Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10)

Painting 6-07

Edges of existing paint shall be feathered in accordance with SSPC-PA 1, Shop, Field, and
Maintenance Coating of Metals, Note 15.20.

6-07.3(10)N Field Coating Application Methods

The Contractor shall apply paint materials in accordance with manufacturer’s
recommendations by air or airless spray, brush, roller, or any combination of these
methods unless otherwise specified. Spray application of the paint shall be accomplished
with spray nozzles and at pressures as recommended by the paint manufacturer to
ensure application of paint at the specified film thickness. The Contractor may apply
stripe coat paint using spray or brush but shall follow spray application using a brush to
ensure complete coverage around structural geometric irregularities and to push the paint
into gaps between existing steel surfaces and around rivets and bolts. All application
techniques shall conform to Section 7, SSPC-PA 1. Painters using brushes shall work from
pails containing a maximum of 2 gallons of paint. This is intended to minimize the impact
of any spill.

6-07.3(10)O Applying Field Coatings

An on-site supervisor shall be present for each work shift at the bridge site.

The first coat shall be a primer coat applied to steel surfaces cleaned to bare metal. The
second coat shall be a primer stripe coat applied to all steel surfaces cleaned to bare
metal and defined to receive a stripe coat. The third coat shall be an intermediate coat.
The fourth coat shall be an intermediate stripe coat applied to steel surfaces defined to
receive a stripe coat. The fifth coat shall be the top coat. The intermediate (third) and top
(fifth) coats shall encapsulate the entire surface area of the structure members specified
to be painted.

Prior to the application of paint, the Contractor shall clean the bridge deck surface for the
purpose of dust control.

During painting operations the Contractor shall furnish, install, and maintain drip tarps
below the areas to be painted to contain all spilled paint, buckets, brushes, and other
deleterious material, and prevent such materials from reaching the environment below or
adjacent to the structure being painted. Drip tarps shall be absorbent material and hung
to minimize puddling.

In addition to the requirements of the Specifications, paint application shall conform to:
1.  The best practices of the trade.
2.  The written recommendations of the paint manufacturer.
3.  All applicable portions of the SSPC-PA 1.

No primer paint shall be applied to any surface until the surface has been inspected
and accepted by the Engineer. Any area to which primer paint has been applied
without the Engineer’s inspection and acceptance will be considered improperly
cleaned. The unauthorized application shall be completely removed and the entire
area recleaned to the satisfaction of the Engineer. After the area has been recleaned,
inspected, and approved, the Contractor may again initiate the painting sequence. No

Page 6-214

additional compensation or extension of time in accordance with

Section 1-08.8

will

be allowed for the removal of any unauthorized paint application and recleaning of the
underlying surface.

All steel surfaces cleaned to bare metal by abrasive blast cleaning shall receive the primer
coat within the same working day as the cleaning to bare metal and before any rust begins
to form. Each successive coat shall be applied as soon as possible over the previous coat,
accounting for drying time of the preceding coat, weather, atmospheric temperature and
other environmental conditions, and the paint manufacturer’s recommendations. Each
coat shall be dry before recoating and shall be sufficiently cured so that succeeding or
additional coats may be applied without causing damage to the previous coat. Recoat
times shall be as shown in the paint manufacturer’s recommendations, but not less than
12 hours. Revision of recoat times to other than recommended by the paint manufacturer
requires the concurrence of the Engineer. If the maximum time between coats is
exceeded, all affected areas shall be prepared to SSPC-SP 7, Brush-off Blast Cleaning,
and recoated with the Contract-specified system at no additional expense or time to the
Contracting Agency.

Each coat shall be applied in a uniform layer, completely covering the preceding coat.
The Contractor shall correct runs, sags, skips, or other deficiencies before application of
succeeding coats. Such corrective work may require recleaning, application of additional
paint, or other means as determined by the Engineer, at no additional cost to the
Contracting Agency.
If fresh paint is damaged by the elements, the Contractor shall replace or repair the paint
to the satisfaction of the Engineer at no additional cost to the Contracting Agency.
After applying the primer or intermediate coats, the Contractor shall apply a primer or
intermediate stripe coat, respectively, on all edges, corners, seams, crevices, interior
angles, junction of joint members, rivet or bolt heads, nuts and threads, weld lines, and
any similar surface irregularities. The coverage of each stripe coat shall extend at least
1 inch beyond the irregular surface. The stripe coat shall be of sufficient thickness to
completely hide the surface being covered and shall be followed as soon as feasible by
the application of the subsequent coat to its specified thickness.
If the primer coat leaves unsealed cracks or crevices, these shall be sealed with single-
component urethane sealant conforming to

Section 9-08.7

(applied in accordance with

the manufacturer’s recommendations) before the intermediate coats are applied.
The Contractor shall correct paint deficiencies before application of succeeding coats.
Such corrective work may require recleaning, application of additional paint, or other
corrective measures in accordance with the paint manufacturer’s recommendations and
as specified by the Engineer. Such corrective work shall be completed at no additional
expense or time to the Contracting Agency.
Each application of primer, primer stripe, intermediate, intermediate stripe, and top coat
shall be considered as separately applied coats. The Contractor shall not use a preceding
or subsequent coat to remedy a deficiency in another coat. The Contractor shall apply
the top coat to at least the minimum specified top coat thickness, to provide a uniform
appearance and consistent finish coverage.

Painting 6-07

If roadway or sidewalk planks lie so close to the metal that they prevent proper cleaning
and painting, the Contractor shall remove or cut the planks to provide at least a 1-inch
clearance. Any plank removal or cutting shall be done with the concurrence of the
Engineer. The Contractor shall replace all planks after painting. If removal breaks or
damages the planks and makes them unfit for reuse, the Contractor shall replace them at
no expense to the Contracting Agency.

6-07.3(10)P

Field Coating Repair

Paint repair shall conform to SSPC-PA 1. Repair areas shall be cleaned of all damaged
paint and the system reapplied using all coats typical to the paint system and shall
meet the minimum coating thickness. Each coat shall be thoroughly dry before applying
subsequent coats. Paint repair shall be in accordance with the paint manufacturer’s
recommendations and as accepted by the Engineer.

6-07.3(10)Q Cleanup

Cleaning of equipment shall not be done in State waters nor shall resultant cleaning
runoff be allowed to enter State waters. No paint cans, lids, brushes, or other debris
shall be allowed to enter State waters. Solvents, paints, paint sludge, cans, buckets, rags,
brushes, and other waste associated with this project shall be collected and disposed of
off-site. Paint products, petroleum products, or other deleterious material shall not be
wasted into, or otherwise enter, State waters as a result of project activities.
Cleanup of the project site shall conform to Sections

1-04.11

and

6-01.12

6-07.3(11) Painting or Powder Coating of Galvanized Surfaces

Galvanized surfaces specified to be coated after galvanizing shall receive either paint
in accordance with

Section 6-07.3(11)A

or powder coating in accordance with

Section

6-07.3(11)B

. The color of the finish coat shall be as specified in the Special Provisions.

6-07.3(11)A

Painting of Galvanized Surfaces

All galvanized surfaces receiving paint shall be prepared for painting in accordance with
the ASTM D6386. The method of preparation shall be brush-off in accordance with SSPC-
SP16 Brush-Off Blast Cleaning of Coated and Uncoated Galvanized Steel, Stainless Steels,
and Non-Ferrous Metals or as otherwise allowed by the Engineer. The Contractor shall
not begin painting until receiving the Engineer’s acceptance of the prepared galvanized
surface. For galvanized bolts used for replacement of deteriorated existing rivets, the
Contractor, with the concurrence of the Engineer and after successful demonstration
testing, may prepare galvanized surfaces in accordance with SSPC-SP1 followed by SSPC-
SP2, Hand Tool Cleaning or SSPC-SP3, Power Tool Cleaning. The demonstration testing
shall include adhesion testing of the first coat of paint over galvanized bolts, nuts, and
washers or a representative galvanized surface. Adhesion testing shall be performed in
accordance with ASTM D4541 for 600 psi minimum adhesion. A minimum of 3 successful
tests shall be performed on the galvanized surface prepared and painted using the same
methods and materials to be used on the galvanized bolts, nuts and washers in the field.

Page 6-216

6-07.3(11)A1 Environmental Conditions

Steel surfaces shall be:

•

Greater than 35ºF, and

•

Less than 115ºF.

or in accordance with the manufacturer’s recommendations, whichever is more stringent.

6-07.3(11)A2 Paint Coat Materials

The Contractor shall paint the dry surface as follows:
1. The first coat over a galvanized surface shall be an epoxy polyamide conforming

to Section 9-08.1(2)E. In the case of galvanized bolts used for replacement of
deteriorated existing rivets and for small surface areas less than or equal to one
square foot, an intermediate moisture cured polyurethane conforming to Section
9-08.1(2)G may be used as a first coat. In both cases the first coat shall be
compatible with galvanizing and as recommended by the top coat manufacturer.

2. The second coat shall be a top coat moisture cured aliphatic polyurethane

conforming to Section 9-08.1(2)H or a top coat polyurethane conforming to Section
6-07.3(10)H Option 2 NEPCOAT performance based paint specification compatible
with the first coat as recommended by the manufacturer.

Each coat shall be dry before the next coat is applied. All coats applied in the shop shall
be dried hard before shipment.

6-07.3(11)B

Powder Coating of Galvanized Surfaces

Powder coating of galvanized surfaces shall consist of the following coats:
1. The first coat shall be an epoxy powder primer coat conforming to Section 9-08.2.
2. The second coat shall be a polyester finish coat conforming to Section 9-08.2.

6-07.3(11)B1 Submittals

The Contractor shall submit Type 2 Working Drawings consisting of the following
information:
1. The name, location, and contact information (mail address, phone, and email) for the

firm performing the powder coating operation.

2. Quality control (QC) programs established and followed by the firm performing the

powder coating operation. Forms to document inspection and testing of coatings as
part of the QC program shall be included in the submittal.

3. Project-specific powder coating plan, including identification of the powder coating

materials used (and manufacturer), and specific cleaning, surface preparation,
preheating, powder coating application, curing, shop and field coating repair,
handling, and storage processes to be taken for the assemblies being coated for
this project.

4. Product data and MSDS sheets for all powder coating and coating repair materials.

Painting 6-07

6-07.3(11)B2 Galvanizing

Prior to the galvanizing operation, the Contractor shall identify to the galvanizer the
specific assemblies and surfaces receiving the powder coating after galvanizing, to ensure
that the galvanizing method used on these assemblies is compatible with subsequent
application of a powder coating system. Specifically, such assemblies shall neither be
water-quenched nor receive a chromate conversion coating as part of the galvanizing
operation.

6-07.3(11)B3 Galvanized Surface Cleaning and Preparation

Galvanized surfaces receiving the powder coating shall be cleaned and prepared for
coating in accordance with ASTM D6386, and the project-specific powder coating plan.

Assemblies conforming to the ASTM D7803 definition for newly galvanized steel shall
receive surface smoothing and surface cleaning in accordance with ASTM D7803, Section
5, and surface preparation in accordance with ASTM D7803, Section 5.1.3.

Assemblies conforming to the ASTM D7803 definition for partially weathered galvanized
steel shall be checked and prepared in accordance with ASTM D7803, Section 6, before
then receiving surface smoothing and surface cleaning in accordance with ASTM D7803,
Section 5, and surface preparation in accordance with ASTM D7803, Section 5.1.3.

Assemblies conforming to the ASTM D7803 definition for weathered galvanized steel
shall be prepared in accordance with ASTM D7803, Section 7 before then receiving
surface smoothing and surface cleaning in accordance with ASTM D7803, Section 5, and
surface preparation in accordance with ASTM D7803, Section 5.3 except as follows:
1. Ferrous metal abrasives are prohibited as a blast media for surface preparation.
2. Surface preparation shall be accomplished using dry abrasive blasting through a blast

nozzle with compressed air. Abrasive blasting with a centrifugal wheel is prohibited.

The Contractor shall notify the Engineer of all surface cleaning and preparation activities
and shall provide the Engineer opportunity to perform quality assurance inspection, in
accordance with

Section 1-05.6

, at the completion of surface cleaning and preparation

activities prior to beginning powder coating application.

6-07.3(11)B4 Powder Coating Application and Curing

After surface preparation, the two-component powder coating shall be applied in
accordance with the powder coating manufacturer’s recommendations, the project-
specific powder coating plan, and as follows:
1. Preheat. The preheat shall be sufficient to prevent pinholes from forming in the

finished coating system.

2. Apply the epoxy primer coat, followed by a partial cure.
3. Apply the polyester finish coat, followed by the finish cure.

Page 6-218

6-07.3(11)B5 Testing

The firm performing the powder coating operation shall conduct, or make arrangements
for, QC testing on all assemblies receiving powder coating for this project, in accordance
with the powder coating firm’s QC program as documented in item 2 of the Submittal
Subsection above. Testing may be performed on coated surfaces of production fabricated
items, or on a representative test panel coated alongside the production fabricated items
being coated. There shall be a minimum of one set of tests representing each cycle of
production fabricated items coated and cured. Additional tests shall be performed at the
request of the Engineer. Repair of damaged coatings on production fabricated items shall
be the responsibility of the firm applying the powder coating, and shall be in accordance
with the project-specific powder coating plan. At a minimum, the QC testing shall test for
the following requirements:
1. Visual inspection for the presence of coating holidays and other unacceptable

surface imperfections.

2. Coating thickness measurement in accordance with

Section 6-07.3(5)

. The minimum

thickness of the epoxy primer coating and polyester finish coating shall be 3 mils
each.

3. Hardness testing in accordance with ASTM D3363, with the finish coat providing a

minimum hardness value of H.

4. Adhesion testing in accordance with ASTM D4541 for 600 psi minimum adhesion for

the complete two-component coating system.

5. Powder Coating Institute (PCI) #8 recommended procedure for solvent cure test.

The results of the QC testing shall be documented in a QC report and submitted as a Type
2 Working Drawing.

The Engineer shall be provided notice and access to all assemblies at the powder coating
facility for the purposes of Contracting Agency acceptance inspection, including notice
and access to witness all hardness and adhesion testing performed by the firm conducting
the QC testing, in accordance with

Section 1-05.6

Assemblies not meeting the above requirements will be subject to rejection by the
Engineer. Rejected assemblies shall be repaired or recoated by the Contractor, at no
additional expense to the Contracting Agency, in accordance with the powder coating
manufacturer’s recommendation as detailed in the project-specific powder coating plan,
until the assemblies satisfy the acceptance testing requirements.

Assemblies shall not be shipped from the powder coating firm’s facility to the project site
until the Contractor receives the Engineer’s acceptance of the QC Report and assembly
inspection performed by the Engineer.

Painting 6-07

6-07.3(11)B6 Coating Protection for Shipping, Storage, and Field

Erection

After curing and acceptance, the Contractor shall protect the coated assemblies with
multiple layers of bubble wrap or other protective wrapping materials specified in the
project-specific powder coating plan.

During storage and shipping, each assembly shall be separated from other assemblies
by expanded polystyrene spacers and other spacing materials specified in the project-
specific powder coating plan.

After erection, all coating damage due to the Contractor’s shipping, storage, handling, and
erection operations shall be repaired by the Contractor in accordance with the project-
specific powder coating plan. The Contractor shall provide the Engineer access to all
locations of all powder-coated members for verification of coating conditions prior to and
following all coating repairs.

6-07.3(12) Painting Ferry Terminal Structures

Painting of ferry terminal structures shall be in accordance with Section 6-07.3 as
supplemented below.

6-07.3(12)A

Painting New Steel Ferry Terminal Structures

Painting of new steel Structures shall be in accordance with Section 6-07.3(9) except that
all coatings (primer, intermediate, intermediate stripe, and top) shall be applied in the shop
with the following exceptions:
1.  Steel surfaces to be field welded.
2.  Steel surfaces to be greased.
3.  The length of piles designated in the Plans not requiring painting.

The minimum drying time between coats shall be as shown in the product data sheets,
but not less than 12 hours. The Contractor shall determine whether the paint has cured
sufficiently for proper application of succeeding coats.

6-07.3(12)A1 Paint Systems

Paint systems for Structural Steel, which includes vehicle transfer spans and towers,
pedestrian overhead loading structures and towers, upland structural steel and
other elements as designated in the Special Provisions shall be as specified in Section
6-07.3(9)A.

Paint systems for Piling, Landing Aids and Life Ladders shall be as specified in the Special
Provisions.

6-07.3(12)A2 Paint Color

Paint colors shall be as specified in the Special Provisions.

Page 6-220

6-07.3(12)A3 Coating Thickness

Coating thicknesses shall be as specified in the Special Provisions.

6-07.3(12)A4 Application of Field Coatings

An on-site supervisor shall be present for each work shift at the project site.

Upon completion of erection Work, all uncoated or damaged areas remaining, including
bolts, nuts, washers, splice plates, and field welds shall be prepared in accordance with
SSPC-SP 1, Solvent Cleaning, followed by SSPC-SP 11, Power Tool Cleaning to Bare
Metal. Surface preparation shall be measured according to SSPC-VIS 3. SSPC-SP 11 shall
be performed for a minimum distance of 1 inch from the uncoated or damaged area. In
addition, intact shop-applied coating surrounding the area shall be abraded or sanded for
a distance of 6 inches out from the properly prepared clean/bare metal areas to provide
adequate roughness for application of field coatings. All sanding dust and contamination
shall be removed prior to application of field coatings.

Field applied paint for Structural Steel shall conform to Section 6-07.3(10)H, as applicable.
Field applied paint for Piling, Landing Aids and Life Ladders shall be as specified in the
Special Provisions.

For areas above the tidal zone, the minimum drying time between coats shall be as shown
in the product data sheets, but not less than 12 hours. For areas within the tidal zone,
the minimum drying time between coats shall be as recommended by the paint system
manufacturer. The Contractor shall determine whether the paint has cured sufficiently for
proper application of succeeding coats.

The maximum time between intermediate and top coats shall be in accordance with
the manufacturer’s written recommendations. If the maximum time between coats is
exceeded, all newly coated surfaces shall be prepared to SSPC-SP 3, Power Tool Cleaning,
and shall be repainted with the same paint that was cleaned, at no additional cost to the
Contracting Agency.

Surface preparation for underwater locations shall consist of removing all dirt, oil, grease,
loose paint, loose rust, and marine growth from the area that is to be repaired. The sound
paint surrounding the damaged area shall be roughened to meet the requirements of
the manufacturer. Paint for underwater applications shall be as specified in the Special
Provisions and shall be applied in accordance with the manufacturer’s recommendations.

6-07.3(12)B

Painting Existing Steel Ferry Terminal Structures

Painting of existing steel structures shall be in accordance with Section 6-07.3(10) as
supplemented by the following.

Painting 6-07

6-07.3(12)B1 Containment

Containment for full removal shall be in accordance with Section 6-07.3(10)A.
Containment for overcoat systems shall be in accordance with all applicable Permits as
required in the Special Provisions.

Prior to cleaning the Contractor shall enclose all exposed electrical and mechanical
equipment to seal out dust, water, and paint. Non-metallic surfaces shall not be abrasive
blasted or painted. Unless otherwise specified, the following metallic surfaces shall not be
painted and shall be protected from abrasive blasting and painting:
1.  Galvanized and stainless steel surfaces not previously painted,
2.  Non-skid surfaces,
3.  Unpainted intentionally greased surfaces,
4.  Equipment labels, identification plates, tags, etc.,
5.  Fire and emergency containers or boxes,
6.  Mechanical hardware such as hoist sheaves, hydraulic cylinders, gear boxes, wire

rope, etc.

The Contractor shall submit a Type 2 Working Drawing consisting of materials and
equipment used to shield components specified to not be cleaned and painted.

The Contractor shall shut off the power prior to working around electrical equipment. The
Contractor shall follow the lock-out/tag-out safety provisions of the WAC 296-803 and
all other applicable safety standards.

6-07.3(12)B2 Surface Preparation

For applications above high water and within the tidal zone, surface preparation for
overcoat painting shall be in accordance with SSPC-SP 1, Solvent Cleaning, followed
by SSPC-SP 3, Power Tool Cleaning. Use of wire brushes is not allowed. After SP 3
cleaning has been completed all surfaces exhibiting coating failure down to the steel
substrate, and those exhibiting visible corrosion, shall be prepared down to clean bare
steel in accordance with SSPC-SP 15, Commercial Grade Power Tool Cleaning. Surface
preparation shall be measured according to SSPC-VIS 3. SSPC-SP 15 shall be performed
for a minimum distance of 1 inch from the area exhibiting failure or visible corrosion.
In addition, intact shop-applied coating surrounding the repair area shall be abraded
or sanded for a distance of 6 inches out from the properly prepared clean/bare metal
areas to provide adequate roughness for application of repair coatings. All sanding dust
and contamination shall be removed prior to application of repair coatings. Surface
preparation for full paint removal shall be in accordance with Section 6-07.3(10)E except
SSPC-SP 11 will be permitted as detailed in the Contractor’s painting plan and as allowed
by the Engineer.

Page 6-222

Removed marine growth may be released to state waters provided the marine growth is
not mixed with contaminants (paint, oil, rust, etc.) and it shall not accumulate on the sea
bed. All marine growth containing contaminants shall be collected for proper disposal.

Surface preparation for the underside of bridge decks (consisting of either a steel grid
system of main bars or tees and a light gauge metal form, in-filled with concrete or a
corrugated light gauge metal form, infilled with concrete) shall be in accordance with
SSPC-SP 2, Hand Tool Cleaning or SSPC-SP 3, Power Tool Cleaning with the intent of
not causing further damage to the light gauge metal form. Following removal of any pack
rust and corroded sections from the underside of the bridge deck, cleaning and flushing
to remove salts and prior to applying the primer coat, the Contractor shall seal the entire
underside of the deck system with rust-penetrating sealer. Damage to galvanized metal
forms and/or grids shall be repaired in accordance with ASTM A 780, with the preferred
method of repair using paints containing zinc dust.

6-07.3(12)B3 Paint Systems

Paint systems for Piling, Landing Aids, Life Ladders, underside of vehicle transfer span
bridge decks, non-skid surface treated areas, and anti-graffiti coatings shall be as
specified in the Special Provisions.

6-07.3(12)B4 Paint Color

Paint colors shall be as specified in the Special Provisions.

6-07.3(12)B5 Coating Thickness

Coating thicknesses shall be as specified in the Special Provisions.

6-07.3(12)B6 Application of Field Coatings

Application of field coatings shall be in accordance with Section 6-07.3(10)O and
Section 6-07.3(12)A2 except for the following:
1. All coatings applied in the field shall be applied using a brush or roller. Spray

application methods may be used if allowed by the Engineer.

2. Applied coatings shall not be immersed until the coating has been cured as required

by the coating manufacturer.

3. Non-skid surface treatment products shall be applied in accordance with the

manufacturer’s recommendations.

4. Anti-graffiti coatings shall be applied in one coat following application of the top

coat, where specified in the Plans.

Painting 6-07

6-07.3(13) Painting Timber Structures

Timber structures shall be painted as specified in the Special Provisions.

6-07.3(14) Metallic Coatings

6-07.3(14)A

General Requirements

This specification covers the requirements for thermal spray metallic coatings, with and
without additional paint coats, as a means to prevent corrosion.

The coating system consists of surface preparation by wash cleaning and abrasive blast
cleaning, thermal spray application of a metallic coating using a material made specifically
for that purpose, and, when specified, shop primer coat or shop primer coat plus top
coat in accordance with

Section 6-07.3(11)A

. The system also includes inspection and

acceptance requirements.

6-07.3(14)B

Reference Standards

SSPC-SP 10/NACE No. 2

Near-White Blast Cleaning

SSPC CS 23.00

Specification for the Application of Thermal Spray Coatings
(Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for
the Corrosion Protection of Steel

ASTM C633

Standard Test Method for Adhesion or Cohesion Strengths of
Thermal Spray Coatings

ASTM D4417

Standard Test Methods for Field Measurement of Surface Profile of
Blast-Cleaned Steel

ASTM D6386

Standard Practice for Preparation of Zinc (Hot-Dip Galvanized)
Coated Iron and Steel Product and Hardware Surfaces for Painting

ASTM D4541

Standard Test Method for Pull-Off Strength of Coatings Using
Portable Adhesion Testers

ANSI/AWS C2.18 Guide for the Protection of Steel with Thermal Sprayed Coatings of

Aluminum, Zinc and their Alloys and Composites

6-07.3(14)C

Quality Assurance

A representative sample of each lot of the coating material used shall be submitted to the
Engineer for analysis prior to use. Zinc shall have a minimum purity of 99.9 percent. Zinc
Aluminum 85/15 wire shall be 14 to 16 percent maximum aluminum.

The thermal sprayed coating shall have a uniform appearance. The coating shall not
contain any blisters, cracks, chips or loosely adhering particles, oil or other surface
contaminants, nodules, or pits exposing the substrate.

The thermal spray coating shall adhere to the substrate with a minimum bond of 700 psi.
The Contractor’s QA program shall include thermal spray coating bond testing.

Page 6-224

The Engineer may cut through the coating with a knife or chisel. If upon doing so, any part
of the coating lifts away from the base metal ¼ inch or more ahead of the cutting blade
without cutting the metal, then the bond is considered not effective and is rejected.

Coated areas which have been rejected or damaged in the inspection procedure described
shall have the defective sections blast cleaned to remove all of the thermal sprayed
coating and shall then be recoated. Before resubmittal and inspection, those sections
where coating has not reached the required thickness shall be sprayed with additional
metal until that thickness is achieved.

6-07.3(14)D Submittals

The Contractor shall submit to the Engineer, prior to abrasive blast cleaning, a 12 inch
square steel plate, of the same material and approximate thickness of the steel to be
coated, blasted clean in accordance with

Section 6-07.3(14)E

. The sample plate will be

checked for specified angular surface pattern, the abrasive grit size and type used, and
the procedure used. This plate shall be used as the visual standard to determine the
acceptability of the cleaned surface. In the event the Contractor’s cleaning operation
is inferior to the sample plate, the Contractor shall be required to correct the cleaning
operation to do a job comparable to the specimen submitted.

At the same time as submitting the abrasive blast cleaned steel plate sample, the
Contractor shall submit to the Engineer, a second 12 inch square steel plate of the same
material and thickness, cleaned and thermal spray coated in accordance with the same
processes and with the same equipment as intended for use in applying the thermal
spray coatings. The Engineer may request additional cleaned and thermal spray coated
samples to be produced and submitted coincident with thermal spray coating of the items
specified in the Plans to receive thermal spray coatings.

6-07.3(14)E

Surface Preparation

Surface irregularities (e.g., sharp edges and/or carburized edges, cracks, delaminations,
pits, etc.) interfering with the application of the coating shall be removed or repaired, prior
to wash cleaning. Thermal cut edges shall be ground to reduce hardness to attain the
surface profile required from abrasive blast cleaning.

All dirt, oil, scaling, etc. shall be removed prior to blast cleaning. All surfaces shall be wash
cleaned with either clean water at 8000 psi or water and detergent at 2000 psi with two
rinses with clean water.

The surface shall be abrasive blast cleaned to near white metal (SSPC-SP 10). The surface
profile shall be measured using a surface profile comparator, replica tape, or other method
suitable for the abrasive being used in accordance with ASTM D4417.

Where zinc coatings up to and including 0.009 inch thick are to be applied, one of the
following abrasive grits shall be used with pressure blast equipment to produce a 3.0 mils
AA anchor tooth pattern:
1. Aluminum oxide or silicon carbide mesh size: SAE G-25 to SAE G-40
2. Hardened steel grit mesh size: SAE G-25 to SAE G-40

Painting 6-07

3. Garnet, flint, or crushed nickel or black beauty coal slag mesh size: SAE G-25 to

SAE G-50

Where zinc coatings greater than 0.010 inch thick are to be applied, one of the following
abrasive grits shall be used with pressure blast equipment to produce a 5.0 mils AA
anchor tooth pattern:
1.  Aluminum oxide or silicon carbide mesh size: SAE G-18 to SAE G-25
2.  Hardened steel grit mesh size: SAE G-18 to SAE G-25
3.  Garnet, flint, or crushed nickel or black beauty coal slag mesh size: SAE G-18 to SAE

G-25

The pressure of the blast nozzle, as measured with a needle probe gauge, with pressure
type blasting equipment shall be as follows:
1. With aluminum oxide, silicon carbide, flint, or slag - 50 psi minimum and 60 psi

maximum.

2. With garnet or steel grit - 75 psi minimum.

The pressure at the blast nozzle, with siphon blasting (suction blasting), shall be as
follows:
1. With aluminum oxide, silicon carbide, flint, or slag - 75 psi maximum.
2. With garnet or steel grit - 90 psi maximum.

The abrasive blast stream shall be directed onto the substrate surface at a spray angle of
75 to 90 degrees, and moved side to side. The nozzle to substrate distance shall be 4 to
12 inches.

6-07.3(14)F

Application of Metallic Coating

No surface shall be sprayed which shows any sign of condensed moisture or which
does not comply with

Section 6-07.3(14)E

. If rust bloom occurs within the holding time

between abrasive blast cleaning and thermal spraying, the surface shall be reblasted at a
blast angle as close to perpendicular to the surface as possible to achieve a 2.0 to 4.0 mil
anchor tooth pattern. Thermal spraying shall not take place when the relative humidity is
90 percent or greater, when the steel temperature is less than 5F above the dew point, or
when the air or steel temperature is less than 40F.

Clean, dry air shall be used with not less than 50 psi air pressure at the air regulator. Not

more than 50 feet of 3/8 inch. ID hose shall be used between the air regulator and the

metallizing gun. The metallizing gun shall be started and adjusted with the spray directed
away from the work. During the spraying operation and depending upon the equipment
being used, the gun shall be held as close to perpendicular as possible to the surface from
5 to 8 inches from the surface of the work.

Manual spraying shall be done in a block pattern, typically 2 feet by 2 feet square. The
sprayed metal shall overlap on each pass to ensure uniform coverage. The specified

Page 6-226

thickness of the coating shall be applied in multiple layers. In no case are fewer than two
passes of thermal spraying, overlapping at right angles, acceptable.

At least one single layer of coating shall be applied within 4 hours of blasting and the
surface shall be completely coated to the specified thickness within 8 hours of blasting.

The minimum coating thickness shall be 6 mils unless otherwise shown in the Plans.

6-07.3(14)G Applications of Shop Coats and Field Coats

The surface shall be wiped clean with solvent immediately before applying the wash
primer. The wash primer shall have a low viscosity appropriate for absorption into the
thermal spray coating, and shall be applied within 8 hours after completion of thermal
spraying or before oxidation occurs. The dry film thickness of the wash primer shall not
exceed 0.5 mils or be less than 0.3 mils. It shall be applied using an appropriate spray gun
except in those areas where brush or roller application is necessary. The subsequent shop
primer or field coats shall be applied no less than one-half hour after a wash primer.

The shop primer coat, when specified, shall be applied in accordance with

Section

6-07.3(11)A

and the paint manufacturer’s recommendations.

All field coats, when specified, shall be applied in accordance with

Section 6-07.3(11)A

and the paint manufacturer’s recommendations. The color of the top coat shall conform to

Section 6-03.3(30)

as supplemented in these Special Provisions.

6-07.4 Measurement

Cleaning, sealing, and caulking pack rust will be measured by the linear foot along the
edge of the steel connection interface cleaned, sealed, and caulked.

Spot abrasive blast cleaning of steel surfaces in accordance with

Section 6-07.3(10)D

will

be measured by the square foot of surface area to be cleaned to bare metal as specified
by the Engineer.

6-07.5 Payment

Payment will be made for each of the following Bid items that are included in the
Proposal:

“Cleaning and Painting - _____”, lump sum.
The lump sum Contract price for “Cleaning and Painting – _____” shall be full
pay for the Work as specified, including developing all submittals; arranging for
and accommodating contact and on-site attendance by the paint manufacturer’s
technical representative; furnishing and placing all necessary staging and rigging;
furnishing, operating, and mooring barges; furnishing and operating fixed and
movable work platforms; accommodating Contracting Agency inspection access;
conducting the Contractor’s quality control inspection program; providing material,
labor, tools, and equipment; furnishing containers for containment waste, collecting
and storing containment waste; collecting, storing, testing, and disposing of all
containment waste not conforming to the definition in

Section 6-07.3(10)F

;

Painting 6-07

performing all cleaning and preparation of surfaces to be painted; applying all coats
of paint and sealant; correcting coating deficiencies; completing coating repairs; and
completing project site cleanup.
When a weather station is specified, all costs in connection with furnishing,
installing, operating, and removing the weather station, including furnishing
mounting hardware and repeaters, accessories and wireless display console units,
processing and submitting daily weather data reports, maintenance and upkeep, shall
be included in the lump sum Contract price for “Cleaning And Painting – _____”.
Progress payments for “Cleaning and Painting – _____” will be made on a monthly
basis and will be based on the percentage of the total estimated area satisfactorily
cleaned and coated as determined by the Engineer. Payment will not be made for
areas that are otherwise complete but have repairs outstanding.
“Cleaning, Sealing, and Caulking Pack Rust”, per linear foot.
The unit contract price per linear foot for “Cleaning, Sealing, and Caulking Pack Rust”
shall be full pay for performing the work as specified, including cleaning out the pack
rust, preparing the gap for the rust penetrating sealer and caulk, and applying the
rust penetrating sealer and caulk.
“Spot Abrasive Blast Cleaning”, per square foot.
The unit contract price per square foot for “Spot Abrasive Blast Cleaning” shall be
full pay for performing the spot abrasive blast cleaning work in accordance with

Section 6-07.3(10)D

“Containment of Abrasives”, lump sum.
The lump sum contract price for “Containment of Abrasives” shall be full payment for
all costs incurred by the Contractor in complying with the requirements as specified
in

Section 6-07.3(10)A

to design, construct, maintain, and remove containment

systems for abrasive blasting operations.
“Testing and Disposal of Containment Waste”, by force account as provided in

Section 1-09.6

All costs in connection with testing containment waste, transporting containment
waste for disposal, and disposing of containment waste in accordance with

Section

6-07.3(10)F

will be paid by force account in accordance with

Section 1-09.6

. For the

purpose of providing a common proposal for all bidders, the Contracting Agency has
entered an amount for the item “Testing and Disposal of Containment Waste” in the
bid proposal to become part of the total bid by the Contractor.
All costs in connection with producing the metallic coatings as specified shall be
included in the unit contract price for the applicable item or items of work.
Payment for painting new steel structures and painting or powder coating of
galvanized surfaces will be in accordance with

Section 6-03.5

. Painting of timber

structures will be in accordance with

Section 6-04.5

Page 6-228

Bituminous Surfacing on Structure Decks

6-08

Bituminous Surfacing on Structure Decks

6-08.1 Description

This Work consists of removing and placing Hot Mix Asphalt (HMA) or Bituminous
Surface Treatment (BST) directly on or over a Structure. This Work also includes
performing concrete bridge deck repair, applying waterproofing membrane, and sealing
paving joints.

6-08.2 Materials

Materials shall meet the requirements of the following sections:

Bituminous Surface Treatment

5-02.2

Hot Mix Asphalt

5-04.2

Joint Sealants

9-04.2

Closed Cell Foam Backer Rod

9-04.2(3)A

Waterproofing Membrane (Deck Seal)

9-11

Bridge Deck Repair Material

9-20.5

6-08.3

Construction Requirements

6-08.3(1) Definitions

Adjusted Removal Depth – the Bituminous Pavement removal depth specified by the
Engineer to supersede the Design Removal Depth after review of the Contractor survey
of the existing Bituminous Pavement grade profile.

Bituminous Pavement – the surfacing material containing an asphalt binder.

Design Removal Depth – the value shown in the “pavement schedule” or elsewhere in the
Plans to indicate the design thickness of Bituminous Pavement to be removed.

Final Grade Profile – the compacted finished grade surface of completed Bituminous
Pavement surfacing consisting of a vertical profile and superelevation cross-slope,
developed by the Engineer for Grade Controlled Structure Decks based on the Contractor
survey.

Grade Controlled – a Structure Deck requiring restriction of Bituminous Pavement work,
including restriction of pavement removal methods and restriction of overlay pavement
thicknesses.

Structure Deck – the bridge deck (concrete or timber), bridge approach slab, top of
concrete box culvert, or other concrete surfaces over or upon which existing Bituminous
Pavement is removed and new Bituminous Pavement is applied.

Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10) - page 35