346 The Contractor shall prohibit all pedestrian and vehicular traffic on the structure during the drying period of the protect ive coating.
601.13.1 1 -Silane Treatment for Bridge Substructure: Before placing any steel
superstructure members on the concrete substructure units, the Contractor shall coat all exposed areas of the abutment, tops, sides, and all faces of pier caps an d pier stems to the ground or water line elevation with an approved silane based concrete sealer except for projects where concrete protective or other coatings are specified. Preparation of surfaces, application rates, and methods shall be as recommended by the silane manufacturer. Upon completion of all superstructure concrete curing operations, the Contractor shall remove all stains from substructure units using proprietary chemical stain removers and/or mild acid etching. Abrasive blast cleaning shal l be used to supplement the other cleaning methods to completely remove all stain s if the stained areas are severe or extensive. All cleaning methods shall be subject to approval of the Engineer. Re-coat all areas where stains were removed, regardless of the cleaning method used, with an approved silane based concrete sealer as specified above.
601.13.2 Epoxy Resin Protective Coating: The top surface of abutment bridge seats,
including drainage areas, and the adjacent bottom six (6) inches of the backwall and the top surface of pier caps which are located beneath expansion devices shall receive an epoxy resin protective coating. The area immediately beneath the bearing masonry plates may be omitted at the Contractor's option. Concrete surfaces to be coated shall be sound, dry and free of all laitance and curing materials. The coating shall not be applied until the concrete has atta ined the age recommended by the manufacturer. When required by the Engineer in the field, concrete surfaces shall be cleaned of all oil, grease and other potential bond inhibiting matter by acid etching with a 10 percent (10%) to 15 percent (15%) muriati c acid solution. The acid solution shall be spread and allowed to react until bubbling has subsided, approximately three to five minutes. The surface shall then be thoroughly flushed with clear water and allowed to dry. Where, in the opinion of the Engine er, acid etching is insufficient to clean the concrete, then sandblasting or an approved method of mechanical abrading shall be required. The exact indicated amounts of the base polymer and the reacting system, as recommended by the manufacturer, shall b e measured into mixing container and mixed thoroughly with a low-speed paddle -type mixer. After mixing, the material shall stand for an induction period of one hour before application. Following the one hour induction period, the mixed protective coatin g may be applied by brush, roller or spray. When applied by roller, a first quality, long nap roller is recommended for rough surfaces, and a short nap roller for smooth surfaces. If applied by spray, an externally atomized spray gun is recommended. If thinning is necessary for spray application, thinner shall be of the type and amount recommended by the coating manufacturer. Two coats of mixed material shall be applied in thin, uniform coats of approximately 2 to 3 mil dry film thickness each (4 -5 mil s wet thickness). The second coat shall be applied approximately 24 hours after the application of the first coat. One gallon of the system will cover approximately 275 square feet of smooth concrete, first coat; a second coat will cover approximately 40 0 square feet. In all cases application shall be made at temperatures recommended by the manufacturer. 347 601.13.3 -Concrete Protective Coating: This section covers requirements for materials to be used as surface finishes for designated surfaces of conc rete structures. The masonry coatings must hide form marks, patches, and other minor irregularities and prevent deterioration, spalling, and other damage to the concrete due to the action of the weather and deicing chemicals. The Engineer will inspect al l concrete surfaces to be coated as stated in the plans and/or contract documents. The field painting (coating) of concrete structures shall follow the provided requirements set forth in this specification unless otherwise noted in the Contract. This spe cification shall apply to surface preparation, coating application, contractor responsibilities, environmental and worker protection, and waste handling/disposal. All structures shall be pre -cleaned and washed in accordance with Section 685 of the Specifi cations. The Engineer will ensure a satisfactory ordinary surface finish prior to coating operations. This section shall apply only when the pay item for concrete protective coating is included in the plans.
601.13.3 1 -Physical Requirements of Coating: Physical requirements shall conform
to Section 711.5.2.
601.13.3 2 -Concrete Surface Preparation: All concrete surfaces to receive a
protective coating shall be prepared in accordance with SSPC -SP 13, Surface Preparation of Concrete, SSPC -The Fundamentals of Cleaning and Coating Concrete, ASTM D4258 - Standard Practice for Surface Cleaning Concrete for Coating. All surfaces to receive a protective coating shall be thoroughly cleaned and kept free of oil, form o il, grease, dust, dirt, mud, curing compound, release agents, loose patching mortar, or any other substances that may prevent bonding.
601.13.3 3 -Paint Application Requirements: The following surfaces shall be coated,
including all beveled edges.
1.Bridge Abutments and Wingwalls – Every exposed surface above a point six (6) inches below ground or fill line. Exclude where epoxy coating is applied.
2.Bridge Pier Caps – The tops (including exposed surfaces of pads, pedestals, and keys), sides and ends. Do not apply the coating to bearing areas. Exclude where epoxy coating is applied.
3.Bridge Superstructure – The tops, inside and outside faces, and ends of all barrier walls, parapets, curbs, and points that will be exposed. Do not apply the coating to the rid ing surface of the bridge deck.
4.Exposed Surfaces of Substructure and the Superstructure – all surfaces identified in 1), 2), and 3) above and the underneath surfaces of slab overhangs that are outside of exterior girders and the exterior side and bottom o f exterior beams or girders, the interior windows of barriers, and all exposed surfaces of piers and abutments. Extend the masonry coating from a point six (6) inches below ground line to the top of the exposed surface.
5.Any other area as designated within the contract plans not mentioned above.
601.13.3 3.1 -Weather Conditions: Painting shall not be done when the ambient
temperature is below 40°F or above 100°F, or the relative humidity above 90 percent (90%) . Painting will only be permitted between the dates of April 15th through October 15th. There will be no painting permitted to occur in a heated containment. 348 601.13.3.3.2 -Paint Storage: Paint and thinners shall be stored in a temperature - controlled environment between 40°F and 100°F. At no time will paint be used beyond the manufacturer’s shelf life.
601.13.3 3.3 -Paint Application: The paint shall be applied by spray, brush or roller
methods. Brushes or rollers, when used, shall have sufficient body and length of bristle or roller nap to spread a uniform coat. Small touch -up areas may be brushed or rolled, if approved by the Engineer. Use of an agitated pot shall be mandatory in s pray application. The agitator or stirring rod shall reach within one (1) inch, of the bottom of the pot and shall be in motion at all times during paint application. Coatings shall be mixed in strict accordance with the coating manufacturer’s written in structions. Under certain conditions, it may be necessary to thin or adjust the solvent balance of the paint. The type and amount of solvent to be used shall be that listed on the coating manufacturer’s product data sheet for that material. Upon thinnin g, the dry film thickness requirement shall still be met by appropriately increasing the wet film thickness. Application requirements and drying times between coats shall be in accordance with the manufacturer’s recommendations. Spray guns must be equi pped with the recommended size tip for the paint product being applied and shall be held perpendicular (90 degrees) to, and at, the proper distance from the receiving surface. Complete protection shall be provided by the contractor against paint spatter, spillage, overspray, wind -blown paint, or similar releases. Appropriate containment shall be placed around the work area to protect public and private property. Staging must be adequate to provide access to all areas being painted. Violation of these re quirements causing excessive paint waste will be justification for the WVDOH Engineer to order the Contractor to cease all work on the project until corrective action has been taken. The method of cleaning and/or replacement shall be submitted to the Engi neer in advance for approval. Coating application shall be suspended any time the ambient temperature or the temperature of the concrete does not comply with the coating manufacturer’s recommendations. Prior to application of the materials, furnish the Engineer with copies of the coating material manufacturer’s brochures or booklets. Apply protective coating materials in strict conformity with the manufacturer’s written instructions and apply the material at a uniform rate of at least 50± 10 ft2/gal. Satisfactorily repair or remove any portions of the coating that are not clean, uniform in color, texture, thickness, tightly bonded, or that are damaged before final acceptance of the project and replace them with an acceptable finish and coating. Provide a neat uniform appearance, and prevent the coating from being dripped, sprayed, or otherwise deposited upon concrete and surfaces not designated to receive the coating. Remove any objectionable deposits or material and repair the surfaces to the Engineer’s satisfaction.
601.13.3 4 -Environmental, Worker Protection, And Waste Handling:
601.13.3 4.1 -General: Environmental protection shall be used when cleaning,
painting, welding or cutting an existing bridge. The containment class, emission assessment methods and levels as defined by the current revision of SSPC Guide 6 shall be as stated in the contract documents. The specific pollution control system which is 349 proposed for the complete capture, containment, collection, and disposal of the “spen t material” generated by the work shall be included in the plan.
601.13.3 4.2 -“Spent Material”: This shall include material generated by surface
preparation operations, and shall be disposed of in accordance with Section7 of SSPC SP -
13.The Contractor shall, at the Contractor’s expense, select a laboratory that will sample and analyze the “spent materials”. The laboratory must be certified by the WVDEP, EPA or by another state’s DEP -equivalent. Certification will be provided to the Engineer prior to the beginning of work. The waste transporter for both hazardous and non -hazardous waste will be listed on the Contractor’s Containment/Disposal Control Plan.
601.13.3 4.3 –Permits for Disposal of “Spent Material”: Shall be in accordance with
Section 10 7.2, Permits, Licenses, and Taxes or any other applicable sections of Section 107. The “spent material” shall not be disposed of until authorized by the Engineer and in no case shall “spent material” be allowed to accumulate longer than 90 days prior to transport.
601.13.3 4.4 -Additional Requirements for All Classes of Containment : Contractor
will provide ground covers beneath the containment area and all equipment where spills are possible to capture inadvertent spills or leaks of debris. Extend the covers a minimum of five ( 5) feet beyond the area to be covered. Debris shall be removed from the covers at least once per shift, or as directed by the Engineer. If the ground beneath the structure serves as the base of the containment, install and maint ain air and dust impenetrable materials such as solid plywood panels or flexible materials such as tarpaulins. Provide explosion –proof lighting inside containment for all paint application. Maintain a minimum of ten (10) foot-candles for surface
601.13.3 5 -Contractor Responsibilities:
601.13.3 5.1 -Concrete Protective Coating Materials: Select masonry coatings from
the Department’s List of Approved Materials. Use a material that is readily recognizable by its name, trademark, container, or other feature. All materials shall conform to subsection 711.5.3.
601.13.3 6 -Inspection Requirements:
601.13.3 6.1 -Inspection of Applied Paint : If in the opinion of the Engineer the
coating has flaws other than deficiencies in the prescribed dry film thic kness, the material shall be repaired or shall be removed and replaced. Defects in the film, including but not limited to runs, sags, mud -cracking, lifting, overspray, and dry spray, shall be corrected until a continuous uniform film has been applied. Excessive film thickness shall be reduced and insufficient film thickness shall be increased. If the thickness of the finish coat is reduced, a thin coat of the finish shall be reapplied to seal the surface and to blend the area into the surrounding coati ng. Depending on the defect, total removal and replacement of the effected coating may be required. No unsightly runs or sags shall be visible. All "mud -cracking" and/or "dry overspray" in the paint film shall be removed. Calibration of the thickness g age and dry film thickness measurements shall be in accordance with MP 708.40.00.
Source: West Virginia Standard Specifications for Road and Bridge Construction, 2023 Edition. Pages 366–369 of 1,006.