropriate due to access or surroundings, the Contractor shall prepare the surfaces using a zinc-phosphate treatment in accordance with the manufacturer’ s recommendations and ASTM D6386. Prepared surfaces shall be coated as soon as possible within 8 hours of preparation.
c.Thermal spray coating of structural steel members shall conform to AISC S8.2.
411.08 Observation Period
The Contractor shall maintain responsibility for the coating system for a 12 month observation period beginning on the date of acceptance of the coating work specified on plans or in the Contract. The Contractor shall guarantee the preparation and installation of the coating system under the payment and performance bond. To successfully complete the observation period, the coating system must meet the following requirements after 12 months in service:
a.No visible rust or rust stains from coated surfaces.
b.No blisters, peeling, cracking or other abnormalities of any coat applied.
c.Have uniform color and gloss and be within the retention values established when tested for acceptance.
d.Have an adhesion rating of at least 80 percent of the initial adhesion when tested for acceptance in accordance with ASTM D4541
411.09 Environmental Protection
In accordance with Section 107, the Contractor shall protect the public and the environment from leaded paint or hazardous material resulting from coating preparation, cleaning, removal operations, blast abrasives, rust, and overspray. The Engineer will not allow the depositing or dropping of waste materials into water, onto the ground, onto roadways, or outside the containment system. Tarpaulins shall cover all pavements and surfaces underneath removal and recycling operations including equipment or other equipment handling hazardous materials and storage during active and inactive operations such as retention or storage until characterization analysis and disposal. Waterways, travel-ways and the public shall be protected against coating drift and overspray. Equipment and containment devices shall arrive at the site in a decontaminated condition and shall be decontaminated prior to relocating or moving unless otherwise properly disposed. Residues from decontamination and any associated disposable items shall be properly disposed of in accordance with all applicable federal, state, and local regulations. The Contractor shall at all times be in compliance with these specifications and the regulations of, but not exclusive to, the following agencies: U.S. Environmental Protection Agency, U.S. Department of 411.09 546Transportation, Virginia Department of Environmental Quality, Virginia Department of Labor and Industry, and the U.S. Coast Guard. The Contractor shall immediately report all instances of non- compliance to the Engineer.
a.Environmental Protection Plan: Where surface preparation operations are required, the Contractor shall submit a detailed site-specific Environmental Protection Plan to the Engineer for and the Engineer’ s review and acceptance. The accepted site-specific Environmental Protection Plan shall become part of the Engineer’ s records for the project. The Contractor shall not construe submittal acceptance as implying any approval of means and methods by the Engineer. The Contractor shall provide one comprehensive Plan that covers all facets of operation. No work shall proceed until the Engineer has notified the Contractor of Plan acceptance. The Environmental Protection Plan shall include controls for capture, containment, collection, air monitoring, storage, and transportation of waste material generated by the work. The Contractor shall use the most effective method possible for capture, collection, containment, and transportation operations. The Plan shall include measures for accidental spill cleanup and spill reporting to the appropriate regulatory agencies. The Environmental Protection Plan shall be certified by an SSPC QP-2 Competent Person. If the containment design involves the erection of a supported or suspended containment system from the bridge structure with a total weight-bearing capacity of greater than 1,000 pounds, the Plan shall also be reviewed and certified by a Professional Engineer licensed to practice engineering in the Commonwealth of Virginia. The certification shall include the structural integrity of the containment structure and verification that the containment system does not adversely affect any portion of the bridge. After project award but not less than 3 weeks prior to commencing operations covered by this Plan, the Environmental Protection Plan shall be submitted to the Engineer. Within 2 weeks of the date of receipt, the Engineer will review the submitted Plan for completeness. Should deficiencies in the Plan exist, the Plan will be returned to the Contractor for incorporation of revisions as noted by the Engineer. The Contractor shall make such revisions and submit a completed corrected Plan for the Engineer’ s record prior to commencing operations. In no case shall the Contractor begin work prior to the Engineer’ s receipt and review of a satisfactorily complete Environmental Protection Plan.
b.Monitoring: The Contractor shall perform continuous visual inspections of the containment structures, the dust collector system and abrasive recycling equipment to detect and control the release of any emissions into the unconfined air space. Emissions will not be permitted outside the containment system. The Contractor shall immediately correct any visual emissions outside the containment system to comply with emission standards. If there are any emissions or discharges noted, the SSPC QP-2 Competent Person shall submit in writing, within 24 hours of notice, what corrective actions were taken to contain the errant emissions or discharges. The SSPC QP-2 Competent Person shall submit written certification each week to the Engineer that removal operations and coating work is being performed in compliance with the accepted Environmental Protection Plan and that the project is meeting the environmental requirements therein. Further the SSPC QP-2 Competent Person shall submit certification to the Engineer at the completion of the project that the Environmental Protection Plan fully complied with all applicable regulations and was fully implemented. Minimal visible air emissions will be allowed for properly operating vacuum-assisted power tools provided that a secondary means for collecting large particles is employed and the technology is applied using usual and customary industry practices inherent to such work. Excessive emissions caused by improperly operating or functioning equipment shall be immediately corrected. Any 411.09 547exhausts from gasoline or diesel equipment used shall be located outside or directed outside of the containment area. The Contractor shall provide adequate lighting as necessary to aid proper performance of the work and visual inspections in accordance with the minimum requirements for illumination as stated in SSPC, Guide 12. The Contractor shall be responsible for performing perimeter air monitoring for all projects requiring removal of greater than 100 square feet of coating, using high-volume air samplers equipped for the collection of Total Suspended Particulate (TSP) samples. Air monitoring equipment used shall be employed, maintained and calibrated in accordance with the manufacturer’ s instructions. The filters shall be replaced daily in the presence of the Engineer and analyzed for lead in accordance with EPA 40 CFR Part 50, Appendix G. Air monitoring equipment shall be in operation for a minimum of 8 hours per day while blasting operations are being performed. The Contractor shall place air monitors within 500 feet downwind of the structure at the point of maximum potential environmental impact of paint abatement, dust collection, and abrasive recycling equipment and at other locations of potential public or environmental exposure as directed by the Engineer. Monitors shall be maintained at downwind positions at all times during the work in the event of shifting wind patterns. As measured by perimeter monitoring, the Contractor shall be responsible for maintaining emissions levels below the National Ambient Air Quality Standard for lead (40 CFR Part 50) using the Adjusted Daily Allowance (ADA) procedure outlined in SSPC-Guide 6, Method D. Should emissions exceed the limits set herein or material begins to reach the ground or enter State waters, the Contractor or the SSPC QP-2 Competent Person shall notify the Engineer and operations shall be halted until such time that corrective actions are implemented. The results of all sample analyses shall be submitted to the Engineer within 48 hours for the first two days of monitoring, and within 5 business days thereafter.
c.Waste Characterization and Storage: Material removed from a Type A structure shall be disposed of as a non-hazardous waste in accordance with (d)1 herein. Solid material removed from a Type B structure shall be contained, collected, and stored in closed 55-gallon USDOT approved steel drums or portable metal roll-off containment refuse disposal bins. For small quantities of waste, approved 5-gallon containers may be used. The Contractor shall, with the oversight of the Engineer; collect and provide to the Department samples for analysis at the following frequency: Containers Samples 1 1 2-6 2 Over 6 1 for every 3 containers The Contractor shall supply containers used to provide the Department waste characterization samples. Containers shall be wide mouth screw top high density Polyethylene or Polypropylene (HDPE or PP) bottles. Solid waste characterization samples shall be submitted in a full 500 ml container and liquid waste characterization samples shall be submitted in a full 1,000 ml container. Solid waste samples shall be randomly collected and shall be representative of the contained waste. The solid waste generated from work performed on T ype B structures will be tested by the Department in accordance with EP A Method 1311, Toxicity Characteristic Leaching Procedure (TCLP), and corresponding EP A 6000 or 7000 series metals analytical method for, but not limited to, the following 411.09 548metals to determine if the waste material(s) requires management as hazardous waste: arsenic, barium, cadmium, chromium, lead, mercury, selenium, and silver. Exception to this testing protocol is that waste generated from abrasive blasting with recycled steel abrasives for Method 5 or Method 9 will be tested for total concentrations of the aforementioned heavy metals in lieu of the TCLP analysis. The Department shall pay the cost of all tests performed by the laboratory on solid wastes. Waste generated from abrasive blasting with recycled steel abrasive shall be classified as hazardous if the total lead level exceeds 0.01 percent. If the material is declared to be a hazardous waste by the Department, the Contractor shall dispose of the material in accordance with Section 411.09(d)3. The Contractor is not relieved from performing waste characterization in accordance with the aforementioned procedures by using test results from samples of coatings collected while adhered to the structural steel. All liquid waste from T ype B structures shall be tested by the Contractor in accordance with EP A Method 1311, Toxicity Characteristic Leaching Procedure (TCLP) to determine waste disposal requirements. All liquid wastes from T ype A structures shall be tested in accordance with any requirements of the disposal facility. Contractor shall pay all costs for laboratory testing and provide the test results to the Department prior to disposal. The Contractor shall provide a separate lockable storage area for each structure for waste material located immediately adjacent to the structure. The storage area shall provide access and egress through a gate or door. The Contractor shall collect the material at the end of each workday and shall transport the waste material to the storage area in a closed container that will not permit leakage. Each container shall be marked indicating the origin of the material; the date the material was placed in the storage area; and a 24-hour telephone number for the Contractor and the Department representative. Prominent warning signs shall be displayed around the perimeter of the storage area. The signs shall be located at a distance from the storage area that will allow personnel to read the sign and take the necessary protective actions required before entering the storage area. Warning signs and notices shall be posted in accordance with CFR 29 Part 1926, Section 62. One centralized storage site may be used to store waste materials from structures at adjacent projects provided that transport of waste over roads open to the public is not required and that the materials is labeled and stored separately. The site for the temporary storage of the waste material shall be approved by the Engineer prior to its establishment and shall not be located within a flood plain, drainage area, or where water will pond. Con - tainers of waste material shall at all times have tops secured and be covered with waterproof coverings. The site shall be secured against unauthorized entry. If such a site is not available immediately adjacent to the structure, an alternate location on state property shall be submitted as a requested amendment to the Environmental Protection Plan and approved by the Engineer prior to use. The Contractor shall be responsible for ensuring any over-the-road transport of hazardous waste complies with all local, state, or federal permitting, licensing, manifesting, and/or fee requirements.
d.Disposal:
1.Solid waste material from a Type A structure or waste from a Type B structure that is determined by the Department not to be a hazardous waste shall be disposed of in a sanitary landfill Resource Conservation and Recovery Act (RCRA) Subtitle D or licensed industrial landfill that has a permit from the Virginia Department of Environmental Quality or an equivalent state or federal agency for out-of-state disposal facilities. The Contractor shall identify the landfill used by name, address, and permit number and shall certify that the waste material actually submitted for disposal met the above criteria and was properly disposed.411.09 549 2. Liquid waste from Type A and Type B structures that is determined not to be a hazardous waste shall be legally disposed of in a publicly owned treatment works facility (POTW). The Contractor shall identify the POTW used by name, address, and permit number and shall cer - tify that the waste material actually disposed of was not hazardous and was properly disposed.
3.If waste material from a Type B structure is classified as hazardous, the Contractor shall obtain a provisional hazardous waste generator number from the Virginia Department of Environ - mental Quality in accordance with applicable federal and state regulations and shall legally store, package, label, and ship such material by a transporter with an RCRA Hazardous Waste Transporter permit to a RCRA, Subtitle C, Treatment Storage and Disposal Facility (TSDF) for treatment and disposal. The Contractor shall prepare a hazardous waste shipping manifest(s) with the site identified by the federal structure ID or if no federal structure ID, then the state structure ID with the Route and County shall be used; the manifest shall be provided to the Engineer for signature. The Engineer’ s signature on the waste shipping manifest does not relieve the Contractor of the Contractor’ s obligations as co-generator of the waste.
4.The Contractor shall dispose of all surface preparation and coating removal wastes within 90 days of the time it is generated and no waste shall remain on site more than 60 days following completion of all coating removal operations.
e.Certifications: The Environmental Protection Plan shall be implemented in accordance with the provisions contained therein; any deviations from the Plan shall be separately submitted by the Contractor and approved by the Engineer. The SSPC QP-2 Competent Person providing the Plan certification shall at a minimum be present during startup and removal operations to ensure that the Plan is fully implemented. Within 1 week following completion of final waste disposal activities, the Contractor shall submit for the Engineer’ s record a written certification by the SSPC QP-2 Supervisor/Competent Person, including notations of any areas of non-compliance and corrective actions taken, that all work has been completed in full compliance with all applicable regulations and requirements as set forth in these specifications and that the Plan on record was fully implemented. The Contractor shall forward for the Engineer’ s record one copy of the Environmental Protection Plan complete with all revisions and results from the air monitoring activities, including notations of any areas of non-compliance and corrective actions taken.
411.10 Health and Safety Protection
In accordance with Section 107, the Contractor shall protect the health and safety of the workers, the public, and the environment from all hazardous material resulting from coating preparation (cleaning) removal operations, blast abrasive, rust treatment, pre-cleaning, surface preparation, coating preparation, coating application, and overspray.
a.Plan: The Worker Health and Safety Plan shall be in accordance with the Virginia Occupational Safety and Health Administration, 29 CFR 1926.62 requirements and the applicable requirements of 29 CFR 1910.1025, and other applicable toxic metal standards, whichever is more restrictive. The Worker Health and Safety Plan shall be approved by a SSPC QP-2 certified organization and their Competent Person assigned to the project. This Plan shall not be submitted to the Engineer for approval but shall be submitted for the Engineer’ s review and record. After project award but not less than 3 weeks prior to commencing operations, the Worker Health and Safety Plan shall be submitted to the Engineer.411.10 550Within 2 weeks of receipt, the Engineer will review the submitted Plan for completeness. Should deficiencies in the Plan exist, the Plan will be returned to the Contractor for incorporation of revisions as noted by the Engineer. The Contractor shall make such revisions and submit a completed corrected Plan for the Engineer’ s record prior to commencing operations. In no case shall the Contractor begin work prior to the Engineer’ s receipt, review, and acceptance of a satisfactorily completed Plan.
b.Monitoring: The SSPC QP-2 Competent Person providing plan approval shall be present during startup, during surface preparation periods, and as needed during removal operations throughout the duration of the project to ensure the provisions of the Worker Safety and Health Plan are properly implemented.
c.Certification: At completion of the project, the SSPC QP-2 Competent Person shall submit a written statement of certification for the Engineer’ s record, complete with all revisions including notations of any areas of non-compliance and corrective actions taken, that the Worker Safety and Health Plan fully complied with all regulations and that the Plan was fully implemented.
411.11 Measurement and Payment
Coating of new metal on structures will not be measured for separate payment but shall be included in the price for structural steel or metal items. When a pay item, coating of new metal on structures will be paid for at the contract lump sum price per structure. Prepare and spot coat existing structure, when a pay item, will be measured in square feet of surface area and will be paid for at the contract unit price per square foot. Prepare and overcoat existing structure, when a pay item, will be paid for at the contract lump sum price per structure. Recoat existing structure, when a pay item, will be paid for at the contract lump sum price per structure. Zone coating of existing structure, when a pay item, will be paid for at the contract lump sum price per structure. These prices shall include washing, surface preparation, and applying protective coating. Environmental protection and health and safety will be paid for at the contract lump sum price per structure. This price shall include setting up, maintaining and dismantling, execution, and acceptance, environmental protection plan and worker safety and health plan preparation and approval, providing SSPC QP-2 Competent Person monitoring services, environmental and worker protection quipment and containment, and all other related costs. Payment for the Environmental Protection Plan and Worker Safety and Health Plan and execution will be made on the basis of two installments per structure. The first installment will be made at 90 percent of the contract lump sum price per structure and will be made on the next progress estimate after an acceptable Environmental Protection and the Worker Safety and Health Plan are received by the Department. Payment of the remaining 10 percent will be made on the progress estimate following the submission of the certifications of compliance for the environmental protection and the worker health and safety plans. Disposal of material will be paid for at the contract lump sum price per structure. This price shall include storing, transporting, and disposal. No payment will be made for this item until the Contractor provides the signed return manifests from the disposal facility(s).411.10 551Payment will be made under: ————————————————————————————— ————————Pay Item Pay Unit————————————————————————————— ————————Coating of new metal on structures (B or Str. No.) Lump sum Prepare and spot coat existing structure (B or Str. No. and type) Square foot Zone coating of existing structure (B or Str. No. and type) Lump sum Prepare and overcoat existing structure (B or Str. No. and type) Lump sum Recoat existing structure (B or Str. No. and type) Lump sum Environmental protection and health and safety (B or Str. No.) Lump sum Disposal of material (B or Str. No. and type) Lump sum————————————————————————————— ———————— SECTION 412—WIDENING, REP AIRING, AND RECONSTRUCTING EXISTING STRUCTURES
412.01 Description
This work shall consist of widening, repairing, or reconstructing existing concrete structures in accor - dance with the lines, dimensions, plan details, and these specifications or as directed by the Engineer.
412.02 Materials
a.Epoxy and mineral fillers shall conform to Section 243. Epoxy for epoxy mortar shall be Type EP-5. Epoxy used for crack repair shall be Type EP-4 or EP-5, low viscosity. Epoxy for epoxy injec - tion shall be Type EP-4 L V Modified and shall have a viscosity of 5 poises or less at 75 degrees F .
b.Hydraulic cement concrete shall conform to Section 217, except that the coarse aggregate shall be size No. 7, No. 8, or No. 78 for depths and steel clearances less than 2 inches and shall be size No. 57, No. 7, No. 8, or No. 78 for depths more than 2 inches. A Department approved accelerator from the Materials Division’ s Approved Products List 2 may be permitted by the Engineer when justified by work restrictions, traffic limitations, or closure timeframes. Concrete specified as High Early Strength (HES) shall be either a high early strength Class A4 ready mixed concrete, or an approved hydraulic cement concrete patching material from the Materials Division’ s Approved Products List 31. The type of material to be used shall be approved by the Engineer prior to the beginning of the work at each location. When a HES patching material is approved for use at the specific location by the Engineer, the patching material volume may be extended with coarse aggregate in accordance with the manufac - turer’ s recommendations. Surface preparation, placement, and curing of the patching material shall be in accordance with the manufacturer’ s instructions and this specification. Patching materials must obtain a minimum compressive strength of 2500 psi when tested in accor - dance with ASTM C1074 prior to permitting vehicular traffic on patched areas. The Contractor shall make trial batches under the observation of the Engineer for each type of patching material used during this project to verify that concrete of the required workability and consistency 412.02
Source: Virginia Road and Bridge Specifications, 2020 Edition. Pages 560–578 of 1,065.