688Field Painting of Metal Structures

688.1-DESCRIPTION: The field painting (coating) of metal structures shall follow the provided requirements set forth in this specification unless otherwise noted in the Contract. This specification shall apply to surface preparation, coating applicati on, contractor responsibilities, environmental and worker protection, and waste handling/disposal. 688.2-GENERAL: 688.2.1-Bridge Pre -Cleaning and Washing: All structures shall be pre -cleaned and washed in accordance with Section 685 of the Specifications. 688.2.2-Surface Preparation: 688.2.2.1-Non-Blasting: When non -blast cleaning is specified in the contract documents, any one or any combination of th e methods below shall be used. The surface and the surface profile after cleaning shall meet the requirements of the methods below. The amount of material, rust scale, and pack rust removed after non -blast cleaning, will meet the requirements of the SSPC methods listed:

688.2.2.2-Blasting: The abrasives used for all blasting shall meet the guidelines set forth in SSPC AB1 for mineral and slag abrasives, and AB3 for ferrous metallic abrasives. Any additive mixed with the abrasive shall be approved by the Division prior to use. The abrasives used shall produce a height of profile between 2.0 and 3.0 mils. In addition, the container or bag of abrasive shall include the name of the abrasive, the name of the manufacturer, and the size of the abrasive. If any additive has been included with the abrasive, the name and the percentage of the additive shall be on the container or bag. The compressed air used for nozzle blasting shall be free of water and oil. The cleanliness of each compressed air system shall be verified at least once per shift using the blotter test in accordance with ASTM D4285, “Standard Test Method for Indicating Oil or Water in Compressed Air”. 688.2.2.2.1-Commercial Blast: Shall meet the requirements of SSPC-SP 6 / NACE 3 prior to painting. The appearance of the steel surface after blast cleaning shall correspond to the applicable and current SP 6 pictorial standards of SSPC Vis 1. 688.2.2.2.2-Brush-Off Blast: Shall meet the requirements of SSPC -SP 7 / NACE 4 prior to painting. The appearance of the steel surface after brush -off blast cleaning shall correspond to the applicable and current SP 7 pictorial standards of SSPC Vis 1. 688.2.2.2.3-Near White Metal Blast: Shall meet the requirements of SSPC - SP 10 / NACE 2 prior to painting. The appearance of the steel surface after blast cleaning shall correspond to the applicable and current SP 10 pictorial standards of SSPC Vis 1. 762 688.2.2.3-Water Jetting: Shall meet the requirements of SSPC-SP WJ-1 / NACE WJ and visual standard condition WJ-1 prior to painting. 688.2.2.4-Post-Surface Preparation: Surface prep operations shall be performed in such a manner that no damage is done to partially or entirely compl eted portions of the work. After surface prep, any areas that are repaired by welding shall be prepped again. Areas repaired by grinding or other means shall have the anchor pattern restored. Visible deposits of oil, grease, or other contaminants shall b e removed according to SSPC -SP 1 "Solvent Cleaning" prior to painting. Dust, loose residues, and the removal of abrasives from pockets and corners shall be removed from prepared surfaces by brushing, blowing off with clean, dry air, vacuum cleaning. The prepped surface shall be checked for cleanliness by wiping a clean, dark cloth across the surface. If residue is present, the surface shall be cleaned again and rechecked. All blast cleaned surfaces shall be painted prior to any rust bloom or flash rust occurring or within 24 hours, whichever comes first. 688.2.3-Paint Application Requirements: 688.2.3.1-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%). The temperature of the steel must be at least 5°F above the dew point. Painting shall not be performed when the surface to be coated is sufficiently hot to cause blistering of the film or too rapid solvent release. 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. 688.2.3.2-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. 688.2.3.3-Paint Application: The blast cleaned surface shall be painted within 24 hours. In the event rust bloom or flash rusting occurs, the affected members shall be re - cleaned by blasting. The paint shall be applied by spray methods, except those areas inaccessible to spray application may be brushed or rolled. 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 spray application of zinc-rich primer. 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 instructions. 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 thinning, 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. Exposed steel surfaces of expansion dams shall be painted as specified for structural steel. Spray guns must be equipped with the recommended size tip for the paint product being applied and shall be held perpendicular (90 degrees) to, and at, the pro per distance from 763 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 requirements 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 Engineer in advance for approval. 688.2.3.3.1-Paint Systems: 3 COAT: Primer, Intermediate, Top Coat 2 COAT: Primer, Top Coat 1 COAT: Epoxy Mastic only 688.2.3.3.2-Painting over Galvanized Surfaces: Painting Galvanized surfaces shall be in accordance to the paint manufacturer’s recommendations. 688.2.3.3.3-Damage to Galvanized Surfaces: The Contractor is to exercise care while cleaning and painting around expansion joints and galvanized surfaces. Any damage to the expansion joints or galvanized surfaces found by the Engineer, as a result of the cleaning and painting operation shall be repaired and/or replaced, to the satisfaction of the Engineer, at the Contractor’s expense. 688.2.4-Inspection Requirements: 688.2.4.1-Inspection of Applied Paint: If in the opinion of the Engineer the coating has flaws other than deficiencies in the prescribed dry film thickness, 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, dry spray, pinholes, and holidays 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 co at is reduced, a thin coat of the finish shall be reapplied to seal the surface and to blend the area into the surrounding coating. 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. Excessive bubbles or pinholes shall not be visible in the coat after examination under 8X magnification. Calibration of the thickness gage and dry film thickness measurements shall be in accordance with MP 708.40.00. 688.2.4.2-Access for Inspection: The Contractor shall furnish suitable safe access and shall provide a time mutually agreed to for inspecting the structural steel prior to and after each coating. The Division’s inspector shall approve all repairs. When providing suitable safe access, rubber rollers or other protective devices shall be used. Metal rollers or clamps and other types of fastenings that will mar or damage freshly coated surfacess hall not be used. No temporary attachments, supports for access, or forms, shall damage the coating system. In particular, on the fascias where bracing is used, sufficient size support pads must be provided. Any damage that occurs from such devices shall be repaired to the satisfaction of the Engineer at the Contractors expense. 764 688.2.4.3-Repair Procedures for Field Paint Deficiencies : All field repairs to the coating shall be made in strict accordance with the coating manufacturer's recommendations, except where the requirements listed in this specification are more stringent. Any products used during repairs to the coating deficiencies shall be from the same manufacturer as the coating being repaired. All welds from which the coating of paint has bee n damaged or is otherwise defective shall be cleaned and repaired. Surfaces that will be inaccessible for coating after erection shall be repaired and/or recoated prior to erection. The Engineer is to review and accept a repair plan before deficient areas are repaired. The requirements specified herein for provisions for inspection, mixing, thinning, temperature and humidity, and application shall govern the coating of the repaired areas. In order to avoid abrupt changes in paint thickness, the area adjacent to repair areas shall transition from zero paint thickness to full system thickness within not less than three (3) inches of the repair area by means of sanding the transition area. The requirements for the dry film thickness of the repair coats are the same as those specified for the paint system. 688.2.5-Submittals: Submittals shall be forwarded through the Prime Contractor and be accepted by the Engineer prior to commencement of the subject work. This is the responsibility of both the Fabricator and the Field Contractor. Electronic submittals will be accepted. 688.2.5.1-Quality Control Plan for Painting : Minimum requirements and document form are set forth in MP 688.02.20. 688.2.5.2-Containment/Disposal Control Plan for Existing Steel Structures: Minimum requirements and document form are set forth in MP 688.03.20. 688.3-COMPLETE PAINTING OF EXISTING STRUCTURES: 688.3.1-General: The field coats (total system) of paint shall meet the requirements of specified in the contract documents. Each coat shall be a contrasting color to the one previously applied. 688.3.2-Surface Preparation: All structural steel shall undergo a near -white blast cleaning in accordance with SSPPC SP 10. All structural steel is to include 100% of the girders, stringers, diaphragms, floor beams, upper and lower chord members, drains, bearing devices, etc. In general, all accessible steel surfaces not galvanized, aluminum, or weathering steel shall be blast cleaned. All laminar and stratified rust that has formed on the existing steel surfaces shall be removed. Pack rust formed along the perimeter of matings urfaces of connected plates or shapes shall be removed to the extent feasible without mechanically detaching the mating surface. The Contractor is to exercise care while cleaning and painting around expansion joints, weathering steel, and galvanized surfa ces. Any damage to these surfaces found by the Engineer as a result of the cleaning and painting operation shall be repaired and/or replaced, to the satisfaction of the Engineer, at the Contractor’s expense. 688.3.3-Paint Application Requirements: Painting shall be in accordance with Section 688.2.3.3. 765 688.3.4-Painting Sequence: FULL PRIME COAT: The structure shall receive one coat of a primer meeting the requirements of Section 711. The full prime coat shall be applied before the stripe coat. The primer used for the full prime coat and the stripe prime coat shall be of the same type and shall be from the same manufacturer. Dry film thickness requirements shall be as specified by the manufacturer’s recommendations, or as specified in the contract documents. STRIPE COAT: All edges, outside corners, seams, bolt heads and nuts, all rivet heads, edges of flanges and plates, welds, sharp edges, in general all edges, shall receive one stripe coat, by brush or roller application, of the same primer as the Full Prime Coat. Striping shall extend a minimum of one (1) inch from the edge. The prime coat shall at a minimum, be set -to-touch before the stripe coat is applied. No dry film thickness is specified for this coat. This coat shall be tinted as allowed by the manufacturer to be in contrast to the full prime coat and intermediate coat. The tinting agent shall be the paint manufacturer’s approved tinting agent. INTERMEDIATE COAT: The structure shall receive one uniform coat of a paint meeting the requirements of Section 711. The color shall be in contrast to the prime and top coats. If tinting is required, the tinting agent shall be the paint manufacturer’s approved tinting agent. The intermediate coat shall not be applied until the primer and stripe coat have fully cured according to the manufacturer’s recommendations. Dry film thickness requirements shall be as specified by the manufacturer’s recommendations, or as specified in the contract documents. CAULKING: Caulking shall be applied before the application of the topcoat. This includes all seams between diaphragm connections to stiffeners and splices and seams between any connection that is riveted or bolted. Any welded connections that are not fully sealed by the weld shall be caulked with a paste type caulk. The caulk shall be pressed into the seams between the adjoining surfaces, by wetted finger or specialty tool, to insure bond and provide a smooth uniform surface. Bottom seams shall not be caulked on vertical surfaces. Caulking in a 3-coat system shall be applied after the intermediate coat has cured. Caulking on a 2-coat system shall be applied after prime coat has cured. The top coat shall not be applied until the caulking has fully cured in accordance with the manufacturer’s recommendations. The caulking material shall be compatible with the paint system being applied and shall be by written recommendation of the paint manufacturer. The caulking material shall be tested for compatibility with the paint system at the same time that the paint is tested for intercoat compatibility. Caulking operations shall be performed only when weather conditions are within the parameters as specified in section 688.2.3.1. TOP COAT: The structure shall re ceive one uniform coat of paint as designated in the plans meeting the requirements of Section 711. The color shall be as designated in the plans and shall be in accordance with current SAE -AMS-STD-595. Dry film thickness 766 requirements shall be as specified by the manufacturer’s recommendations, or as specified in the contract documents. 688.3.5-Vegetation: Vegetation may need to be trimmed or removed in order to accomplish the cleaning or painting of the structure. If allowed by the Contract Documents , the Contractor may waste vegetation within the Right-of-Way. Otherwise, any such vegetation cut, shall be removed from the site by the contractor. No direct payment will be made for this work, but shall be included in the contract price for the item in connections with which it is used. 688.3.6-Utilities: Shall be in accordance with Section 107.17, Contractor Responsibility for Utility Property and Services or any other applicable sections of Section 107. 688.3.7-Paint Designation Label: 688.3.7.1-Description: The bridge paint designation label shall consist of painting on the fascia web of the exterior girder with the following information; the paint system, contractor, and the month-year the project was completed. This paint designation label will only be utilized during the complete removal and pain ting of existing or new structures. The acronyms and details for the paint designation label will be assigned to the Contractor by the Materials Control, Soils and Testing Division when the Quality Control Plan for Painting is approved. 688.3.7.1-Location: The paint designation label will be located at abutment number one on the fascia web of the exterior girder with a southern or eastern orientation, and paint color shall be a semi-gloss black paint compatible with the topcoat material. 688.3.7.2-General: All work performed regarding the paint designation label shall be considered incidental to the painting of the structure. 688.4-ZONE PAINTING OF EXISTING STRUCTURES: 688.4.1-General: The field coats (total system) of paint shall meet the requirements of Section 711. The applicable sections of 711, the dry film thickness shall be in accordance with the manufacturer’s recommendations and the color shall be as specified in the contract documents. Each coat shall be a contrasting color to the one previously applied. The contract documents shall specify the areas to be prepared and zone painted. 688.4.2-Surface Preparation: The surface shall be prepared as specified in the contract documents. Specific instructions will be given on the amount of surface required to be cleaned in accordance with the specific standards identified in subsection 688.2.2. All laminar and stratified rust that has formed on the existing steel surfaces shall be removed. Pack rust formed along the perimeter of mating surfaces of connected plates or shapes shall be removed to the extent feasible without mechanically detaching the mating surface. Any rust remaining after cleaning shall be tight 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 work shall be suspended, and the damaged areas repaired to the satisfaction of the Engineer, at the Contractor’s expense. The Contractor is to exercise care while cleaning and painting around expansion joints and galvanized surfaces. Any damage to the expansion joints or galv anized 767 surfaces found by the Engineer, as a result of the cleaning and painting operation shall be repaired and/or replaced, to the satisfaction of the Engineer, at the Contractor’s expense. 688.4.3-Paint Application Requirements: Painting shall be in a ccordance with Section 688.2.3.3. 688.4.4-Painting Sequence: Painting shall be in accordance with Section 688.3.4. 688.4.5-Vegetation: - Shall be in accordance with Section 688.3.5 688.4.6-Utilities: Shall be in accordance with Section 107.17, Con tractor Responsibility for Utility Property and Services or any other applicable sections of Section 107. 688.5-FIELD PAINTING OF SHOP PRIME-COATED STEEL: 688.5.1-General: Field painting of new shop prime coated structures: Shall include, unless otherwise specified in the contract, the preparation of the primed surface for painting, the procurement of all materials to meet the necessary specifications and the application of the coatings. In addition, the Contractor shall protect pedestrian, vehicular, and other traffic on or underneath the structure from splattering, splashing, or dripping paint. Railings, curbs and all other superstructure and substructure shall be protected against spatters, splashes, and the like. 688.5.2-Sheer Studs: When shear studs are applied in the field, repair to the Prime Coat shall be completed to the satisfaction of the Engineer and prior to any and adjoining concrete work. 688.5.3-Materials: The field coats (Intermediate and/or Top Coats) of paint shall meet the requirements of 711.22.3 and 711.22.4. Dry film thickness requirements shall be as specified by the manufacturer’s recommendations, or as specified in the contract documents. Each coat shall be a contrasting color to the previous coat. In addition, the field intercoat adhesion shall be at least 3A when tested in accordance with MP 711.00.20. 688.5.4-Surface Preparation: Prior to field coats, surface contamination such as rust, dirt, mud, oil, concrete, loose zinc, salts, or other foreign matter shall be removed. The shop primed structural steel shall be pressure washed, with a soluble salt remover from the division’s approved product list, at 2000 – 3000 psi. Touch up of the primer shall be in accordance with section 688.2.3.3. 688.5.5-Paint Application Requirements: Painting shall be in accordance with Section 688.2.3. 688.5.6-Paint Sequence: Painting shall be in accordance with Section 688.3.4, with the exception of the Full Prime Coat and Stripe Coat. Paint containment shall be a minimum of Class 3P as specified in the current edition of SSPC Guide 6. 688.6-ENVIRONMENTAL, WORKER PROTECTION, AND WASTE HANDLING: 688.6.1-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 proposed for the complete capture, 768 containment, collection, and disposal of the “spent material” generated by the work shall be included in the plan. 688.6.2–Permits for Disposal of “Spent Material”: Shall be in accordance with Section 107.2, 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. 688.6.2.1-“Spent Material”: This shall include material generated by surface preparation operations and shall be sampled and tested in accordance with the current revision of SSPC Guide 7 The Con tractor 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 pr ior 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. 688.6.3-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

per shift, or as directed by the Engineer. If the ground beneath the structure serves as the base of the containment, install and maintain air and dust impenetrable materials such as solid plywood panels or flexible materials such as tarpaul ins. Provide explosion –proof lighting inside containment for all paint application. Maintain a minimum of ten (10) foot-candles for surface preparation and painting, and a minimum of thirty (30) foot-candles for inspection. Water booms shall be used to contain inadvertent releases of debris unless prohibited by navigation lanes. In these cases, a boat with a skimmer shall be available to collect fugitive materials. Remove all project -related debris from the surface of the water or from the stream sediment at the end of each working day at a minimum unless directed otherwise by the Engineer. 688.6.4-Temporary Waste Storage: The Division (WVDOH) will obtain a provisional

The location of the temporary waste storage site at the project shall be noted in the Contractor’s Containment/Disposal Control Plan. This location must be approved by the Division prior to beginning work. 688.6.5-Worker Protection: Shall be in accordance with Section 107.7, Public Convenience and Safety, or any other applicable sections of Section 107. The Contractor shall have a Certified Industrial Hygienist (CIH) develop, review and approve their written compliance plan. The CIH shall be certified by the American Board of Industrial Hygiene. The CIH, or a technician working under the direction of the CIH, shall be present during the first three days of work and at least twice a month thereafter. The CIH shall certify in writing during the first week of work and at the end of the work that the worker protection plan fully complied with all regulations and that the plans were fully implanted. Daily inspections of the work area shall be made by the project “competent p erson”. The Contractor shall have identified the “competent person” by name in both the CIH’s written compliance plan and the 769 Contractor’s Containment/Disposal Control Plan. The compliance plan shall also include the “competent person’s” qualifications and the frequency of inspections to be taken. The CIH requirements will not apply to those zone painting projects where only SP 2 and SP 3 surface preparation is being done. 688.6.6-Division Employee Worker Protection: The Contractor shall provide respiratory protection and protective clothing and other necessary equipment for up to 2 Division employees at each site. 688.7-METHOD OF MEASUREMENT: The unit of measurement for “Clean and Paint Existing Steel Bridges”, "Containment and Disposal of Spent Material", “Field Painting of Shop Primed Steel” shall be lump sum. The unit of measurement for “Zone Cleaning and Painting Steel Bridges” shall be square foot. 688.8-BASIS OF PAYMENT: Basis of Payment for “Clean and Paint Existing Steel Bridges”, "Containment and Disposal of Spent Material", “Field Painting of Shop Primed Steel” shall be lump sum price bid. “Zone Cleaning and Painting Steel Bridge” shall be square foot price bid. The cost for the items listed below, which price and payment shall be full compensation for furnishing all the materials and doing all the work herein prescribed in workmanlike and acceptable m anner, including all labor, tools, equipment, supplies and incidentals necessary to complete the work. 688.9-PAY ITEMS: ITEM DESCRIPTION UNIT 688001-* Clean and Paint Existing Steel Bridge Lump Sum 688003-* Containment and Disposal of Spent Material Lump Sum 688005-* Zone Cleaning and Painting Steel Bridge Square Foot 688007-* Field Painting of Shop Primed Steel Lump Sum * Sequence number

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