5-184 SECTIO N 513 – FIELD PAINTIN G STEEL 513.0 1 DESCRIPTION . This work shall consist of the preparation and coating of the designated surfaces with the materials and methods specified in the Contract. All steel to be painted under this specification shall be bare steel. 513.0 2 MATERIALS. Materials shall meet the requirements of the following subsections: Structural Steel Coat ing Systems ................................ ................................ ............... 708.0 3 Grease Rustproofing Compound ................................ ................................ ................ 708.0 4 513.0 3 QUALIFICATIONS . The following qualification requirements shall be met and certified status shall be maintain ed throughout the duration of the painting work under the Contract.
a.Painting Contractor . The painting c ontractor shall possess current SSPC -QP 1 and SSPC -QP 2 certifications.
b.Quality Control (QC) Manager . The QC manager shall possess a minimum classification as a NACE Coating Inspector Level 2 – Certified.
c.Quality Control (QC) Inspector . The QC inspector shall possess a minimum classification as a NACE Coating Inspector Level 1 - Certified . 513.0 4 SEQUENCE OF WORK . The Contractor shall prepare the surfaces specified in the Plans in accordance with the follo wing sequence:
a.Remove Existing Coatings . Any existing coatings on the steel shall be removed in accordance with the requirements of the Contract prior to the initiation of work under this specification. All payment for the removal and disposal of existing coatings will be made under the appropriate Section 511 pay items.
b.Prepare Surfaces . The Contractor shall prepare the surface of the existin g steel to meet the requirements specified in Subsection 513.15 .
c.Remediate Soluble Salts . The Contractor shall remediate soluble salts on the existing bare steel as specified in Subsection 513.17 .
d.Apply Coatings . The Contractor shall apply the coat ing system specified in the Plans according to the requirements of this specification. 5-185 513.0 5 HOLD POINTS. Specific inspection items throughout these specifications are designated as hold points . These hold points are for the Engineer to perform QA inspections of the completed specified work. Unless an alternative timeframe is required by this specification o r other arrangements are made at the project site, the Contractor shall notify the Engineer a minimum of 4 hours before a hold point will be reached. If the 4 hour notification is provided and the work is ready for inspection at that time, and the necessar y QC inspections are performed, the Engineer will conduct the necessary QA observations. QA inspections will be performed only after a proper QC inspection by the Contractor. If the work is not ready at the appointed time, unless other arrangements are made, an additional 4 hour notification is required. Permission to proceed beyond a hold point without a QA inspection will be granted solely at the discretion of the Engineer, a nd only on a case -by-case basis. If re-work is necessary as determined by a QA inspection, it shall be accomplished and a new hold point for the re -work shall be observed as defined above. 513.0 6 SUBMITTALS . The Contractor shall submit to the Engineer, i n accordance with Subsection 105.0 6, the following information for completing the work. Complete submittals shall be provided a minimum of 21 calendar days prior to the anticipated start of the work.
a.Contractor and Contractor’s Personnel Qualifications . The Contractor shall submit evidence of their qualifications and the names and qualifications, experience, and training of the personnel managing and implementing the quality control program and conducting the quality control tests. At a mi nimum this sh all include the quality control manager and the quality control inspector . Copies of certifications shall be provided to show that all requirements of Subsection 513.03 have been met.
b.Quality Control (QC) Program . The QC program shall be signed by the quality control manager and shall identify the following:
1.Instrumentation that will be used.
2.Schedule of required measurements and observations.
3.Procedures for correcting unacceptable work.
4.Procedures for improving surface pre paration and painting quality as a result of quality control findings. 5-186 (c) Inspection Access Plan . The inspection access plan is for use by the Contractor ’s QC personnel for ongoing inspections and by the Engineer during quality assurance (QA) observations. The plan shall include the design of any necessary scaffolding or staging required for QC/QA inspections. All staging and scaffolding shall be designed by a qualified professional engineer .
d.Surface Preparation and Painting Plan . The surface preparation and painting plan shall include the specified methods of surface preparation and types of equipment to be used for water washing; hand and power tool cleaning; removal of rust, mill scale, grease, or foreign matter; abrasive blast cleaning; and remediation of chloride. If d etergents, additives, or inhibitors are incorporated into the water used for any coating work operations, the plan shall include the names of the materials and safety data sheet s (SDS). The plan shall identify the solvents proposed for solvent cleaning, t ogether with the SDS. The plan shall also include the methods of coating application, including any required stripe coats, and all equipment to be used. Stripe coats shall only be applied by brushing, the use of rollers or daubers will not be permitted. If the Contractor proposes to heat or dehumidify the containment, the methods and equipment proposed for use shall be included in the plan for the Engineer’s consideration.
e.Abrasives . The Contractor shall submit the type of abrasives to be used for abras ive blast cleaning and the SDS. For expendable abrasives, the Contractor shall provide certification from the abrasive supplier that the abrasive meets the requirements of SSPC -AB 1. For steel grit abrasives, the certification shall indicate that the abras ive meets the requirements of SSPC -AB 3.
f.Coating System Information . The Contractor shall submit the latest version of the product manufacturer’s application and thinning instructions, SDS, and product data sheets for each and every coating, thinner, s ealer, and grease rustproofing compound. Specific attention shall be drawn to storage temperatures and the temperatures of the material, surface, and ambient air at the time of application. The following information shall be provided by the coating manufac turer’s technical representative in written form:
1.The recommended minimum ambient weather conditions and minimum surface temperatures during each of the curing/drying periods. 5-187 (2) Drying schedules (similar to that found on the product data sheet) representing dry to handle, dry to recoat , and full cure, for each coat, at both the minimum and maximum DFT range as specified in Subsection 513.19(g) . These schedules shall also include the minimum time that each coat must be protected from cold and inclement weather (e.g. exposure to rain, snow, temperatures below 40°F, etc.) These drying schedules shall account for varying temperatures and low ventil ation (where applicable). If the product used is a moisture cured product or a water -based product, these schedules shall be for 50% relative humidity, or the lowest relative humidity that is expected to be encountered. It is acceptable for the manufactu rer to provide variable ranges, or multiple curing/drying schedules. The curing/drying times given in the schedule will be considered applicable provided that the actual field conditions are within the tolerances specified below. If the actual field cond itions exceed the tolerances listed below, the schedule shall be modified by the manufacturer’s technical representative prior to painting. It shall be noted that the unlimited tolerances listed below are only unlimited in regards to affecting curing/dryin g times and do not supersede limits stated elsewhere in this specification or the product data sheets.
a.Temperature . Schedule condition minus 0°F ( positive tolerance unlimited)
b.Relative Humidity . Schedule condition minus 0% ( positive tolerance unlimit ed) (only applies to moisture cured and water -based products)
c.Ventilation . If the actual containment systems have minimal ventilation, the schedule shall acknowledge these conditions and the curing/drying schedule shall reflect these conditions. Copies of these documents shall be available on the project site at all times. When the Contractor proposes to use penetrating sealer, sealant caulk, rust inhibitor, or chemical soluble salt remover, they shall submit a letter from the coating system manufactur er indicating that the material will not adversely affect the performance of the coating system.
g.Containment of Paint and Debris . The Contractor shall submit a plan for containing or controlling surface preparation and paint debris (e.g. abrasive medi a, droplets, spills, overspray, etc.). 5-188 If dry abrasive blast cleaning without vacuum is used, the containment shall meet the requirements of SSPC Class 1A. If dry abrasive vacuum blast cleaning is used, the containment shall meet the requirements of S SPC Class 4A. Any tarpaulins or protective coverings proposed for use shall be fire retardant.
h.Progress Schedule . A progress schedule shall be submitted and shall identify all major work items and associated hold points (e.g. installation of rigging and containment, surface preparation, and coating application). The Contractor shall provide updated progress schedules as requested by the Engineer. When the Engineer accepts the submittals, the Contractor will receive written notification. The Contractor shall not begin any work covered under this specification until the Engineer has accepted the submittals and a pre -paint meeting has been held, as de fined in Subsection 513.11 . The Contractor shall not construe Engineer acceptance of the submittals to imply approval of any particular method or sequence for conducting the work, or for addressing health and safety concerns. Acceptance of the submittals does not relieve the Contractor from the responsibility to conduct the work according to the requirements of federal, state, or local regulations, this specification, or to adequately protect the health and safety of all workers involved in the project and any members of the public who may be affected by the project. The Contractor remains solely responsible for the adequacy and completeness of the programs and work practices, and adherence to them.
513.07 QUALITY CONTROL (QC) INSPECTIONS . The C ontractor shall perform first line, in progress
QC inspections. The Contractor shall implement the submitted and accepted QC program to ensure that the work accomplished complies with these specifications.
a.Personnel . The Contractor’s quality control m anager is responsible for managing the Contractor’s QC program. The quality control manager shall be on the project for the first 48 hours of paint application and after that time be available to be back on the project with 24 hours’ notice. The quality c ontrol inspector shall not participate in any production activities related to surface preparation or painting and shall be onsite full time during any operations that affect the quality of the coating system, including but not limited to surface preparati on and chloride remediation, coating mixing and application, and evaluations between coats, and upon project completion. Completed daily reports for all quality control testing and observations shall be provided to the Engineer before work resumes the foll owing day. 5-189 The personnel performing any QC tests shall be trained in coatings inspection and the use of the testing instruments. Documentation of training shall be provided. Painters shall perform wet film thickness measurements, with the quality cont rol inspector conducting random spot checks of the wet film. The Contractor shall not replace the QC personnel assigned to the project without advance notice to the Engineer, and acceptance of the replacements by the Engineer.
b.Inspection Focus . Contrac tor QC inspections shall include, but not be limited to, the following:
1.Suitability of protective coverings and the means employed to control project debris and paint spills, overspray, etc.
2.Ambient conditions.
3.Compressed air cleanliness .
4.Surface preparation and surface profile (solvent cleaning, pressure washing, hand and power tool cleaning, abrasive blast cleaning, etc.).
5.Chloride remediation.
6.Coating application (materials verification, mixing, thinning, induction/sweat -in time, and wet and dry film thickness).
7.Re-coat times and cleanliness between coats.
8.Coating continuity and coverage (freedom from runs, sags, overspray, dry spray, pinholes, shadow -through, skips, misses, etc.).
9.Records of Co ntractor QC inspections shall document the location on the structure and any applicable product batch numbers.
c.Inspection Equipment . The following equipment shall be provided by the Contractor as necessary to perform QC inspections:
1.Psychrometer o r comparable equipment for the measurement of dew point and relative humidity, together with all necessary weather bureau tables or psychrometric charts.
2.Surface temperature digital spot thermometer. 5-190 (3) SSPC -VIS 1 and SSPC -VIS 3 .
4.Commercially available putty knife of a minimum thickness of 40 mils and a width between 1 and 3 inches.
5.Replica tape and spring micrometer.
6.Chloride titrator strip for chloride determinations.
7.Wet film thickness gauge.
8.Blotter paper for compressed air cleanliness checks.
9.Type 2 electronic dry film thickness gauge per SSPC -PA 2.
10.Calibration standards for dry film thickness gauge.
11.Light meter for measuring light intensity during surface preparation, painting, and inspection ac tivities.
12.Printed copies of all applicable ASTM and SSPC standards used for the work.
13.SSPC Manual of Good Painting Practice, Volume 1 . The instruments shall be calibrated within 12 months of the date of project usage or according to the equipment manufacturer’s recommendations and the Contractor’s QC program if they require a shorter duration. If item 631.18 00 is not included in the Contract, the Contractor’s QC inspection equipment shall be made available to the Engineer for QA observations as re quested.
513.08 QUALIT Y ASSURANCE (QA) OBSERVATIONS. The Engineer will conduct QA observations
of any or all phases of the work. The presence or activity of Engineer observations in no way relieves the Contractor of the responsibility to provide all neces sary daily QC inspections and to comply with all requirements of this specification. The Engineer has the right to reject any work that was performed without adequate provision for QA observations. 5-191 513.0 9 INSPECTIO N ACCES S AND LIGHTING . The Contractor shall facilitate the Engineer’s observations as required, including allowing ample time to view the work. The Contractor shall furnish, erect, and move scaffolding or other mechanical equipment to permit close observation of all surfaces t o be cleaned and painted. This equipment shall be provided during all phases of the work. Examples of acceptable access structures include:
a.Mechanical lifting equipment, such as scissor trucks, hydraulic booms, etc.
b.Platforms suspended from the st ructure comprised of trusses or other stiff supporting members and including rails and kick boards.
c.Simple catenary supports are permitted only if independent lifelines for attaching a fall arrest system according to VOSHA regulations are approved. When the surface to be inspected is more than 6 feet above the ground or water surface, and fall protection is not provided (e.g. railings), the Contractor shall provide the Engineer with a lifeline according to VOSHA regulations. The lifeline and attachment shall not direct the fall into oncoming traffic. The Contractor shall provide a method of attaching the lifeline to the structure independent of the inspection facility or any support of the platform. When the inspection facility (e.g. platform) is more t han 2 -1/2 feet above the ground, the Contractor shall provide a VOSHA compliant means of access onto the platform. The Contractor shall provide artificial lighting in areas where natural light is inadequate, as determined by the Engineer, to allow proper c leaning, inspection, and painting. Illumination for inspection shall be at least 30 foot -candles. Illumination for cleaning and painting, including the working platforms, access, and entryways shall be at least 20 foot -candles. 513.1 0 SURFAC E PREPARATIO N AND PAINTIN G EQUIPMENT . All cleaning and painting equipment shall include gauges capable of accurately measuring fluid and air pressures and shall have valves capable of regulating the flow of air, water, or paint as recommended by the equipment manufactur er. The equipment shall be maintained in proper working order. Diesel or gasoline powered equipment shall be positioned or vented in a manner to prevent deposition of combustion contaminants on any part of the structure. Hand tools, power tools, pressure w ashing, water jetting, abrasive blast cleaning equipment, brushes, rollers, and spray equipment shall be of suitable size and capacity to perform the work required. All power tools shall be equipped with vacuums and high efficiency particulate air (HEPA) f iltration. 5-192 Appropriate filters, traps, and dryers shall be provided for the compressed air used for abrasive blast cleaning and conventional spray application. Paint pots shall be equipped with air operated continuous agitation devices unless prohibite d by the coating manufacturer. The air discharge from power tools and air motors shall be directed away from steel surfaces . If this is not possible a filtering device shall be appropriately placed.
513.11 PRE-PAIN T MEETING . A meeting shall be held after the acceptance of all submittals related to
the structural steel painting. Work under this specification shall not proceed until after this meeting has been held. The purpose of the meeting shall be to review all aspects of the surface preparation and pai nting of the steel. Individuals attending the meeting representing the Contractor shall be the project superintendent, quality control manager, and the quality control inspector. a qualified manufacturer’s technical representative for the coating system shall also attend. The Engineer will notify the Contractor a minimum of 7 calendar days in advance of the meeting. If a pre -work meeting for paint removal operations is required by another item in the Contract, that meeting may be combined with the pre -paint meeting of this specification. If combined into one meeting, the meeting shall occur pri or to any paint removal or painting activities.
513.12 TEST SECTIONS (HOL D POINT) . Prior to surface preparation, the Contractor shall prepare test
sections on each structure to be painted in locations which the Engineer considers to be representative of the existing surface condition and steel type for the structure as a whole. More than one test section may be needed to represent the various design configurations of the structure. The purpose of the test sections is to demonstrate the use of the tools an d degree of cleaning required (cleanliness and profile) for each method of surface preparation that will be used on the project. Each test section shall be approximately 10 square feet. The test sections shall be prepared using the same equipment, material s, and procedures as the production operations. The Contractor shall prepare the test sections to the specified level of cleaning according to the appropriate SSPC visual standards, modified as necessary to comply with the requirements of these specificat ions. The written requirements of these specifications prevail in the event of a conflict with the SSPC visual standards. Only after the test sections have been approved shall the Contractor proceed with surface preparation operations. 5-193 The test section shall be preserved and sealed with a clear coat. At the conclusion of painting activities the test section shall be re -blasted and the specified coating system applied. For the production cleaning operations, these specifications and written definitions, the test sections, and the SSPC visual standards shall be used, in that order, for determining compliance with Contract requirements. Additional compensation will not be paid to the Contractor for preparation of the test sections. 513.1 3 AMBIEN T CONDITION S. Surfaces to be painted after cleaning shall remain free of moisture and other contaminants. The Contractor shall control operations to ensure that dust, dirt, or moisture does not come in contact with surfaces cleaned or painted that day. The following ambient conditions shall be met:
a.The surface and ambient temperatures shall be at least 5ºF above the dew point during final surface preparation operations.
b.The surface and ambient temperatures shall be a minimum of 40ºF, at least 5ºF above the d ew point, and the maximum relative humidity shall be 85% or less during the application and cure/dry time in accordance with the information provided in Subsection 513.06(f)(2) . If the manufacturer’s published literature is more restrictive, it shall be fo llowed for specific temperature, dew point, and humidity conditions during the application and cure/dry time of each coat. The cure/dry time shall be measured as the time following application when the ambient conditions are within the ranges above.
c.If the Contractor proposes to control the weather conditions inside containment, proposed methods and equipment for heating or dehumidification shall be included in the surface preparation and painting plan submitted for the Engineer’s review. Any heating or dehumidification proposals reviewed by the Engineer shall be implemented at no additional cost to the Agency.
d.Cleaning and painting shall only be performed between April 1 6th and October 31st, inclusive, unless otherwise authorized in writing by the Engineer. If the weather conditions are forecast to be outside the limits above during surface preparation, application, or the applicable curing/drying period, then work shall not proceed. The Contractor shall monitor and document temperat ure, dew point, and relative humidity at the beginning of each work day and every 4 hours during surface preparation and coating application, in the specific areas where the work is being performed. The frequency of monitoring shall increase if weather con ditions are changing. 5-194 If the weather conditions are forecast to be borderline relative to the limits established by the manufacturer, monitoring shall continue at a minimum of 4 hour intervals throughout the applicable curing/drying period. The Engineer has the right to reject any work that was performed under unfavorable weather conditions. Rejected work shall be removed, re -cleaned, and re -painted at the Contractor’s expense.
513.14 COMPRESSE D AIR CLEANLINESS . Prior to using compressed air for abrasive blast cleaning,
blowing down the surfaces, and painting with conventional spray, the Contractor shall verify that the compressed air is free of moisture and oil contamination in accordance with the requirements of ASTM D4285 . The tests shall be c onducted at least one time each shift for each compressor system in operation. If air contamination is evident, the Contractor shall change filters, clean traps, add moisture separators or filters, or make other adjustments as necessary to achieve clean, dry air. The Contractor shall also examine the work performed since the last acceptable test for evidence of defects or contamination caused by the compressed air. Affected work shall be repaired at the Contractor’s expense.
513.15 SURFAC E PREPARATION (HOLD POINT) . All designated surfaces shall be prepared for
coating by dry abrasive blast cleaning, including areas that may be concealed by the containment connection points. All equipment allowed under SSPC -SP 10, including vacuum blast cleaning equipment, shall be permitted. The Contractor shall note that the surface of the steel beneath the existing coating system may contain corrosion or mill scale. If said corrosion or mill scale is not removed under another item in the Contract, then its removal shall be considered included in this work and no extra compensation will be allowed. Following surface preparation, soluble salts shall be remediated as specified in Subsection 513.17 .
a.Blast Cleaning . All existing steel shall be prepared by dry abrasive blast cleaning to meet the requirements of SSPC -SP 10.
1.Abrasives . Dry abrasive blast cleaning shall be performed using either expendable abrasives (other than silica sand) or recyclable steel grit abrasives. Expendable abrasives shall be used one time and disposed of. On a daily basis, the Contractor shall verify that recycled abrasives are free of oil contamination by conducting oil content tests in accordance with SSPC -AB 2. 5-195 All surfaces prepared with abrasives not meeting the SSPC -AB 1, SSPC -AB 2, or SSPC -AB 3 requirements, as applicable, shall be solvent cleaned or low pressure water cleaned as directed by the Engineer, and re -blast cleaned at the Contractor’s expense. When metallic abr asives are used, extra care shall be taken to recover all of the abrasive from joints, horizontal surfaces, and hard to access areas to prevent rust bleed caused by fugitive abrasives.
2.Surface Condition . After surface preparation, the surface, when viewed without magnification, shall be free of all visible oil, grease, dirt, dust, mill scale, rust, paint, oxides, corrosion products, and other foreign matter, except for staining. Random staining shall be limited to no more than 5% of each 9 square in ches of surface area and may consist of light shadows, slight streaks, or minor discoloration caused by stains of rust, stains of mill scale, or stains of previously applied paint. With the exception of crevices as defined below, surface discoloration will be considered to be a residue that must be removed, rather than a stain, if it possesses enough mass or thickness that it can be removed as a powder or in chips when scraped with a pocketknife. A surface profile shall be created on the steel as defined i n Subsection 513.15(d) . At the discretion of the Engineer, after a best effort cleaning, slight traces of existing coating may be permitted to remain within crevices such as those created between rivets, bolts, and plates, and the underlying steel. When t races of coating are permitted to remain, the coating shall be tightly bonded when examined by probing with a dull putty knife. The traces of coating shall be confined to the bottom portion of the crevices only, and shall not extend onto the surrounding st eel or plate or onto the outer surface of the rivets or bolts. Pitted steel is excluded from exemption considerations and shall be cleaned in accordance with SSPC -SP 10. If hackles or slivers are visible on the steel surface after cleaning, the Contractor shall remove them by grinding followed by re -blast cleaning. At the discretion of the Engineer, the use of power tools to clean the localized areas after grinding, and to establish a surface profile acceptable to the coating manufacturer, can be used in l ieu of blast cleaning.
b.Limited Access Areas . A best effort with the specified method of cleaning shall be performed in limited access areas, such as the backsides of rivets inside built -up box members. The equipment being used for the majority of the c leaning may need to be supplemented with other commercially available equipment, such as angle nozzles, to properly clean the limited access areas. The acceptability of the best effort cleaning in these areas is at the sole discretion of the Engineer. 5-196 (c) Condition of Edges and Corners . All existing sharp edges and corners, such as those generated by torch cutting, shearing, or milling, shall be rounded to a radius between 1/16 inch and 1/8 inch. The Engineer will tactilely or visually assess the edges and corners and document that they were appropriately rounded.
d.Surface Profile . The abrasives used for blast cleaning shall have a gradation such that the abrasive will produce a uniform surface profile of 1.5 mils to 3.5 mils. If the profile requireme nts of the coating manufacturer are more restrictive, the Contractor shall advise the Engineer and comply with the more restrictive requirements. For recycled abrasives, an appropriate operating mix shall be maintained in order to control the profile withi n these limits. The surface profile produced by the Contractor’s surface preparation procedures shall be determined by replica tape and spring micrometer at the beginning of the work, and each day that the surface preparation is performed. Areas having un acceptable measurements shall be further tested to determine the limits of the deficient area. The replica tape shall be attached to the daily report. When unacceptable profiles are produced, work shall be suspended. The Contractor shall submit a plan for the necessary adjustments to ensure that the correct surface profile is achieved on all surfaces. The Contractor shall not resume work until the new profile is verified by the QA observations and the Engineer confirms that the profile is acceptable.
e.Surface Cleaning for Hardware . The requirements of this part shall apply when the Contract requires installation of bolts that are to be painted. This work shall occur after bolt tensioning has been completed. All exposed oils, lubricants, and wax on the bolts, nuts, washers, and surrounding surfaces to be painted shall be completely removed by solvent cleaning. This also includes any foreign material that has come out of the DTIs during the tensioning process. Light hand wire brushing or scrubbing with br istle brushes is allowed. Use of power tools is not allowed. For galvanized hardware, the Contractor shall remove the colored lubricant from the nuts. The galvanizer may be able to provide information to the Contractor on the most effective solvent cleaner to remove the colored lubricant (common examples include methyl-ethyl -ketone (MEK), foaming glass cleaners containing ammonia, and foaming alkaline -type household cleaners) . It is not necessary to remove 100% of the dye, and it is acceptable for some staining to remain after cleaning. A white cloth wipe test with n o color transfer can be used to confirm that all lubricant and non -absorbed dye has been removed, leaving only the residual stain on the surface. The final cleanliness shall be acceptable to the Engineer. 5-197 513.16 STRUCTURAL STEEL MATING SURFACES . All lam inar, stratified, or pack rust that has formed on or between the existing steel surfaces shall be removed as follows:
a.Disassembled Mating Surfaces . When the Contract requires existing mating surfaces to be disassembled, or when new faying surfaces are created on existing steel due to additional steel being added, the Contractor shall clean and prepare the mating surface as a faying surface. Faying surfaces for all steel connections shall be abrasive blast cleaned and prime coated only as specified herein prior to being re -assembled. The Contractor may request that the Engineer waive the requirements for NACE certification and SSPC -QP 1 certification from Subsection 513.03 for blast cleaning and priming of faying surfaces on existing steel only. Requests will be reviewed on a case -by-case basis and will only be considered if a fully qualified Contract or will not be on site when the faying surfaces are to be blast cleaned an d primed. If the Engineer grants the request, all other requirements for certifications, inspections, quality control, supplying inspection equipment, hold points, etc. will remain in effect and the NACE and SSPC -QP 1 certifications will be required for al l work other than blast cleaning and priming of the faying surfaces.
b.Assembled Mating Surfaces . Pack rust formed along the perimeter of mating surfaces of connected plates or shapes of structural steel shall be removed to the extent feasible without me chanically detaching the mating surface. Pack rust between mating surfaces shall be removed to a level equal to or below the level of mating surfaces between which the rust is packed. Any pack rust remaining after cleaning the mating surfaces shall be ti ght and intact when examined using a dull putty knife. The tools used to remove these corrosion products shall be identified in the submittals and accepted by the Engineer. If the surface preparation or removal of rust results in nicks or gouges, the w ork shall be suspended, and the damaged areas repaired at the Contractor’s expense to the satisfaction of the Engineer. The Contractor shall also demonstrate that they have made the necessary adjustments to prevent a reoccurrence of the damage prior to res uming work. Epoxy penetrating sealer and sealant caulk shall be applied to pack rusted mating surfaces which have been addressed as specified above. The sealer and caulk shall be applied per the manufacturer’s recommendations. 5-198 513.17 SOLUBL E SALT REMEDIATION (HOL D POINT) . Following dry abrasive blast cleaning, the Contractor shall implement surface preparation procedures and processes that will remove chloride from the surfaces. Surfaces that may be contaminated with chloride include, but are not li mited to, expansion joints and all areas that are subject to roadway spray or run -off, such as fascia beams and stringers. Methods of chloride removal shall be determined by the Contractor. If steam or water cleaning methods of chloride removal are used over surfaces where the coating has been completely removed, and the water does not contact any lead containing coatings, the water does not have to be collected. The Contractor shall provide the proposed procedures for chloride remediation in the surface pr eparation and painting plan. Upon completion of the chloride remediation steps, the Contractor shall use chloride titrator strips to test representative surfaces that were previously rusted (e.g. pitted steel) for the presence of remaining chlorides. Rema ining chloride levels shall be no greater than 7 micrograms per square centimeter as read directly from the surface without any multiplier applied to the results. The testing shall be performed, and the results must be acceptable, prior to painting each da y. A minimum of 5 tests per 1,000 square feet, or fraction thereof completed in a given day, shall be conducted. If any results of greater than 7 micrograms per square centimeter are detected, the surfaces shall be re -cleaned and re -tested at the same frequen cy. If acceptable results are achieved on three consecutive days in which testing is conducted, the test frequency may be reduced to 1 test per 1,000 square feet prepared each day, provided the chloride remediation process remains unchanged. If unacceptab le results are encountered, or the methods of chloride remediation are changed, the Contractor shall resume testing at a frequency of 5 tests per 1,000 square feet. The Engineer shall approve of the actual location of the chloride tests prior to them being performed.
513.18 SURFAC E CONDITIO N PRIOR TO PAINTING (HOL D POINT) . Prepared surfaces shall meet
the specified degrees of cleaning immediately prior to painting, and shall be painted before rusting appears on the surface. If rust appears or bare steel remains unpainted for more than 8 hours, the affected area shall be prepared again at the expense of the Contractor. All surface preparation cleaning residue on bridge steel surfaces, scaffolding and platforms, containment materials, and tops of abut ments and pier caps shall be removed prior to painting. The quality of the surface condition and cleaning of surface dust and debris shall be accepted by the Engineer prior to painting. The Engineer has the right to reject any work that was performed with out adequate provision for QA observations to accept the degree of cleaning. Rejected coating work shall be removed and replaced at the Contractor’s expense. 5-199 513.19 GENERA L PAINT REQUIREMENTS . Paint storage, mixing, and application shall be accomplishe d according to these specifications and as specified in the paint manufacturer’s written instructions and product data sheets for the paint system used. In the event of a conflict between these specifications and the coating manufacturer’s instructions and data sheets, the Contractor shall advise the Engineer and comply with the most restrictive requirements. Unless noted otherwise, if a new concrete deck or repair to an existing deck is required, painting , except primer painting of surfaces exposed by deck repairs, shall be done after the deck is placed and the forms have been removed.
a.Paint Storage and Mixing . All paint shall be stored according to the manufacturer’s published instructions, including handling, minimum and maximum temperatures, and warm ing as required prior to mixing. All coatings shall be supplied in sealed containers bearing the manufacturer’s name, product designation, batch number, and mixing and thinning instructions. Leaking containers shall not be used. The paint shall be stored i n a secure, fireproof location. Mixing shall be performed according to the manufacturer’s instructions. Thinning shall be performed using thinner provided by the manufacturer, and only to the extent allowed by the manufacturer’s written instructions. In n o case shall thinning be permitted that would cause the coating to exceed the local volatile organic compound emission restrictions. For multiple component paints, only complete kits shall be mixed and used. Partial mixing is not allowed. The ingredients in the containers of paint shall be thoroughly mixed by mechanical power mixers according to the manufacturer’s instructions, in the original containers before use or mixing with other containers of paint. The paint shall be mixed in a manner that will bre ak up all lumps, completely disperse pigment, and result in a uniform composition. Paint shall be carefully examined after mixing for uniformity and to verify that no unmixed pigment remains on the bottom of the container. Excessive skinning or partial h ardening due to improper or prolonged storage will be cause for rejection of the paint, even though it may have been previously inspected and accepted. Manufacturer recommended induction/sweat -in times and temperature of mixed coatings shall be observed. Multiple component coatings shall be discarded after the expiration of the pot life. Single component paint shall not remain in spray pots, paint buckets, etc. overnight and shall be stored in a covered container and remixed before use. 5-200 The Engineer reserves the right to sample and test field paint (both individual components and the mixed material). If the paint does not meet the product requirements due to excessive thinning or because of other field problems, the coating shall be removed from that section of the structure and replaced as directed by the Engineer at no additional cost to the Agency.
b.Manufacturer’s Ambient Condition Recommendations . If the manufacturer’s restrictions differ from the restrictions stated in Subsection 513.13 , the more restrictive requirements shall be followed. The written recommendations required to be submitted in Subsection 513.06(f) shall be observed. If the actual field conditions differ from what was anticipated at the time of the submittal, then revise d documentation shall be submitted and observed. Upon acceptance by the Engineer, these times shall be used to govern the duration that protection shall be maintained during curing/drying. The manufacturer’s technical representative shall be on the projec t for the first 48 hours of paint application and after that time be available to be back on the project with 24 hours’ notice.
c.Paint Application . Painting shall be performed in a neat and skilled manner. Each coat of paint shall be applied as a continuous film of uniform thickness free of defects, including, but not limited to, runs, sags, overspray, dry spray, pinholes, voids, skips, misses, and shadow -through. Defects such as runs and sags shall be brushed out immediately during application. Unless prohibited by the coating manufacturer’s written instructions, paint may be applied by spray methods, rollers, or brushes. If applied with conventional or airless spray methods, paint shall be applied in a uniform layer with overlapping at the edges of the spray pattern. The painters shall monitor the wet film thickness of each coat during application. The wet film thickness shall be calculated based on the specified dry film thickness using the solids by volume of the material and the amount of thinn er added. When brushes or rollers are used to apply the coating, additional applications may be required to achieve the specified thickness per layer. Prime coats shall be applied to all bare metal surfaces. Faying surfaces for disassembled mating surface s for steel connections shall receive a prime coat that will remain in the assembled connection. If disassembled faying surfaces are slip critical, an organic zinc rich primer with an appropriate slip/creep coefficient shall be applied to the surfaces. 5-201 Damage to vehicles and property caused by the Contractor’s painting or surface preparation activities shall be remedied at the Contractor’s expense. The Contractor shall ensure that all areas not scheduled for paint will be protected against overspray. All areas accidentally painted will be cleaned at the Contractor’s expense.
d.Re-Coating and Film Continuity (Hold Point for Each Coat) . Paint shall be considered dry for re - coating according to the re -coat time/temperature/humidity/dry film thickness c riteria provided in the manufacturer’s instructions submitted as required in Subsection 513.06(f) , and when an additional coat can be applied without the development of film irregularities such as lifting, wrinkling, or loss of adhesion of the under coat. If surfaces are contaminated, washing shall be accomplished prior to intermediate and final coats. Wash water does not have to be collected unless the water contacts existing lead -containing coatings.
e.Stripe Coats . Unless indicated otherwise in the C ontract, the Contractor shall apply an additional stripe coat to all edges, rivets, bolts, crevices, welds, and similar surface irregularities for each coating applied (prime, intermediate, and top coats). The stripe coat shall be applied by brush only ( the use of rollers or daubers will not be permitted) such that the coating is thoroughly worked into or on the irregular surfaces, and shall extend onto the surrounding steel a minimum of 1 inch in all directions. The purpose of the stripe coat is to build additional thickness and to assure complete coverage of these areas. The stripe coat is in addition to the requirement for penetrating sealer. The stripe coat shall not be applied as part of the application of the full coat. The stripe coat shall be appl ied and dried separately according to the manufacturer’s recommended curing/drying times for re -coating. The color of the stripe coat shall contrast with the colors used for the full coats immediately preceding and succeeding the stripe coat, except that t he top stripe coat may be the same color as the full top coat.
f.Coating Sequence . For locations painted under this specification, coatings shall be applied as follows:
1.Prime Coat . The full prime coat shall be applied first to protect the steel. Once the full prime coat has dried, the prime stripe coat shall be applied.
2.Intermediate Coat . After the prime stripe coat has dried, an intermediate stripe coat shall be applied and a llowed to dry, followed by the full intermediate coat.
3.Top Coat . After the full intermediate coat has dried, a top stripe coat shall be applied and allowed to dry, followed by the full top coat. 5-202 (g) Coating Thickness . The dry film thickness of each full coat shall be within the applicable range specified below, as measured in accordance with SSPC -PA 2.
1.Prime Coat . The prime coat of organic zinc -rich primer shall be between 3.5 mils and 5.0 mils dry film thickness .
2.Intermediate Coat . The intermediate coat of epoxy or urethane shall be between 3.0 mils and 6.0 mils dry film thickness.
3.Top Coat . The top coat of aliphatic urethane shall be between 2.5 mils and 4.0 mils dry film thickness. The color of the to p coat shall be as specified in the Contract and shall conform to the applicable SAE AMS -STD-595 chip number specified in Subsection 708.0 3(b). If the thickness range specified by the manufacturer differs from the range specified above for a given coat, the required dry film thickness range shall be between the largest specified minimum thickness and the smallest specified maximum thickness. For e xample, the thickness range specified above for the prime coat is 3.5 mils to 5.0 mils. If the manufacturer’s specified prime coat thickness is 4.0 mils to 6.0 mils, the required thickness range would then be between 4.0 mils and 5.0 mils.
h.Amine Blush . Amine blush is a residue that can form on newly applied epoxy coating films under certain conditions. Amine blush often appears as a yellowish milky or blotchy residue on the coating surface and is a deterrent to the adhesion of subsequently applied coati ng layers. If amine blush is detected, the Contractor shall provide the Engineer with written procedures from the coating manufacturer for complete removal prior to the application of additional coating layers.
513.20 WATE R CLEANIN G AND SOLVEN T CLEANING (HOL D POINT) . When foreign matter has
accumulated on a previously applied coat, washing shall be performed prior to the application of any subsequent coating products. Washing shall involve the use of chlorine free potable water at a minimum of 1, 000 psi and less than 5,000 psi pressure, in accordance with low pressure water cleaning of SSPC -SP 12. Paint spray equipment shall not be used to perform the water cleaning. The cleaning shall be performed in such a manner as to remove dust, dirt, chalk, insect and animal nests, bird droppings, and other foreign matter. The water does not need to be collected unless it contacts existing lead containing coatings. If detergents or additives are added to the water, the detergents or additives shall be include d in the submittals and not used until accepted by the Engineer. When detergents or additives are used, the surface shall be rinsed with chlorine free potable water before the detergent water dries. 5-203 513.21 REPAI R OF DAMAG E AND AREA S CONCEALE D BY CONTAIN MENT . The Contractor shall repair all damage to the newly installed coating system and areas concealed by the containment or protective covering attachment points, at no cost to the Agency. If the damage extends to the substrate and the original preparation involved abrasive blast cleaning, the damaged areas shall be prepared to meet the requirements of SSPC -SP 15. If the original preparation was other than blast cleaning or the damage does n ot extend to the substrate, the loose, fractured paint shall be cleaned to meet the requirements of SSPC -SP 3. The surrounding coating at each repair location shall be feathered for a minimum distance of 1 -1/2 inches to achieve a smooth transition between the prepared areas and the existing coating. If the bare steel is exposed, all coats shall be applied to the prepared area. If only the intermediate and finish coats are damaged, the intermediate and finish coats shall be applied. If onl y the finish coat is damaged, the finish coat shall be applied. All hold point s and specifications are applicable to the repair of damaged areas and areas concealed by containment.
513.22 GREAS E COATING . If required by the plans, a coat of grease rustproo fing compound shall be
uniformly applied by brush or spray at an approximate rate of 20 square feet per gallon to the steel as specified. The grease coating shall be applied after all concrete form work has been removed, and after the final coat of paint, including repairs, has fully cured. A fully cured condition has occurred when a thumbnail driven into the coating surface does not leave an impression and when a thumb firmly pushed against the surface and twisted does not disturb the coating. Surfaces ad jacent to areas being grease coated shall be protected against over -spray. Non -metallic and stainless steel surfaces shall not be coated.
513.23 Special Instructions .
a.At the completion of the work, the Contractor shall stencil the painting date and the paint code on the bridge in a color contrasting to the color of the top coat. The letters shall be capitals, not less than 2 inches and not more than 3 inches in height. The stencil shall contain the phrase “PAINTED BY (Insert the name of the Contr actor)” and shall show the month and year in which the painting was completed, followed by the appropriate code for the coating material applied, all stenciled on successive lines. 5-204 Coding shall be as follows:
1.CODE LA for full lead abatement . This co de shall only be used when the entire steel structure has been prepared in accordance with this specification .
2.CODE Z1 for a field-applied three coat system . This information shall be stenciled on the cover plate of a truss end post near the top of the railing, or on the inside face of an outside beam or girder near one end of the bridge, or at some equally visible surface near the end of the bridge, as designated by the Engineer.
b.All surfaces painted inadvertently shall be cleaned immediately to th e satisfaction of the Engineer.
c.The paint used for stenciling shall be compatible with the top coat. The cost of all work outlined above for stenciling will be included in the cost of painting existing steel and no extra compensation will be allowed.
513.24 METHO D OF MEASUREMENT . The quantity of Field Painting Steel, Three Coat System at the
location specified to be measured for payment will be on a lump sum ba sis in the complete and accepted work.
513.25 BASI S OF PAYMENT . The accepted quantity of Field Painting Steel, Three Coat System will be
paid for at the Contract lump sum price. Payment will be full compensation for performing all work specified and for f urnishing all labor, tools, equipment, and incidentals to complete the work. Partial p ayment s will be made as follows:
a.The first payment of 15% of the Contract unit price will be paid when all submittal requirements have been met and accepted by the Ag ency and the Contractor is fully mobilized to begin work.
b.An additional 75% of the Contract unit price will be paid when all cleaning and painting work is complete.
c.The final 10% of the Contract unit price will be paid when the Contractor has fully demobilized and all equipment and waste have been removed from the project site to the satisfaction of the Engineer. Payment will be made under: Pay Item Pay Unit 513.1030 Field Painting Steel, Three Coat System ................................ .................. Lump Sum 5-205 SECTIO N 514 – WATE R REPELLENT , SILANE 514.0 1 DESCRIPTION . This work shall consist of furnishing and applying a penetrating -type protective sealer on concrete surfaces. 514.0 2 MATERIALS . Materials shall meet the requirements of the following subsections: Water Repell ent, Silane ................................ ................................ ............................. 726.10 514.0 3 PACKAGING , DELIVERY , AND STORAGE . The material shall be delivered to the project in the original, unopened manufacturer’s containers and stored in accordance with the manufacturer’s recommendations. 514.0 4 PREPARATIO N OF SURFACES . All surfaces on which the protective sealer is to be applied shall be clean and thoroughly dry to the satisfaction of the Engineer and in accordan ce with the manufacturer’s recommendations. Dirt, grease, curing compounds, asphalt, or other foreign materials shall be removed from the concrete surface before application of the sealer. 514.0 5 APPLICATION . The material shall be applied to the satisfact ion of the Engineer and in accordance with the manufacturer’s recommendations. The minimum application rate for Type I silane water repellent shall be 125 square feet per gallon or per the manufacturer’s recommendations, whichever is greater. The minimum a pplication rate for Type II silane water repellent shall be 300 square feet per gallon or per the manufacturer’s recommendation, whichever is greater. In the absence of specific recommendations from the manufacturer, the protective sealer shall not be applied to new concrete surfaces that are less than 14 days old. The concrete surfaces shall be free from precipitation for 48 hours prior to application of the sealer. Application of the sealer shall be completed within 40 days of original concrete placement. 514.0 6 PROTECTION . After application of the sealer, the concrete surfaces shall be protected to the satisfaction of the Engineer and in accordance with the manufacturer’s recommendations.
514.07 METHO D OF MEASUREMENT . The quantity of Water Repellent, Silane to be measured for
payment will be the number of gallons of solution applied in the complete and accepted work, measured to the nearest gallon.
Source: Vermont Standard Specifications for Construction, 2024 Edition. Pages 598–618 of 1,380.