435 CLEANING AND PAINTING NEW STRUCTURAL STEEL

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435.01 DESCRIPTION
Clean and paint new structural steel used for work such as new construction, deck widening, and repairs that require installation of new structural steel. When the existing steel is not scheduled for repainting, this work will include repairing existing coatings damaged during the Contractor’s operations and areas where new steel ties into existing steel. When the existing steel is scheduled for repainting, refer to Section 436. When the new or existing steel is prepared by abrasive blast cleaning in the field, refer to Section 436 for containment and environmental monitoring requirements.
435.01.01 Areas to be Coated. Areas of shop cleaning and priming, and field cleaning and painting pertain to the following surfaces:
(a) Nonweathering Steel - All surfaces. Refer to 436.01.01(a).
(b) Weathering Steel
(1) The outside facing surfaces of the fascia stringers for all structures over roadways and for structures over water that contain curb openings. For dual structures, this includes the median fascia. These surfaces include the underside of the top flange, the web facing away from the structure, the top of the bottom flange, the outside edge of the bottom flange, the underside of the bottom flange, the inside edge of the bottom flange, and the top of the bottom flange on the inside facing surface up to and including the fillet weld. A sharp well defined transition between the new paint on the flange and the bare steel above the fillet is not required. Overspray onto the web is acceptable. All attached bearings are included in the cleaning and painting.
(2) At abutments, the end 10 ft of all stringers and all other structural steel within the 10 ft area (e.g., stiffeners, cross bracing, and bearings).
(3) At piers, 10 ft in each direction from the center line of the pier (giving a total length at each pier of 20 ft) and all other structural steel within the area.
(4) At bolted field splices, 12 in. beyond the longest splice plate for each particular splice and all splice material.
(5) All steel surfaces when specified. Refer to 436.01.01(a).
(c) Roadway Joints
(1) New Roadway Joints. Prior to any shop painting operations, clean all surfaces of the expansion dam and backwall angles. Apply the prime coat in the shop to the entire area of the backwall and expansion dam angles including those areas in contact with concrete, except the portion that is masked to receive adhesive for the seal.
(2) Existing Roadway Joints and New Portions. Prior to any painting operations on existing expansion joints and new steel used to modify them, all surfaces of the expansion dam angles and backwall angles to be painted or receive adhesive for the seal shall be thoroughly cleaned. The area that will be in contact with the seal shall then be completely masked for full length and depth of seal.
The backwall and expansion dam angles shall have all coats applied to the entire area that will be exposed in the finished structure, both above and below the seal.
435.01.02 General. Refer to 436.01.02.
435.01.03 Minimum Contracting Requirements for Field Painting. Refer to 436.01.03.
435.01.04 Minimum Contracting Requirements for Shop Painting. To be eligible to perform the work of removing and applying paint in a shop environment, certification as specified in (a) or (b) is required. All certificates shall be effective prior to Award of Contract and shall remain in effect for the duration of the Contract. Refer to 436.01.03.
(a) SSPC-QP3. Standard Procedure for Evaluating of Qualifications of Painting Contractors; Shop Application to Complex Structures.
(b) AISC 420-10. Certification Standard for Shop Application of Complex Protective Coating Systems.
435.01.05 Definition of Bridge. Refer to 436.01.04.
435.02 MATERIALS
Paint Systems 435.02.01 and 912.05
435.02.01 Paint Systems. Refer to 436.02.01.
New Steel (Includes New Structures, Repairs, and Widenings). The paint shall meet Paint System B. Touch up paint for the shop primer prior to Coats II and III shall conform to Coat I of Paint System C as approved by the coating manufacturer. The color of the finish coat shall match AMS-STD-595A, exact color as specified.
Existing Coatings Damaged Due to Steel/Deck Repairs or New Connections. Use spot coats of Coat I of Paint System H, and Coats II and III of Paint System B.
Bolts and Field Welds. Prime all bolts and field welds with Coat I of Paint System C prior to the application of Paint System B, Coats II and III.
Roadway Joints. The color of the finish coat shall conform to AMS-STD-595A, Color No. 26440.
(a) New Roadway Joints. 912.05, System B.
(b) Existing Roadway Joints and New Portions. 912.05, System E.
435.02.02 Abrasives. Refer to 436.02.02.
435.03 CONSTRUCTION
435.03.01 Submittals. Refer to 436.03.01.
435.03.02  Inspection Equipment. The shop and field Contractor shall provide for the exclusive use of the Engineer, the equipment for the QA observations of the Contractor’s cleaning and painting operations. Refer to 436.03.04.
435.03.03 Paint Quality Assurance (QA) Inspector Notification.
(a) Field. Refer to 436.03.05.
(b) Shop. Notify the Office of Materials Technology at least 5 working days prior to beginning cleaning and painting.
435.03.04 Floodlighting. Refer to 436.03.06.
435.03.05 Shop Priming of New Steel. Solvent clean, abrasive blast clean, and prime all new structural steel in the shop with Coat I of Paint System B. Perform blast cleaning and painting after all shop fabrication is complete.
435.03.06 Field Cleaning and Painting. Solvent clean, pressure wash, and hand/power tool clean the surfaces of the shop primed steel after it is erected. Follow with touch up using Coat I of Paint System C. Apply Coats II and III of Paint System B to all exposed structural steel in the completed structure. Follow the stripe coat schedule as specified in 436.03.21.
When new steel is added to existing steel and the existing steel is not scheduled for repainting, repair the existing coating at new steel connection points and at locations where the existing coating is damaged by the steel installation work. Solvent clean and hand/vacuum-shrouded power tool clean the surfaces. Follow with the spot application of the penetrating sealer of Paint System H and the spot application of Coats II and III of Paint System B.
435.03.07 Painting Sequence. Refer to 436.03.08.
435.03.08 Surface Preparation. Prepare surfaces as specified in 435.03.09(a) thru (h), the pertinent SSPC Specifications, and the Contract Documents. Surface conditions shall meet the pertinent SSPC VIS Standards. Surface preparation performed in the shop shall also meet 435.03.12.
435.03.09 Methods of Cleaning. Methods shown in the following table apply to both shop and field cleaning, and shall be performed in the order shown. The methods are invoked based on the paint system specified. Refer to 436.03.10 for methods of cleaning.
SUBSTRATE CONDITION PAINT SYSTEM METHODS OF CLEANING
Abrasive Blast Cleaned Steel. B (Coat I, II, and III) Shop coating - (a) and (h)
Shop touch up of damaged primer:

Damage extending to substrate - (f)

Damage not extending to substrate - (d) and (e)

Field coating of shop primed steel - (a) and (b), followed by localized repair of damage:

Damage extending to steel substrate - (f)

Damage not extending to substrate - (d) and (e)

Bolts and Field Welds C (Coat I)

B (Coat II and III)

Field - (a) followed by (d) and (e)
Existing Coatings Damaged Due to Steel Repair, New Connection, or Contractor’s Operations. H (Coat I)

B (Coat II and III)

Field - (a) followed by (d) and (e)
Existing Roadway Joints and Modified Portions E (Coat I, II, and III) Field - (a) followed by (f) or (h)
435.03.10 Base Metal Readings (BMR). BMR shall be obtained in the fabrication shop on the bare steel in conformance with SSPC-PA 2. Report this reading along with the dry film thickness readings from the shop for the shop applied coatings. If not obtained or reported, field inspectors will assume a 1.0 mil BMR in conformance with SSPC-PA 2.
435.03.11 Repair of Surface Imperfections. Refer to 436.03.13.
435.03.12 Surface Condition Prior to Painting. Refer to 436.03.15.
435.03.13 Paint Storage and Mixing. Refer to 436.03.16.
435.03.14 Paint Representative. Refer to 436.03.17.
435.03.15 Shop Priming and Field Finish Painting. Meet SSPC-PA 1 for painting application and 435.03.16 thru .21.
435.03.16 Restrictions for Shop and Field Painting. Apply shop paint at any time in an enclosed facility under controlled environmental conditions and according to the manufacturer’s recommendations.
(a) Apply shop paint at any time in an enclosed facility under controlled environmental conditions and according to the manufacturer's recommendations.
(b) For field painting, refer to 436.03.18.
435.03.17 Weather Requirements for Painting. Refer to 436.03.19.
435.03.18 Shop Application of Prime Coat. Apply the prime coat in the shop from agitated containers and as recommended by the manufacturer in a single application employing multiple spray passes. Apply the dry film thickness specified in 912.05, except reduce the thickness to approximately 1.0 mil within the areas of field welding and on the top and both edges of the top flange where steel stud shear developers will be attached. Measurements shall be according to SSPC-PA 2.
Remove all dry spray, runs, mud cracking, and damaged primer. Feather the area prior to touch up so that the repainted surface has a reasonably smooth appearance. Use organic zinc primer to touch up the inorganic zinc primer coat in the shop and field unless otherwise approved by the manufacturer and the Engineer. Ensure that touch ups have the same dry film thickness as the coat being repaired. Organic zinc may be applied by brush.
Primer used for areas designated as slip critical shall have been tested and approved for Slip B by an AASHTO National Transportation Product Evaluation Program (NEPEP) approved independent testing laboratory according to the Research Council on Structural Connections’ “Specification for Structural Joints Using High-Strength Bolts.” Provide certification for all thinners used in the primer.
435.03.19 Field Application of Prime, Intermediate, and Finish Coats. Prior to field coating, pressure wash the surfaces of the steel with potable water as specified in 436.03.10(b) to remove dirt and contaminants as described in 436.03.15.
Unless otherwise specified, apply Coats II and III after all field welded areas, bolted areas, and damaged primer coatings are cleaned and primed as specified or as directed.
Apply all paint according to the manufacturer’s recommendations except the dry film thickness shall conform to 912.05. Spray painting will be permitted provided the Engineer approves the location and method of spray application. Paint all areas adjacent to machinery and mechanical components, etc., by brush application unless the Engineer approves spray application. Paint surfaces inaccessible for painting by regular means by using sheepskin daubers or other means as necessary to ensure coverage of the proper coating thickness.
Maintain, calibrate, and adjust the thickness measuring instruments and take measurements according to SSPC-PA 2. Stripe coat all edges, outside corners, crevices, welds (including welds of fabricated members), rivets, bolts, nuts, and washers. Apply a stripe coat of the intermediate coat prior to the application of the full intermediate coat. Apply a stripe coat of the finish coat prior to the application of the full finish coat. Apply stripe coats by brush, dauber, or roller.
Ensure that each coat is free of shadow-through, skips, misses, and thin or heavy coating thickness. Repair defects prior to the application of the next coat. Keep the surface to be coated dust free during painting operations, and protect newly coated surfaces from the cleaning operations. If a previously cleaned area becomes soiled, contaminated, or rusted, reclean the area to the specified condition and completely recoat at no additional cost to the Administration.
Apply the finish coat within 30 days after the intermediate coat unless approved in writing by the paint manufacturer. If the recoat window is exceeded, reclean the surface as approved by the paint manufacturer and the Engineer.
435.03.20 Bolts and Field Welds. Do not shop coat bolts for field assembly. After field welding and prior to applying Coat II (first field coat) clean these bolts, field welds, and adjacent areas as specified in 435.03.09. Apply the first field coat (Coat II) within 24 hours of cleaning. Before Coat II is applied, solvent clean any prime coat stained from rusted bolts according to SSPC-SP 1.
435.03.21 Control of Overspray and Spills. Refer to 436.03.22.
435.03.22 Caulking. Refer to 436.03.23.
435.03.23 Defective Work. Refer to 436.03.24.
435.03.24 Repair of Coatings. Refer to 435.03.09.
435.03.25 Final Identification. Refer to 436.03.26.
435.03.26 Field Cleaning Waste Containment. Refer to 436.03.27.
435.03.27 Field Cleaning Containment System Plan Guidelines. Refer to 436.03.28.
435.03.28 Containment System Requirements by Method of Preparation. Refer to 436.03.29.
435.03.29 Worker Protection. Refer to 436.03.30.
435.03.30 Environmental Protection. Refer to 436.03.32.
435.03.31 Environmental Protection Plan of Action. Refer to 436.03.33.
435.03.32 Methods for Assessing Emissions. Refer to 436.03.34.
435.03.33 Field Cleaning Waste Disposal. Refer to 436.03.35.
435.03.34 Waste Handling Plan of Action. Refer to 436.03.36.
435.03.35 Waste Sampling and Analysis. Refer to 436.03.37.
435.03.36 Hazardous Waste Transportation and Disposal. Refer to 436.03.40.
435.03.37 Nonhazardous Waste Disposal. Refer to 436.03.41.
435.04 MEASUREMENT AND PAYMENT
The Contract unit price for the item specified will be full compensation for all cleaning and painting, scaffolding, platforms, containment systems, permits, working drawings, daily quality control records, professional engineer’s services used for containment, industrial hygienist services, air monitoring, sampling and testing of materials for toxic metal content, including any revisions and resubmissions that may be required during the execution of the work, providing safe access for inspections, hand wash station/clean up area, floodlighting, test plates, drums, collection and storage at the temporary storage site, hauling and disposal at an approved industrial waste site or hazardous waste site, removing and replacing planking, removal of debris, and all material, labor, equipment (including test equipment), tools, and incidentals necessary to complete the work.
435.04.01  Cleaning and painting new structural steel will not be measured but the cost will be incidental to the pertinent Fabricated Structural Steel item.
435.04.02  All costs associated with repair of existing coatings due to new connections and existing coatings damaged during steel/deck repairs will not be measured but will be incidental to the pertinent Repair, Structural Steel, or Cleaning and Painting items.