Rev. 2-4-97 

BRIDGE PAINTING 

619-M-048

 

The Standard Specifications are revised as follows:

 

SECTION 619, BEGIN LINE 8 DELETE AND INSERT AS FOLLOWS:

 

619.02 Materials. Materials shall be in accordance with the following:

 

Encapsulation Bridge Paint System

909.03

Inorganic Zinc Primer

909.02(a)1

Epoxy Intermediate Paint

909.02(d)1

Multi-Component Inorganic Zinc Primer

909.02(a)1b

Organic Zinc Primer

909.02(a)3

Polyurethane Finish Coat

909.02(d)2

Single Component Inorganic Zinc Primer

909.02(a)2

Two Component Inorganic Zinc Primer

909.02(a)1a

Two-Component Water Based Primer

909.02(a)1c

Vinyl Finish Paint

909.02(b)

Waterborne Finish Paint

909.02(c)

 

CONSTRUCTION REQUIREMENTS

 

619.03 General Requirements. Except as modified herein in the plans, all surfaces to be painted shall receive one coat of inorganic zinc primer and one coat of waterborne finish paint either of the paint systems defined in 619.07(a) and is to be applied in accordance with the manufacturer's specifications. The dry film

SECTION 619, BEGIN LINE 117, DELETE AND INSERT AS FOLLOWS:

619.06 Pollution Control. Blasting materials, scrapings, wire brushings, and paint particles shall be contained in accordance with SSPC-Guide 61 6 (con) Class 5 3A specifically for zinc primed bridges, and SSPC-Guide 61 6 (con) Class 3 2A for lead primed bridges. The

SECTION 619, DELETE LINES 177 THROUGH 190.

SECTION 619, AFTER LINE 191, INSERT AS FOLLOWS:

(a) Structural Steel Coating Systems. These coatings systems shall consist of an inorganic zinc primer, an epoxy intermediate paint and a polyurethane finish coat, or an inorganic zinc primer with a waterborne acrylic finish coat, for the painting of steel bridges and other structural steel. All of the coatings within any coating system shall be manufactured by the same manufacturer and shall be compatible with one another. All coatings shall be in accordance with 909.01.

SECTION 619, BEGIN LINE 220, DELETE AND INSERT AS FOLLOWS:

All members which are inaccessible to field painting after being placed in final position shall have been given the waterborne finish all coats of paint before being erected.

SECTION 619, AFTER LINE 250, INSERT AS FOLLOWS:

The pot life and induction time shall be in accordance with the manufacturer's recommendations for the existing ambient temperature.

Drying time between coats shall be a minimum of 24 h for the primer and 8 h for the intermediate coat. The recoat time will vary depending on temperature. The manufacturer's recommendations shall be observed. The urethane finish coat shall be placed within 12 days of placement of the intermediate coat.

No partially used containers of paint shall be used. No partial mixing of containers will be permitted. All paint containers shall remain closed until they are needed for mixing.

Paint shall be stored in accordance with the manufacturer's recommendations.

The paint shall be used within the manufacturer's recommended shelf life.

Painting shall begin only when the 24 h ambient temperature is to remain above 10E C (50E F) after paint application, and the substrate temperature is between 10E C and 40E C (50E F and 100E F). Coating and curing shall be done only when the relative humidity is between 30% and 80%.

SECTION 619, BEGIN LINE 317, DELETE AND INSERT AS FOLLOWS:

Primer paints shall be applied at a minimum dry film thickness of 65 :m (2.5 mils), or that which is in accordance with the manufacturer's recommendations, whichever is greater the waterborne finish coat with a minimum dry film thickness of 75 :m (3.0 mils), the epoxy intermediate coat with a dry film thickness of 100 :m (4 mils), and the urethane finish coat with a mininum dry film thickness of 75 :m (3 mils). If the proper dry film thickness of the inorganic zinc primer is not obtained

SECTION 619, AFTER LINE 323, INSERT AS FOLLOWS:

A failing spot film thickness is either less than 80% below or greater than 110% above the required minimum dry film thickness.

SECTION 909, AFTER LINE 245, INSERT AS FOLLOWS:

 (d) Structural Steel Coating Systems.

 1. Epoxy Intermediate Paint. Epoxy intermediate paint shall be a two component coating consisting of an epoxy resin and a curing agent, together with prime and filler pigments, colorants, gellant, leveling agents and solvents. This coating when mixed shall be suitable for application over inorganic and organic zinc primers and shall be compatible with a polyurethane finish coat. The color of this coating shall be such that a definite contrast between the coating and other coatings within the coating system shall be readily apparent. The mixed coating shall meet the following requirements:

 

Volatile Organic Compounds, ASTM D 3960 336 g/L max
Volume Solids, ASTM D 2697 60% min
Set-to-touch, FS 141 Method 4061.1, 25 " 1 EC 4 hours max
Potlife, 25 " 1 EC 6 hours min
Mass per liter variance from the initially approved batch, ASTM D 1475, 25 EC, 0.060 kg/L max
Total Solids variance from the initially approved batch, ASTM D 2369 3.0% max

 

The infrared spectra of each component and of the mixed coating shall essentially match the spectrums of the initially approved batch.

 2. Polyurethane Finish Coat. Polyurethane finish coat shall be a two component polyester and/or acrylic aliphatic polyurethane suitable for use as a finish coat over epoxy intermediate paint. The mixed coating shall meet the Federal Standard 595a as follows:

 

 Color No. Color
14260 Green
15450 Lt. Blue
17886 White
17038 Black
13711 Buff
13538 Yellow

 

In addition to the above, the mixed coating shall meet the following requirements:

 

Specular Gloss, 60E, ASTM D 523

75 min

Volume Solids, ASTM D 2697

60% min

Total Solids, ASTM D 2369

70% min

Volatile Organic Compounds,ASTM D 3960

336 g/L max

Viscosity, ASTM D 562,

100 Kreb Units max

Contrast Ratio, ASTM D 2805, 127 :m wet film thickness dried 24 hours @ 25 " 2 EC on Leneta Form 2A or 2C

0.95 min

Set-to-touch, FS 141 Method 4061.1 25 " 2 EC, 50 " 10% Relative Humidity

30 minutes min

Dry Hard FS 141 Method 4061.1, 25 " 2 EC, 50 " 10% Relative Humidity

24 hours max

 

The infrared spectra of each component and of the mixed coating shall essentially match the spectrums of the initially approved batch.

 

 3. Coating System Chemical and Resistance Requirements.

 

 

 a. Toxicity. The cured film of each coating within the structural steel coatings system shall not contain any toxic heavy metals above the limits of the regulatory levels of 40 CFR 261.24, table 1, when tested in accordance with EPA Toxicity Characteristics Leaching Procedures, or contain any other material which will require characterization as a hazardous waste for the disposal of the dried film.

 

 b. Resistance. The test panels for all resistance tests shall be prepared in accordance with section 4.6.4 of AASHTO M 300. After the curing of the zinc primer in accordance with section 4.6.4 of AASHTO M 300, the epoxy intermediate paint and the polyurethane finish coat or the waterborne acrylic finish coat shall be applied and permitted to cure in accordance with manufacturer's printed product data sheets. Three panels for each of the resistance tests shall be prepared and tested. Each panel shall be reported for the coating system.

 

The dry film thickness of each of the coatings in the structural steel coating system tested shall be as follows:

 

Inorganic Zinc Primer 75 to 90 :m (3.0 to 3.5 mils)
Organic Zinc Primer 75 to 90 :m (3.0 to 3.5 mils)
Epoxy Intermediate Paint 75 to 100 :m (3.0 to 4.0 mils)
Polyurethane Finish Coat 65 to 90 :m (2.5 to 3.5 mils)
Waterborne Acrylic Finish Coat 65 to 90 :m (2.5 to 3.5 mils)

 

The dry film thickness of each coating shall be measured in accordance with SSPC-PA2.

After preparation of the test panels with the coating system to be evaluated, the edges shall be sealed and protected by applying either electrical tape or a wax specially made for exposure testing.

The test panels which are specified to be scribed shall be scribed completely through the coating system to the base metal with a single "x" mark in accordance with ASTM D 1654. The "x" scribe shall be centered on the test panels with rectangular dimensions of 50 mm by 100 mm.

Upon completion of the resistance tests, the panels shall be evaluated in accordance with ASTM D 610 for rust, ASTM D 714 for blistering, ASTM D 4541 for adhesion, ASTM D 2244 Section 6.2 CIE 1976 L*a*b* )E for color, ASTM D 523 for specular gloss. Rust creepage from the scribe shall be measured and any form of delamination reported.

 (1) Fresh Water Resistance. ASTM D 870. Scribed panels immersed in fresh tap water at 23 " 3 EC (75 " 5 EF) for 30 days.

 (2) Salt Water Resistance. ASTM D 870. Scribed panels immersed in a solution of 5 percent sodium chloride at 23 " 3 EC (75 " 5 EF) for 30 days.

 (3) Weathering Resistance. ASTM D 4587 Method D utilizing UV A 340 bulbs. The unscribed panels shall be placed at the beginning of a wet cycle for 3000 hours of continuous exposure.

 (4) Cyclic Salt Fog Resistance. ASTM G85 Annex A5. The scribed panels shall be exposed for 4000 hours of continuous exposure.

 (5) Relative Humidity Resistance. ASTM D 2247. The scribed panels shall be exposed for 4000 hours of continuous exposure.

 (c) Resistance Test Acceptance Criteria. All test panels shall have a rust rating of six minimum, blister rating of six minimum with a frequency of few, maintain a minimum of 50 percent relative of the initial adhesion, Color change )E of 15 maximum, spectral gloss at 60E minimum of 60 percent relative of the initial gloss and maximum rust creepage of 6 mm from the scribe. Delamination of the finish coat on the unscribed portions of any test panel is unacceptable.

 (d) Inorganic Zinc Primers. Inorganic zinc primers shall meet the slip coefficient requirement of 0.5 minimum when tested in accordance with NEPCOAT Test No. 1.

 (e) Adhesion. The structural steel coating system shall meet the minimum adhesion test requirements when tested in accordance with NEPCOAT Test No. 6 of 18 kilograms per square centimeter for inorganic zinc primer systems and 42 kilograms per square centimeter for organic zinc primer systems.

 4. Approval of Structural Steel Coating Systems. The manufacturer shall obtain approval of each structural steel coating system prior to furnishing any of these coatings. An approved list of Structural Steel Coating System will be maintained by the Department. The list will specify the manufacturer's designation of each coating of the structural steel coating system. Manufacturers who desire to have products added to the List of Structural Steel Coating Systems shall submit the following documentation to the Materials and Tests Division.

a. A certified test report from an independent testing laboratory which provides test results for all quantitative requirements and resistance test requirement for each coating and for the coating system in these specifications. The test report shall include the manufacturer's name, brand name of each coating, formulation identification of each coating, batch numbers, beginning and ending dates of each test, date of manufacture for each coating, and the exact mass and volume ratio of each component used for mixing multiple component coatings.

b. Material safety data sheet for each coating.

c. Product data sheet for each coating. The product data sheets shall be in accordance with NEPCOAT specification criteria for protective coatings dated June 15, 1994.

d. Quality control plan which includes all aspects of the production process for each coating, starting with raw materials and concluding with the shipment of the finished products. The quality control plan shall include sampling and testing frequency and specific test used for the quality control of each product.

e. Documentation of quality assurance within the manufacturer's laboratory.

f. Performance history indicating that the specific coating system has performed successfully for a minimum of three years. The performance history shall include the name, address and telephone number of the structure owner including the name of a responsible contact person, location of the structure and dates of coating application and inspection.

(1) New products which do not have a three year field performance history may be accepted under an experimental basis. The coatings manufacturer shall provide a three year performance warranty for the coating material costs for each structure on all coating systems which are accepted on an experimental basis.

 

 5. Structural Steel Coating Systems Reapproval. Reapproval shall be required:

a. every seven years

b. each time there is a change in the formulation or the manufacturing process of each coating

c. if three consecutive years elapse without furnishing any of the approved coatings

d. when testing of the coating furnished indicate continual non-compliance with the specifications

e. when field evaluations indicate that the coating system does not provide the required protection to the structural steel