Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020)

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At least 28 days before beginning surface preparation, the Contractor shall submit a written plan for
acceptance that details the measures to be used for protecting the environment, public, adjacent
property, and workers. The Contactor shall include in the plan the following:

a. Manufacturer's material safety data sheets and product data sheets for all cleaning and

painting products.

b. A detailed containment plan for removed material, cleaning products, and paint debris. The

Contractor shall include details of attachment that do not require welding or drilling holes in
the existing structure. Connections with clamps or other approved devices shall be made.

c. A detailed disposal plan for removed material, cleaning products, and paint debris.
d. The Contractor shall include specific safety measures to protect workers from site hazards

including falls, fumes, fires, or explosions.

e. If paint being removed is a hazardous material, the Contractor shall include specific safety

measures to comply with 29 CFR 1926.62, 40 CFR 50.6, 40 CFR 50.12, and other 40 CFR
Parts 260-268.

f. Emergency spill procedures.
g. To perform quality control functions, the Contractor shall provide a competent person as

defined in SSPC-QP 2 with the following:

1. An SSPC Competent Person Certificate or equivalent subject to the E

ngineer’s

approval;

2. A certificate of completion of 29 CFR 1926.62 Lead in Construction training or

equivalent subject to the Engineer’s approval;

3. Minimum of 2 years industrial field painting experience;
4. Minimum of 90 days of field supervisory or management experience in paint removal

projects; and

Documentation of the individual’s qualifications including records of training and
experience.

The Contractor shall perform work according to the accepted plan. If the measures fail to perform as
intended, the Contractor shall immediately stop work and take corrective action. The Contractor shall
collect and properly dispose of all material including waste water that is used in preparing, cleaning,
or painting.

24.1.3

Protection of Work

Adjacent surfaces that are not to be painted shall be protected by using tarps, screens, paper, cloth,
or other suitable means. The Contractor shall prevent contamination of freshly-painted surfaces by
dust, oil, grease, or other harmful or deleterious material. Additionally, the Contractor shall protect
all parts of work under construction against disfigurement by splatters, splashes, and smirches of
paint materials.

Surfaces that are marred or damaged as a result painting operations shall be repaired by the
Contractor, at its expense, with materials and to a condition equal to that of the coating specified
herein.

If traffic causes an objectionable amount of dust to collect where the Contractor is conducting
painting operations, the Engineer may require the Contractor to sprinkle the adjacent roadbed and
shoulders with water or a dust palliative.

Upon completion of all painting operations, and of any other work that deposits dust, grease, or other
foreign materials on painted surfaces, the Contractor shall thoroughly clean the painted surfaces.
When structures are opened to public traffic, the Contractor shall have completed all painting and
surfaces shall be undamaged and clean.

24.1.4

Qualification Samples and Tests

The manufacturer shall supply, to an independent test laboratory and to the Owner, samples of the
paint system for evaluation. Prior to approval and use, the manufacturer shall submit a certification

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of the independent laboratory, together with results of all tests, stating that these materials meet the
requirements as set forth herein. The certified test report

shall state lots tested, manufacturer’s

name, product names, and dates of manufacture. New certified test results and samples for testing
by the Owner shall be submitted any time the manufacturing process or paint formulation is changed.
All costs of testing, other than tests conducted by the Owner, shall be borne by the manufacturer.

24.1.5

General Requirements for Surface Preparation

The surface preparation and application procedures shall be in accordance with instructions by the
paint manufacturer. The Contractor shall submit complete instructions by the paint manufacturer for
the preparation of all surfaces and the application of all final paint materials to the Engineer. The
Contractor shall also submit materials content data for each paint and performance data indicating
expected durability in the Abu Dhabi climate.

The Contractor shall notify the Engineer in writing at least 7 days before beginning operations.
Immediately before painting, the Contractor shall prepare the surface according to the following:

a. Clean the surface to the specified cleanliness level.
b. Remove dirt, dust, and other contaminants from the surface using methods recommended

by the paint manufacturer.

c. Thoroughly dry the surface.
d. Determine that the surface temperature is between 10

C and 32

e. Determine that the humidity is 85 percent or less, unless specified otherwise on the

manufacturer's product data sheet.

Suitable engineering controls such as enclosures and dehumidification may be used to provide the
conditions required above. Subject to the approval of the Engineer, the Contractor may provide a
suitable enclosure to permit painting during inclement weather. Such provisions shall artificially
control atmospheric conditions inside an enclosure within limits suitable for painting throughout the
painting operation.

Surfaces painted under cover in damp or cold weather shall remain under cover at no additional cost
until the paint dries or weather conditions permit open exposure.

All blast cleaning, except that performed within enclosed structures, and all painting shall be
performed during daylight hours unless the Contract documents specify otherwise.

24.1.6

General Requirements for Paint Application

The Contractor shall use safe handling practices that conform to the manufacturer's safety data
sheet and instructions. Paint shall be mixed and applied according to the product instructions. Paint
shall be mixed with mechanical mixers for a sufficient length of time to thoroughly blend the pigment
and vehicle together. Mixing shall be continued during application. The Contractor shall not thin paint
that is formulated ready for application.

The Contractor shall paint in a neat and workmanlike manner that does not produce excessive paint
build-up, runs, sags, skips, holidays, or thin areas in the paint film. The wet film thickness shall be
measured during application and the application rate shall be adjusted such that, after curing, the
desired dry film thickness (DFT) is obtained. Paint shall be applied by brush, spray, roller, or any
combination thereof if permitted by the manufacturer's product data sheet.

The Contractor shall use brushes that have sufficient bristle body and length to spread the paint in
a uniform film.

Airless or conventional spray equipment shall be used with suitable traps, filters, or separators to
exclude oil and water from the compressed air. The Contractor shall use compressed air that does
not show black or wet spots when tested according to ASTM D4285 - 83(2012). Spray gun tip sizes
and pressures recommended by the manufacturer shall be used.

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The Contractor shall use rollers only on flat, even surfaces. Rollers that leave a stippled texture in
the paint film shall not be used.

The Contractor shall use sheepskin daubers, bottle brushes, or other acceptable methods to paint
surfaces that are inaccessible for painting by regular means.

Each coat of paint shall be cured by the contractor according to the manufacturer's
recommendations. The Contractor shall correct all thin areas, skips, holidays, and other deficiencies
before the next application of paint. Succeeding applications of paint shall be tinted to contrast with
the paint being covered. The Owner shall approve the color for the finish coat before application.

Surfaces that will be inaccessible after erection shall be coated with the full number of undercoats
required before erection. After erection, the Contractor shall thoroughly clean all areas where the
undercoating is damaged or deteriorated, and shall spot coat these with the specified undercoats to
the required thickness before applying the final coat.

24.2

Reference Standards and Codes

All painting materials for which the Contract documents do not define specific requirements shall
comply with the requirements for applicable materials that are outlined in this section.

Standards and codes for painting shall be as specified in these specifications, in the Contract
documents, if any, and the following, in their latest edition:

AASHTO LRFD

American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Construction
Specifications;

AASHTO LRFD

American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Design Specifications;

AASHTO

Standard Specifications for Transportation Materials and Methods of
Sampling and Testing;

AAMA

American Architectural Manufacturers Association;

AAMA 2605-05

Voluntary Specification, Performance Requirements and Test
Procedures for Superior Performing Organic Coatings on Aluminum
Extrusions and Panels;

AAMA 620-02

Voluntary Specifications for High Performance Organic Coatings on
Coil Coated Architectural Aluminum Substrates Specifications and test
methods used to evaluate coil coatings on aluminium;

ADQCC (TR-516)

Road Structures Design Manual;

AISC

American Institute of Steel Construction;

AISC-420-10/

Certification Standard for Shop Application of Complex Protective
Coating

SPE-QP3

Systems;

APAS

Australian Paint Approval Scheme;

ASTM

American Society for Testing and Materials;

FED-STD-595B

Federal Standard 595B - Colors Used In Government Procurement;

FSS

Federal Specifications and Standards;

MIL-DTL-53022D

Detail Specification: Primer, Epoxy Coating, Corrosion Inhibiting Lead
and Chromate Free;

MIL-DTL-53039D

Detail Specification: Coating, Aliphatic Polyurethane, Single
Component, Chemical Agent Resistant;

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MIL-P-24441/1B

Military Specification Formula - Paint, Epoxy-Polyamide Green Primer,

Formula 150 Type 1;

NIST

National Institute of Standards and Technology;

OSHA

Occupational Safety and Health Administration;

SSPC

Steel Structures Painting Council;

SSPC-PA

Guide to Safety and Health Requirements;

Guide 10

SSPC-PA 1

Shop, Field, and Maintenance Painting of Steel;

SSPC-PA 2

Procedure for Determining Conformance to Dry Coating Thickness
Requirements;

SSPC-PS 28.02

Three Coat Moisture Cured Polyurethane Coating System,
Performance Based;

SSPC-SP 1

Solvent Cleaning;

SSPC-SP 2

Hand Tool Cleaning;

SSPC-SP 3

Power Tool Cleaning;

SSPC-SP 5

White Metal Blast Cleaning;

SSPC-SP 6

Commercial Blast Cleaning;

SSPC-SP 10/

Near-White Blast Cleaning;

NACE No. 2

SSPC-Paint 16

Coal Tar Epoxy-Polyamide Black (or Dark Red);

SSPC-Paint 20

Zinc-Rich Primers (Type I, Inorganic, and Type II, Organic);

SSPC-Paint 21

White or Colored Silicone Alkyd Paint;

SSPC Paint 22

Epoxy Polyamide Paints (Primer, Intermediate, and Topcoat);

SSPC-Paint 23

Latex Primer for Steel Surfaces;

SSPC-Paint 24

Latex Semigloss Exterior Topcoat;

SSPC-Paint 27

Basic Zinc Chromate-Vinyl Butyral Wash Primer;

SSPC-Paint 31

Single-Package Waterborne Alkyd Primer for Steel Surfaces,
Performance-Based;

SSPC-Paint 36

Two-Component Weatherable Aliphatic Polyurethane Topcoat,

Performance-Based;

SSPC-Paint 38

Single-Component Moisture-Cure Weatherable, A;

SSPC-Paint 40

Zinc-Rich Moisture-Cure Polyurethane Primer, P;

SSPC-Paint 41

Moisture-Cured Polyurethane Primer;

SSPC-Paint 104

White or Tinted Alkyd Paint;

SSPC QP2

Certification Program (Field Removal of Hazardous Coatings);

SSPC-AB 3

Ferrous Metallic Abrasive;

TT-P-645B

Federal Specification - Primer, Paint, Zinc-Molybdate, Alkyd Type;

NACE RP0178-

Standard Recommended Practice - Fabrication Details, Surface Finish

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2003 (21002)

Requirements and Proper Design Considerations for Tanks and
Vessels to be Lined for Immersion Service.

Table 24-1 and

Table 24-2 presents American Association of State Highway and Transportation Officials (AASHTO),
American Society for Testing and Materials (ASTM), British (BS), European (BS EN), and German
(DIN) Standards that are related to materials for painting works. It also includes designations and
titles.

Table 24-1: Designations and titles for AASHTO and ASTM standards that apply to painting

works

AASHTO
Designation

ASTM
Designation

Title

AASHTO T 277-
07 (2011)

ASTM C1202 -
12

Standard Test Method for Electrical Indication of
Concrete's Ability to Resist Chloride Ion Penetration

ASTM D4541 -
09e1

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

ASTM D4060 -
10

Standard Test Method for Abrasion Resistance of Organic
Coatings by the Taber Abraser

ASTM D3960 -
05

Standard Practice for Determining Volatile Organic
Compound (VOC) Content of Paints and Related Coatings

ASTM C642 -
06

Standard Test Method for Density, Absorption, and Voids
in Hardened Concrete

ASTM D2697 -
03(2008)

Standard Test Method for Volume Nonvolatile Matter in
Clear or Pigmented Coatings

AASHTO M
300-03 (2012)

Standard Specification for Inorganic Zinc-Rich Primer

ASTM D520 -
00(2011)

Standard Specification for Zinc Dust Pigment

ASTM D609 -
00(2012)

Standard Practice for Preparation of Cold-Rolled Steel
Panels for Testing Paint, Varnish, Conversion Coatings,
and Related Coating Products

ASTM G7 /
G7M - 13

Standard Practice for Atmospheric Environmental
Exposure Testing of Nonmetallic Materials

ASTM G152 -
13

Standard Practice for Operating Open Flame Carbon Arc
Light Apparatus for Exposure of Nonmetallic Materials

ASTM G153 -
13

Standard Practice for Operating Enclosed Carbon Arc Light
Apparatus for Exposure of Nonmetallic Materials

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AASHTO
Designation

ASTM
Designation

Title

ASTM G154 -
12a

Standard Practice for Operating Fluorescent Ultraviolet
(UV) Lamp Apparatus for Exposure of Nonmetallic
Materials

ASTM B117 -
11

Standard Practice for Operating Salt Spray (Fog)
Apparatus

ASTM D3359 -
09e2

Standard Test Methods for Measuring Adhesion by Tape
Test

ASTM D4285 -
83(2012)

Standard Test Method for Indicating Oil or Water in
Compressed Air

ASTM D4417 -
11

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

ASTM A36 /
A36M - 12

Standard Specification for Carbon Structural Steel

ASTM D1654 -
08

Standard Test Method for Evaluation of Painted or Coated
Specimens Subjected to Corrosive Environments

ASTM A325M -
13

Standard Specification for Structural Bolts, Steel, Heat
Treated 830 MPa Minimum Tensile Strength (Metric)

ASTM A490M -
12

Standard Specification for High-Strength Steel Bolts,
Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)

ASTM D823 -
95(2012)e1

Standard Practices for Producing Films of Uniform
Thickness of Paint, Varnish, and Related Products on Test
Panels

ASTM D2805 -
11

Standard Test Method for Hiding Power of Paints by
Reflectometry

ASTM D1730 -
09

Standard Practices for Preparation of Aluminum and
Aluminum-Alloy Surfaces for Painting

AASHTO R 31-
09

Standard Practice for Evaluation of Coating Systems for
Structural Steel

ASTM D5894 -
10

Standard Practice for Cyclic Salt Fog/UV Exposure of
Painted Metal, (Alternating Exposures in a Fog/Dry Cabinet
and a UV/Condensation Cabinet)

ASTM A123 /
A123M - 12

Standard Specification for Zinc (Hot-Dip Galvanized)
Coatings on Iron and Steel Products

ASTM B330-12

Standard Test Methods for Estimating Average Particle
Size of Metal Powders and Related Compounds Using Air
Permeability

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AASHTO
Designation

ASTM
Designation

Title

ASTM D2794 -
93(2010)

Standard Test Method for Resistance of Organic Coatings
to the Effects of Rapid Deformation (Impact)

ASTM D522 -
93a(2008)

Standard Test Methods for Mandrel Bend Test of Attached
Organic Coatings

ASTM D610 -
08(2012)

Standard Practice for Evaluating Degree of Rusting on
Painted Steel Surfaces

ASTM D714 -
02(2009)

Standard Test Method for Evaluating Degree of Blistering
of Paints

ASTM D2244 -
11

Standard Practice for Calculation of Color Tolerances and
Color Differences from Instrumentally Measured Color
Coordinates

ASTM D523 -
08

Standard Test Method for Specular Gloss

ASTM D543 -
06

Standard Practices for Evaluating the Resistance of
Plastics to Chemical Reagents

ASTM D638 -
10

Standard Test Method for Tensile Properties of Plastics

ASTM D1894 -
11e1

Standard Test Method for Static and Kinetic Coefficients of
Friction of Plastic Film and Sheeting

ASTM D149 -
09(2013)

Standard Test Method for Dielectric Breakdown Voltage
and Dielectric Strength of Solid Electrical Insulating
Materials at Commercial Power Frequencies

ASTM D2240 -
05(2010)

Standard Test Method for Rubber Property

—Durometer

Hardness

ASTM D5796 -
10

Standard Test Method for Measurement of Dry Film
Thickness of Thin Film Coil-Coated Systems by Destructive
Means Using a Boring Device

ASTM D624 -
00(2012)

Standard Test Method for Tear Strength of Conventional
Vulcanized Rubber and Thermoplastic Elastomers

ASTM C672 /
C672M - 12

Standard Test Method for Scaling Resistance of Concrete
Surfaces Exposed to Deicing Chemicals

ASTM D412 -
06a(2013)

Standard Test Methods for Vulcanized Rubber and
Thermoplastic Elastomers

—Tension

ASTM D4263 -
83(2012)

Standard Test Method for Indicating Moisture in Concrete
by the Plastic Sheet Method

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Table 24-2: Designations and titles for BS, and BS EN, and DIN standards that apply to

painting works

BS & BS EN

Designation

DIN
Designation

Title

BS 1881-122:2011

Testing concrete Method for determination of water
absorption

BS 1881-124:1988

Testing concrete Methods for analysis of hardened
concrete

BS 3177:1959

Method for determining the permeability to water vapour of
flexible sheet materials used for packaging

12390-

8:2009

Testing hardened concrete. Depth of penetration of water
under pressure

DIN 53122-1
(2001-08)

Determination of the water vapour transmission rate of
plastic film, rubber sheeting, paper, board and other sheet
materials by gravimetry

BS EN ISO
2808:2007, BS
3900-C5:2007

Paints and varnishes. Determination of film thickness

ISO 19840:2012

Paints  and  varnishes  -  Corrosion  protection  of  steel
structures  by  protective  paint  systems  -  Measurement  of,
and  acceptance  criteria  for,  the  thickness  of  dry  films  on
rough surfaces

BS EN 1504-
9:2008

Products  and  systems  for  the  protection  and  repair  of
concrete  structures.  Definitions,  requirements,  quality
control and evaluation of conformity - General principles for
use of products and systems

24.3

Painting Structural Iron and Steel Surfaces

24.3.1

General

All painting work shall consist of preparing the surfaces, furnishing and applying paint to all iron and
steel surfaces of structures or portions thereof that are designated to be painted unless otherwise
indicated on the Contract plans. The Contractor shall include the protection from paint spatter and
disfigurement of adjacent or nearby structures, and final cleanup, all in accordance with these
standard specifications and requirements of Contract documents.

All paint materials applied to structural iron and steel works shall comply with the following
requirements unless otherwise specified herein, indicated on the Contract plans, or specified in the
Particular Specifications.

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1. All coating systems shall be stored, thinned, handled, mixed and applied in accordance with

SSPC-PA 1, Shop, Field and Maintenance Painting of Steel, and the recommendations on
the Manufacturer’s product data sheets.

2. All paint furnished shall be shipped in strong, substantial containers, plainly marked with the

following:

•

Trade name or trade mark;

•

Paint type, color, formulation, lot number, and date of manufacture;

•

Net mass;

•

Volume including the percent of solids and the percent of volatile organic compound (VOC);

•

Storage requirements;

•

Mixing instructions and equipment cleanup instructions; and

•

Name and address of the manufacturer.

3. The paint shall not show excessive settling in a freshly-opened full can, and shall easily be

re-dispersed with a paddle to a smooth, homogeneous state. The paint shall show no
curdling, livering, caking or color separation, and shall be free from lumps and skins.

4. The paint as received shall brush easily, possess good leveling properties, and show no

running or sagging tendencies when applied to smooth steel vertical surfaces.

5. The paint shall not skin within 48 hours in a three-quarters-filled closed container.
6. The paint shall dry to a smooth uniform finish, free from roughness, grit, unevenness, and

other surface imperfections. The paint shall show no streaking or separation when flowed on
clean glass.

7. The paint shall show no thickening, curdling, gelling, or hard caking after six months storage

in a full, tightly-covered container at a temperature of 21°C.

24.3.1.1

Compatibility

Each coating in the paint system shall be supplied by the same paint manufacturer.

24.3.1.2

Toxicity

Each coating shall contain less than 0.01 percent lead in the dry film and no more than trace amounts
of hexavalent chromium, cadmium, mercury or other toxic heavy metals.

24.3.1.3

Volatile Organics

The volatile organic compounds (VOC) content shall conform to the following VOC limits for both
shop and field painting:

a. Clear (unpigmented) coatings 1.68 kg per gallon max.
b. Other coatings 1.31 kg per gallon max.

More stringent limits shall be applied if required by SSPC-PA Guide 10, OSHA or local regulations.

24.3.1.4

Color

The Contractor shall furnish a contrasting color for each coat of paint. The finish coat color shall
conform to FED-STD-595B or Classic RAL System as approved by the Owner. The Contractor shall
provide color chips from the paint supplier.

24.3.1.5

Performance Requirements

Unless otherwise specified in this chapter, the Contractor shall prepare and submit to the Owner four
composite and four flat-scribed test panels in accordance with AASHTO R 31-09. In addition, the
Contractor shall submit 1 liter wet samples of each component of each coating incorporated in the
system being evaluated. Panels shall subject to outdoor exposure testing in accordance with ASTM
G7 / G7M - 13.

All coatings, regardless of color, shall meet the requirements below as shown in Table 24-3.

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Table 24-3: Performance requirements of coatings

Laboratory Testing

Property

Test Method

Requirement

Slip Coefficient

AASHTO R 31-09

Min. Class B (primer only)

Salt

Fog

Resistance

AASHTO R 31-09

Blister Size = 10

Average Rust Creep at the
Scribe ≤ 2.5 mm

Cyclic Weathering
Resistance

AASHTO R 31-09

Blister Size = 10

Average Rust Creep at the
Scribe ≤ 5.0 mm

Color Retention ΔE ≤ 8,

Gloss loss less than 30 units

Abrasion
Resistance

AASHTO R 31-09

Wear Index ≤ 2.7 mg/cycle

Adhesion

AASHTO R 31-09

Avg. system tensile strength ≥
5.52 MPa

Freeze

Thaw

Stability

AASHTO R 31-09

Avg. tensile strength ≥ 5.52 MPa

Coatings
Identification

Fourier

Transform

Infrared

Spectroscopy

IR scan (2.5 to 15 um) for each
base,

catalyst,

and

mixed

coating.

Impact Resistance

ASTM D2794 - 93(2010)

Greater than 1400 mm/kg

, 1/2”

impact, intrusion

Flexibility

AASHTO R 31-09, ASTM D522 -
93a(2008), 25 mm cylindrical mandrel

No cracking

Outdoor Testing

Rusting

ASTM D610 -08(2012)

ASTM D1654 - 08 (scribed)

ASTM D1654 - 08 (un-scribed)

≥ 9 after 5 years

Blistering

ASTM D714 - 02(2009)

10 after 5 years

Adhesion

ASTM D4541 - 09e1; annex A4

≥ 5.52 MPa (un-scribed area)
after 5 years

Color Retention

ASTM D2244 - 11

ΔE ≤ 8 after 2 years

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Laboratory Testing

Property

Test Method

Requirement

Gloss

ASTM D523 - 08

≤ 30 gloss units after 2 years

24.3.2

Paint Systems for New External Visible Surfaces or Surfaces
with All Existing Paint Removed

All structural iron and steel shall be painted with one of the following systems as shown in Table
24-4. The required system or choice of systems shall be shown on the Contract plans or in the
Particular Specifications.

If not indicated on the Contract plans or specified in the Particular Specifications, the paint system
applied to all structural iron and steel surfaces shall be System No. 2, Zinc Rich Epoxy System.

Table 24-4: Structural iron and steel coating systems for new surfaces and surfaces with all

existing paint removed

Coat

Paint System

Aggressive

Environments

Aggressive

Environments

Aggressive

Environments

Less
Aggressive

Environments

Less
Aggressive

Environments

Primer

Inorganic zinc
Silicate

4-5 mils DFT

Zinc-rich
epoxy

4-5 mils DFT

Aromatic
Moisture-
cured

Polyurethane

3-4 mils DFT

Acrylic latex

2-3 mils DFT

Low

VOC

alkyd

3-4 mils DFT

Intermediate

Epoxy
Polyamide

3-5 mils DFT

Epoxy
Polyamide

3-5 mils DFT

Aromatic
Moisture-
cured

Polyurethane

3-5 mils DFT

Acrylic latex

2-3 mils DFT

Low

VOC

alkyd

3-4 mils DFT

Top Coat

Aliphatic
Polyurethane
Acrylic

2-3 mils DFT

Aliphatic
polyurethane
Acrylic

2-3 mils DFT

Aliphatic
Moisture-
cured

Polyurethane

2-3 mils DFT

Acrylic latex

2-3 mils DFT

Low

VOC

silicone-alkyd

2-3 mils DFT

Total
Thickness

9-13 mils DFT

8-12 mils DFT 6-9 mils DFT

8-11 mils DFT

Note 1: System 1, 2, or 3 is for the corrosion protection of iron and steel in aggressively corrosive
atmospheric environments such as marine, coastal, or industrial. System 4 or 5 is for use in those
environments with less humidity and free from high concentrations of salts or pollutants that cause
aggressive corrosion environments.

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Note 2: Dry Film Thickness (DFT).

24.3.2.1

Paint System No. 1 - Inorganic Zinc Silicate System

Paint System No. 1 shall consist of the following:

1. Primer coat on bare steel (not galvanized):

Inorganic zinc silicate paint shall be a two-

component self-curing type conforming to SSPC-Paint 20, Type I, which, when mixed, cures
without the use of a separate curing solution, and shall have the properties described herein.

Pigment:

The zinc pigment component shall comply with the requirements of ASTM D520 - 00(2011)

for Type II. The average particle size of the zinc powder shall not exceed 10 microns as determined
by the Fisher Sub-sieve Sizer and in accordance with ASTM B330-12.

Vehicle:

The vehicle component shall consist primarily of an alkyd silicate in an appropriate alcohol

solvent. Total solids, by content shall be determined by drying the sample to a constant weight at
100°C.

Mixed paint shall comply with the following requirements:

The zinc portion shall be at least 75 percent by weight of the total solids of the dried
coating.

ii.

The total solids, when heated at 100°C for 3 hours, shall be not less than 72 percent by
weight.

iii.

The paint shall tolerate up to one percent water contamination without gellation.

iv.

The usable pot life of the mixed paint shall be not less than 12 hours at 25°C. There shall
be no hard settling which cannot be easily re-dispersed during this period.

The inorganic zinc coating shall be so formulated as to produce a distinct contrast in color
with the blast cleaned iron and steel surfaces and with the topcoat.

Tests:

Test panels of the iron and steel, meeting the requirements of ASTM D609 - 00(2012) having

dimensions of 5 cm x 13 cm x 3 mm, shall be prepared by thoroughly cleaning all surfaces. A 3-4
mils coating (DFT) shall then be applied to the test panels in accordance with the manufacturer's
current printed instruction. The coating shall be cured as recommended by the manufacturer. Each
of the following tests shall be performed on a minimum of three panels. The material will not be
accepted if any individual test panel fails any of the following tests:

Fresh Water Resistance: Panels shall be scribed down to base metal with an X of at least
5 cm legs and shall be immersed in fresh tap water at 24°C + 2°C. The panels shall show
no rusting, blistering, or softening when examined after 30 days.

ii.

Salt Water Resistance: Panels shall be scribed down to base metal with an X of at least 5
cm legs and immersed in 5 percent sodium chloride at 24°C + 2°C at 7, 14 and 30 days.
The sodium chloride solution shall be replaced with fresh solution after each examination.

iii.

Weathering Resistance: Panels shall be tested in accordance with ASTM G152

– 13 and

ASTM G153 - 13, Type D. The panels shall be placed on test at the beginning of the wet
cycle. After 1,000 hours continuous exposure, the coating shall show no rusting, loss of
adhesion to the steel test panel, or blistering.

iv.

Weather and Salt Fog Resistance: Panels shall be tested in the weatherometer as
specified in (iii) for 300 hours. After this period the panels shall be removed and scribed
with an X of at least 5 cm legs down to base metal. The test panels shall then be tested in
accordance with ASTM B117 - 11. After 1,000 hours of continuous exposure, the coating
shall show no loss of bond, nor shall it show rusting or blistering beyond 2 mm from the
center of the scribe mark.

Resistance to Elevated Temperatures and Thermal Shock: Panels shall be exposed to a
temperature of 260°C for one hour, then quenched immediately in 18°C + 2°C water.
Panels subjected to this test shall show no blistering or flaking of the coating.

vi.

Adhesion panels shall be tested in accordance with ASTM D3359 - 09e2 and shall attain
a rating of 3 or greater.

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vii.

Mud Cracking Resistance: The coating when applied to test panels as above to a 5 to 6
mils DFT shall show no mud cracking when viewed under 10-X magnification.

The manufacturer and Brand Name Approval for Inorganic Zinc Primer: Prior to approval and use of
inorganic zinc, the Contractor shall submit in triplicate to the Engineer a certified test report from an
approved independent testing laboratory showing specific test results complying with all quantitative
and resistance test requirements specified. The certified test report shall also contain the exact ratio,
by weight, of the pigment component to the vehicle component of the paint used for the tests, the lot
tested, the manufacturer's name, brand name of paint, and date of manufacture.

New certified test results shall be submitted whenever the manufacturing process or the paint
formulation is changed, and may be required by the Engineer when sampling and testing of material
offered for use indicates noncompliance with any of the requirements herein specified.

2. Intermediate Coat:

On surfaces prepared with primer as specified in Paragraph 1 of Article

24.3.2.1, an intermediate coat of high-build epoxy polyamide conforming to SSPC Paint 22
shall be applied as recommended by the manufacturer in a single application employing
multiple spray passes. The color of the intermediate coat shall contrast with both the primer
and top coat. The intermediate coat shall comply with MIL-P-24441/1B, Formula 150.

3. Top Coat:

Top coat shall be an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36,

applied  as  recommended  by  the  manufacturer  in  a  single  application  employing  multiple
spray  passes.  The  aliphatic  polyurethane  acrylic  shall  comply  with  the  following  minimum
requirements:
Solids

45.0% by volume

Pigment

19.7% by weight

Non-volatile vehicle

36.4% by weight

(Acrylic resin - 25.8% by weight)
(Polyurethane resin - 8.3% by weight)
(Additives - 2.3% by weight)
The Contractor shall submit top coat color chips for selection of color by the Engineer.

24.3.2.2

Paint System No. 2

– Zinc Rich Epoxy System

Paint System No. 2 shall consist of the following:

1. Primer coat on bare steel (not galvanized):

Zinc-rich epoxy paint shall be a two-

component, high solid zinc-rich, (part A + part B) epoxy primer, conforming to composition
and performance requirements of SSPC-Paint 20 standard. It shall comply with the following
minimum requirements:
Solids

62+2% by volume

Gloss at 60ºC

Matt.

Recommended thinner

4-100

All materials shall be applied in accordance with the manufacturer's directions. The
Contractor shall prepare the surface to achieve a 30-50 microns profile. The Contractor shall
stir well before application and while painting. Zinc-rich epoxy primer shall not be applied
when temperature falls below 10ºC.

2. Intermediate coat:

an intermediate coat of high-build epoxy polyamide conforming to SSPC-

Paint 22 shall be applied as per Paragraph 2 of Article 24.3.2.1.

3. Top coat:

op coat of an aliphatic polyurethane acrylic conforming to SSPC-Paint 36 shall

be applied as per Paragraph 3 of Article 24.3.2.1.

24.3.2.3

Paint System No. 3

– Moisture Cured Polyurethane System

The moisture cured polyurethane paint system shall consist of an aromatic moisture cured
polyurethane primer, an aromatic moisture cured polyurethane intermediate coat, and aliphatic
moisture cured polyurethane top coats conforming to the performance requirements of SSPC-PS
28.02. It is intended for field painting blast-cleaned existing structures.

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1. Zinc - Rich moisture cured polyurethane Primer Requirements:

The material shall be a single component zinc-rich aromatic moisture cured
polyurethane primer conforming to the performance requirements of SSPC-Paint 40.
It shall be suitable for topcoating with polyurethanes.

ii.

The zinc dust pigment shall be according to ASTM D520 - 00(2011), Type II.

iii.

The organic zinc coating shall meet a Class B AASHTO LRFD Bridge Design
Specifications slip coefficient (0.50 or greater) for structural steel joints using ASTM
A325M

– 13 or ASTM A490M - 12 bolts.

iv.

The adhesion to an abrasively blasted steel substrate shall not be less than 6.2 MPa
when tested according to ASTM D4541 - 09e1 Annex A4.

2. Intermediate Coat Requirements:

The material shall be a single component aromatic moisture cured polyurethane
conforming to SSPC-Paint 41. It shall be suitable as an intermediate coat over the
primer and compatible with the top coat.

ii.

The color of the intermediate coat shall provide a distinct contrast between the primer
and the finish coat.

3. Polyurethane Top Coat Requirements:

The material shall be a single component aliphatic moisture cured polyurethane
conforming to SSPC-Paint 38. It shall be suitable as a topcoat over the intermediate
coat.

ii.

The top coat color shall be as specified in the Contract documents and as approved
by  the  Owner  conforming  to  FED-STD-595B  or  Classic  RAL  System.  The  color
difference  shall  not  exceed  3.0  Hunter  Delta  E  Units.  Color  difference  shall  be
measured by instrumental comparison of the designated standard to a minimum DFT
of 3 mils (75 microns) of sample coating produced on a test panel according to ASTM
D823  -  95(2012)e1,  Practice  E,  Hand

–Held, Blade Film Application. Color

measurements  shall  be  determined  on  a  spectrophotometer  with  45  degrees
circumferential/zero  degrees  geometry,  illuminant  C,  and  two  degrees  observer
angle.  The  spectrophotometer  shall  measure  the  visible  spectrum  from  380-720
nanometers with a wavelength interval and spectral bandpass of 10 nanometers.

The contrast ratio of the finish coat at 3 mils DFT shall not be less than 0.99 when tested
according to ASTM D2805 - 11.

iii.

Test panels shall be aluminum alloy measuring 300 x 100 mm prepared according to
ASTM D1730

– 09 Type A, Method 1 Solvent Cleaning. A minimum dry film thickness

of 3 mils of top coat shall be applied to three test panels according to ASTM D823 -
95(2012)e1, Practice E, Hand Held Blade Film Application. The coated panels shall
be cured at least 30 days and not more than 45 days at 25 °C ± 2 °C and 65 ± 5
percent relative humidity. The panels shall be subjected to 300 hours of accelerated
weathering using the light and water exposure apparatus (fluorescent UV -
condensation type) as specified in ASTM G154 - 12a (equipped with UVB-313 lamps).
The cycle shall consist of eight hours UV exposure at 60 °C followed by four hours of
condensation at 40 °C. After exposure, the panel shall be rinsed with clean water and
allowed to dry at room temperature for one hour. The exposed panels shall not show
a color change of more than 3 Hunter Delta E Units.

4. Test Panel Preparation:

Test panels shall be ASTM A36 / A36M - 12, hot-rolled steel measuring 100 x 150
mm. Panels shall be blast-cleaned per SSPC

–SP5 white metal condition using

recyclable metallic abrasive according to SSPC-AB3. The abrasive shall be a 60/40
mix of shot and grit. The shot shall be an SAE shot number S230 and the grit an SAE
number G40. Hardness of the shot and grit shall be Rockwell C45. The anchor profile
shall be 1.5-2.5 mils measured according to ASTM D4417 - 11, Method C.

ii.

All coatings shall be spray applied at the manufacturer's recommended film thickness.
The coated panels shall be cured at least 30 days and not more than 45 days at 25
°C ± 2 °C and 65 ± 5 percent relative humidity.

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iii.

The test panels shall be scribed according to ASTM D1654

– 08 with a single “X”

mark centered on the panel. The rectangular dimensions of the scribe shall have a
top width of 50 mm and a height of 100 mm. The scribe cut shall expose the steel
substrate as verified with a microscope.

iv.

All testing shall be performed on triplicate panels as per the testing requirements of
Paragraph 5 of Article 24.3.2.3 .

5. Testing Requirements:

For testing purposes, the color of the top coat shall match FED-STD-595B, color chip
14062 (green), as approved by the Owner.

ii.

Salt fog when tested according to ASTM B117

– 11 and evaluated according to

AASHTO R 31-09, the paint system shall exhibit no spontaneous delamination and
not exceed the following acceptance levels shown in Table 24-5 after 5,000 hours of
salt fog exposure.

Table 24-5: Acceptance levels for salt fog

Salt Fog Acceptance Criteria (max.)

Blister Conversion Value

Rust Criteria

After 4000 Hours

Maximum Creep

Average Creep

6 mm

2 mm

iii.

Cyclic exposure when tested according to ASTM D5894

– 10 and evaluated

according to AASHTO R 31-09, the paint system shall exhibit no spontaneous
delamination and not exceed the following acceptance levels shown in Table 24-6
after 5,040 hours of cyclic exposure.

Table 24-6: Acceptance levels for cyclic exposure

Cyclic Exposure Acceptance Criteria (max.)

Blister Conversion Value

Rust Criteria

Maximum Creep

Average Creep

13 mm

7 mm

iv.

The adhesion to an abrasively blasted steel substrate shall not be less than 6.2 MPa
when tested according to ASTM D4541 - 09e1 Annex A4.

24.3.2.4

Paint System No. 4

– Acrylic Latex System

Paint System No. 4 shall consist of the following:

1. Primer coat on bare steel (not galvanized):

Acrylic latex primer, conforming to composition

and performance requirements of SSPC-Paint 23 standard.

Intermediate coat:

an intermediate coat of acrylic latex conforming to SSPC Paint 24 shall

be applied.

2. Top coat:

op coat of acrylic latex conforming to SSPC-Paint 24 shall be applied.

24.3.2.5

Paint System No. 5

– Low VOC Alkyd System

Paint System No. 5 shall consist of the following:

1. Primer coat on bare steel (not galvanized):

Low VOC Alkyd primer, conforming to

composition and performance requirements of SSPC-Paint 31 standard.

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2. Intermediate coat:

an intermediate coat of Low VOC alkyd conforming to SSPC- Paint 104

shall be applied.

3. Top coat:

op coat of Low VOC silicone alkyd conforming to SSPC-Paint 21 shall be

applied.

24.3.3

Paint Systems for Surfaces with Existing Sound Paint

The Contractor shall furnish one of the paint systems shown in Table 24-7. The required system or
choice of systems shall be shown on the Contract plans or in the Particular Specifications.

If not indicated on the Contract plans or specified in the Particular Specifications, the paint system
applied to all painted structural iron and steel surfaces shall be Paint System No. 6 Moisture-cured
Polyurethane System.

The Contractor shall confirm the selected paint system is compatible with the existing paint.

At least 14 days before ordering paint, the Contractor shall verify compatibility of the proposed
system with the existing system as follows:

a. Select a test area of at least 2.8 square meter in a condition representative of the condition

of the structure. Perform the specified level of surface preparation, and apply the proposed
system to the existing topcoat and to the existing primer. Observe for lifting, bleeding,
blistering, wrinkling, cracking, flaking, or other evidence of incompatibility.

b. Verify that no indication of incompatibility exists at least 14 days after the application of each

product.  Perform  adhesion  tests  according  to  ASTM  D3359  -  09e2,  method  A.  Notify  the
Owner  immediately  if  adhesion  testing  fails  at  the  interface  of  the  existing  system  and
substrate  or  between  the  existing  finish  coat  and  primer.  An  adhesion  failure  indicates
incompatibility. Choose a more compatible paint system.

Table 24-7: Structural iron and steel coating systems for surfaces with existing sound paint

Coat

Paint System

Aggressive

Environments

Less

Aggressive

Environments

Less

Aggressive

Environments

Primer

Aromatic

Moisture-cured

Polyurethane

2-3 mils DFT

Low VOC alkyd

2-3 mils DFT

Low viscosity epoxy
sealer

1-2 mils DFT

Intermediate

Aromatic

Moisture-cured

Polyurethane

2-3 mils DFT

Low VOC alkyd

2-3 mils DFT

Epoxy

3-4 mils DFT

Top Coat

Aliphatic

Moisture-cured

Polyurethane

2-3 mils DFT

Low

VOC

silicone-

alkyd

2-3 mils DFT

Aliphatic

Polyurethane

2-3 mils DFT

Total
Thickness

6-9 mils DFT

Note 1: System 6 is for the corrosion protection of iron and steel in aggressively corrosive
atmospheric environments such as marine, coastal, or industrial. System 7 or 8 is for use in those

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environments with less humidity and free from high concentrations of salts or pollutants that cause
aggressive corrosion environments.

Note 2: Dry Film Thickness (DFT).

24.3.3.1

Paint System No. 6

– Moisture Cured Polyurethane System

The  moisture  cured  polyurethane  paint  system  No.  6  shall  consist  of an aromatic moisture cured
polyurethane  primer,  an  aromatic  moisture  cured  polyurethane  intermediate  coat,  and  aliphatic
moisture  cured  polyurethane  top  coats  conforming  to  the  requirements  of  Article  24.3.2.3.  It  is
intended for field painting blast-cleaned existing structures.

24.3.3.2

Paint System No. 7

– Low VOC Alkyd System

The low VOC alkyd paint system No. 7 shall consist of Low VOC Alkyd primer, Low VOC Alkyd
intermediate coat, and a Low VOC silicone alkyd top coats conforming to the requirements of Article
24.3.2.324.3.2.5.

24.3.3.3

Paint System No. 8

– Low Viscosity Epoxy System

Paint System No. 8 shall consist of the following:

1. Primer coat:

Two-pack low viscosity epoxy sealer with a polyamide or similar curing agent

conforming to the manufacturer recommendations and approved to APAS Specification
2971. It shall be physically and chemically compatible with the existing sound paint and later
coatings in the system.

2. Intermediate coat:

an intermediate coat of epoxy polyamide conforming to SSPC- Paint 22

shall be applied.

3. Top coat:

op coat of an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36 and

Paragraph 3 of Article 24.3.2.1 shall be applied.

24.3.4

Paint System No. 9 for New Internal Invisible Surfaces

Paint System No. 9 shall consist of the following:

1. Primer coat:

Inorganic zinc dust pigment shall be a minimum of Type II in accordance with

ASTM D520 - 00(2011). Inorganic zinc rich primer shall meet the requirements of SSPC-
Paint 20, Type I, Level 2.

2. Top Coat

: The top coat shall be one coat of white polyamide or cycloaliphatic amine epoxy

coating. The performance requirements for gloss and color retention are not applicable.

24.3.5

Surface Preparation of Iron and Steel Surfaces

All exposed structural iron and steel surfaces, except galvanised or metallised surfaces, shall be
cleaned and painted.

The Contractor shall not remove sound paint of existing structures unless specifically required by
the Contract documents.

24.3.5.1

New surfaces or Surfaces with all Existing Paint Removed

New surfaces of iron and steel to be painted, including galvanized surfaces and surfaces with paint
removed, shall be thoroughly cleaned to the condition specified herein by removing rust, loose mill
scale, welding slag, dirt, oil, grease, and other foreign substances.

The Contractor shall remove all dirt, mill scale, rust, paint, and other foreign material from exposed
surfaces by Blast Cleaning in accordance with Article 24.3.5.3, Method D, unless otherwise specified
in the Contract documents or approved in writing by the Engineer.

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The Contractor shall use compressed air that is free from oil or moisture and does not show black
or wet spots when tested according to D4285 - 83(2012). Unwashed sand or abrasives that contain
salts, dirt, oil, or other foreign matter shall not be used. Before blast cleaning near machinery, the
Contractor shall seal bearings, journals, motors, and moving parts against entry of abrasive dust.

The Contractor shall blast clean with clean dry slag, mineral grit, steel shot, or steel grit. A suitable
gradation shall be used to produce a dense, uniform anchor pattern. An anchor profile height of 1 to
2 mils shall be produced, but not less than that recommended by the paint system manufacturer's
product data sheet. The Contractor shall measure anchor profile height using the tape method
according to ASTM D4417 - 11.

The same day cleaning is performed, the Contractor shall remove dirt, dust, and other debris from
the surface by brushing, blowing with clean dry air, or vacuuming and shall apply the first coat of
paint to the blast cleaned surfaces. If the cleaned surfaces rust or become contaminated before
painting, the blast cleaning shall be repeated.

24.3.5.2

Surfaces with Existing Sound Paint

All areas to be painted shall be washed by the Contractor with pressurized water to remove dirt,
surface chalking, loose rust, and contaminants such as chlorides. A wash water pressure of at least
3.45 MPa shall be maintained. All wash water and removed waste shall be captured according to
appropriate regulations.

The Contractor shall clean surfaces having sound paint according to Method B (Hand Tool Cleaning),
Method C (Power Tool Cleaning), or Method E (Commercial Blast Cleaning) of Article 24.3.5.3 to
remove dirt, loose mill scale, loose rust, or paint that is not firmly bonded to the underlying surface.
The Contractor shall clean small areas that show pinhole corrosion, stone damage from traffic, or
minor scratches. At least 50mm shall be cleaned beyond the damaged areas.

The Contractor shall feather edges of remaining old paint to achieve a reasonably smooth surface.

The same day hand or power tool cleaning is performed, the Contractor shall remove dirt, dust, and
other contaminants from the surface with Method A (Solvent-cleaning) in accordance with Article
24.3.5.3, and shall spot paint all bare steel areas with the first coat of paint. If the cleaned surfaces
rust or become contaminated before painting, solvent cleaning shall be repeated. All damage to
sound paint shall be repaired by the Contractor by applying the entire system.

24.3.5.3

Cleaning Methods of Iron and Steel Surfaces

Methods used for cleaning iron and steel surfaces shall conform to the specifications in this article.

Method A: Solvent Cleaning

It is intended that solvent cleaning shall be used prior to the application of paint, and with other
methods of surface cleaning. Method A of cleaning shall be performed in accordance with SSPC-SP
1 and the following requirements:

Soil, cement spatter, drawing compounds, salts, soluble welding flux residues, or other foreign matter
(other than grease or oil) shall be removed by cleaning with solutions of alkaline cleaners, providing
brushing with stiff fibre or wire brushes, or by scraping, or by cleaners followed by a fresh water
rinse, or by a combination of these methods.

Oil or grease shall be removed by any of the following methods:

1. Wiping or scrubbing the surface with rags or brushes wetted with solvent.
2. Spraying of the surface with solvent. The final spraying shall be done with clean

solvent.

3. Vapor degreasing, using stabilized chlorinated hydrocarbon solvents.
4. Complete immersion in a tank or tanks of solvent.

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5. Emulsion cleaners or steam cleaning may be used in place of the methods above,

provided that after treatment the surface shall be washed with hot water to remove
detrimental residue.

b. Method B: Hand Tool Cleaning

Method B of cleaning shall be performed in accordance with SSPC-SP 2 and the following
requirements:

After oil, grease, soluble welding flux residues, or salts are removed by methods prescribed under
Method  A,  loose  mill  scale,  loose  rust,  and  other  detrimental  foreign  matter  shall  be  removed  by
hand  brushing,  hand  sanding,  hand  scraping,  hand  chipping,  hand  hammering,  or  other  methods
using hand impact tools, or by a combination of these methods.

All accessible weld flux and spatter shall be removed by hand scraping or by hand impact tools
followed by wirebrushing.

Areas which will be inaccessible after assembly shall be cleaned before assembly.

All bolts, welds, corners, joints, and openings shall be properly cleaned. The steel wires of the wire
brushes shall have sufficient rigidity to clean the surface, shall be kept free of excess foreign matter,
and shall be discarded when they are no longer effective. Hand scrapers shall be kept sharp enough
to be effective. The tools shall be operated in such a manner that no burrs or sharp ridges are left
on the surface and no sharp cuts made into the steel.

After hand cleaning is completed, dust and other loose matter shall be removed from the surface.
Detrimental amounts of grease or oil still present shall be spot cleaned with solvent.

c. Method C: Power Tool Cleaning

Method C of cleaning shall be performed in accordance with SSPC-SP 3 and the following
requirements:

After  oil,  grease,  soluble  welding  flux  residues,  or  salts  are  removed  by  the  methods  prescribed
under Method A, loose mill scale, loose rust, weld flux, and spatter shall be removed with power wire
brushes,  power  impact  tools,  power  grinders,  power  sanders,  or  by  any  combination  of  these
methods.

Power wire brushes shall be of the rotary cup type of suitable size for entering all accessible
openings, angles, joints, and corners. The steel wires of such brushes shall have sufficient rigidity to
clean the surface, shall be kept free of excess foreign matter, and shall be discarded when they are
no longer effective.

Power impact tools shall include power-driven chipping or scaling hammers, rotary scalers, single or
multiple piston scalers, or other similar impact cleaning tools. Cutting edges of all tools shall be kept
in effective condition.

Sanding or abrasive materials used in power sanding shall be discarded when they become
ineffective.

Rivet heads, cracks, crevices, lap joints, fillet welds, and re-entrant angles shall be cleaned by the
use of power wirebrushes, sharp chisels used in chipping, or scaling hammers, rotary grinders, or
sanders, or by a combination of such tools.

All tools shall be operated in such a manner that no burrs or sharp ridges are left on the surface and
no sharp cuts are made into the steel. Areas inaccessible for cleaning by power tools but accessible
for hand tool cleaning shall be cleaned by methods outlined under Method B.

After these cleaning operations are completed, dust and other loose matter shall be removed from
the surface. If detrimental amounts of grease or oil are still present, these areas shall be spot cleaned
with solvent.

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d. Method D: White Metal Blast Cleaning

Method D of cleaning shall be performed in accordance with SSPC-SP 5 and the following
requirements:

After heavy deposits of oil, grease, soluble welding flux residues, or salts are removed by the
methods prescribed under Method A, loose mill scale, rust-scale, and other foreign matter shall be
removed and the entire surface thoroughly cleaned by blasting except that excessive rust-scale shall,
preferably, be removed by impact tools, as prescribed under Methods B and C. Any of the following
blast cleaning methods may be used:

1. Dry sandblasting, using compressed air blast nozzles and dry sand.
2. Wet or water-vapor sandblasting, using compressed air blast nozzles and water and

sand.

3. Grit-blasting, using compressed air blast nozzles and grit made of crushed cast iron,

malleable iron, steel, or other metals.

4. Shot-blasting, using compressed air nozzles and cast-iron, malleable-iron, or steel

pellets.

5. Closed, recirculating nozzle-blasting using compressed air or vacuum with any of the

above named abrasives.

6. Grit-blasting using centrifugal wheels and grit made of crushed cast iron, malleable

iron, steel, or other metals.

7. Shot-blasting using centrifugal wheels and cast-iron, malleable-iron, or steel pellets.

Blast cleaning shall be performed with SAE No. S-330 shot or smaller, SAE No. C-25 grit or smaller,
or dry sand passing through No. 16 sieve (1.18 mm), U.S. Standard Sieve Series.

The surface, if dry blasted, shall be brushed with clean brushes made of hair, bristle, or fiber, or
blown off with compressed air (from which detrimental oil and water have been removed), or cleaned
by vacuum, for the purpose of removing any traces of blast products from the surface, and also for
the removal of abrasive from pockets and corners.

The surface, if wet sandblasted, shall be cleaned by rinsing with fresh water to which sufficient
corrosion inhibitor has been added to prevent rusting, or with fresh water followed immediately by
an inhibitive treatment. This cleaning shall be supplemented by brushing, if necessary, to remove
any residue.

The compressed air used for nozzle blasting shall be free of detrimental amounts of water or oil.
Adequate separators and traps shall be provided.

Blast cleaning operations shall be done in such a manner that no damage is done to partially or
entirely completed portions of the work.

The blast-cleaned surface shall be examined for any traces of oil, grease, or smudges deposited in
the cleaning operations. If present, they shall be removed as outlined under Method A. The Engineer
will assure that surfaces have been cleaned prior to painting.

e. Method E: Commercial Blast Cleaning

Method E of cleaning shall be performed in accordance with SSPC-SP 6 and the following
requirements:

Commercial blast cleaned surface, when viewed without magnification, shall be free of all visible oil,
grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products, and other foreign matter,
except for staining as noted. Random staining shall be limited to no more than 33 percent of each
unit area of surface, which shall be 75 mm x 75 mm, and may consist of light shadows, slight streaks,
or minor discolorations caused by stains of rust, stains of mill scale, or stains of previously applied
coating.

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24.3.6

Sampling and Testing

Unless otherwise specified, sampling shall be performed by the Engineer in accordance with FSS
141 method 1021, and the testing of the paint properties will be according to the procedures and
methods listed in FSS 141, and as shown in

Table 24-8:

Table 24-8: Methods of testing Paint properties

Test

Method

Percentage of pigment

4021

Isolation of vehicle

4032

Non-volatile in vehicle

4053

Ahthalic anhydride

7021

Uncombined water

4081 or 4082

Consistency: Krebs-Stormer

4281

Coarse particles and skins

4091

Weight per gallon

4184

Set to touch time

4061

Condition in container

3011

Brushing properties

2141, 4321

Skinning

4141

Rosin and resin derivatives

5031

Storage stability

4142

Dry through time

4061

Fineness of grind

4411

Note 1: A gravity convection oven may be used to determine the non-volatile content of the
supercentrifuged vehicle if the procedure outlined in FSS 141 method 4041 is modified as follows:
Weigh accurately from 0.8 to 1.2 g. of sample (by difference), heat for one hour, cool and weigh. Use
the lower value to calculate the percentage of non-volatile matter.

Note 2: Make the test on a portion of the isolated vehicle.

24.3.7

Time of Application

The prime coat of paint, or pretreatment when specified, shall be applied as soon as possible after
the surface has been cleaned and before deterioration of the surface occurs. Surfaces that have
been cleaned with power tool or blast cleaning shall be prime coated within 8 hours after cleaning
before visible or detrimental rusting occurs. Any oil, grease, soil, dust, or foreign matter deposited

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on the surface after the surface preparation is completed shall be removed prior to painting. In the
event that rusting occurs after completion of the surface preparation, the surfaces shall be again
cleaned.

Particular care shall be taken to prevent the contamination of cleaned surfaces with salts, acids,
alkali, or other corrosive chemicals before the prime coat is applied and between applications of the
remaining coats of paint. Such contaminants shall be removed from the surface. Under these
circumstances, the pretreatments or, in the absence of a pretreatment, the prime coat of paint shall
be applied immediately after the surface has been cleaned.

24.3.8

Storage of Paint and Thinner

All paint and thinner should preferably be stored in a separate building or room that is well ventilated
and free from excessive heat, sparks, flame, or the direct rays of the sun. Paints susceptible to
damage from excessive heat shall be kept in a cooled storage space when necessary. The
Contractor shall take all mitigation measures to minimize fire hazard, e.g. the storage of cloths or
cotton waste in metal containers or destroyed on daily basis.

All containers of paint shall remain unopened until required for use. Containers which have been
opened shall be used first.

Paint which has livered, gelled, or otherwise deteriorated during storage shall not be used.
Thixotropic materials which may be stirred to attain normal consistency are satisfactory.

24.3.9

Mixing and Thinning

All ingredients in any container of paint shall be thoroughly mixed before use and shall be agitated
often enough during application to keep the pigment in suspension.

Paint mixed in the original container shall not be transferred until all settled pigment is incorporated
into the vehicle. This does not imply that part of the vehicle cannot be poured off temporarily to
simplify the mixing.

Mixing shall be by mechanical methods, except that hand mixing will be permitted for containers up
to 20 liters in size.

Mixing in open containers shall be done in a well ventilated area away from sparks or flames.

Paint shall not be mixed or kept in suspension by means of an air stream bubbling under the paint
surface.

Where a skin has formed in the container, the skin shall be cut loose from the sides of the container,
removed, and discarded. If such skins are thick enough to have a practical effect on the composition
and quality of the paint, the paint shall not be used.

The paint shall be mixed in a manner which will ensure breaking up of all lumps, complete dispersion
of settled pigment, and a uniform composition. If mixing is done by hand, most of the vehicle shall
be poured off into a clean container. The pigment in the paint shall be lifted from the bottom of the
container with a broad, flat paddle, lumps shall be broken up, and the pigment thoroughly mixed with
the vehicle. The poured-off vehicle shall be returned to the paint with simultaneous stirring, or pouring
repeatedly from one container to another until the composition is uniform. The bottom of the
container shall be inspected for unmixed pigment.

Tinting pastes or colors shall be wetted with a small amount of thinner, vehicle, or paint and
thoroughly mixed. The thinned mixture shall then be added to the large container of paint and mixed
until the color is uniform.

Paint which does not have a limited pot life, or does not deteriorate on standing, may be mixed at
any time before using, but if settling has occurred it must be remixed immediately before using. Paint
shall not remain in spray pots, painters' buckets, or similar containers overnight, but shall be gathered
into a container and remixed before use.

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No thinner shall be added to the paint unless necessary for proper application. In no case shall more
than 0.5 liter of thinner be added per 4 liters unless the paint is intentionally formulated for greater
thinning.

The type of thinner shall comply with the paint specification.

When the use of thinner is permissible, thinner shall be added to paint during the mixing process.
Painters shall not add thinner to paint after it has been thinned to the correct consistency.

All thinning shall be done under supervision of one acquainted with the correct amount and type of
thinner to be added to the paint. Coating materials shall be stirred at all times when adding thinner.

24.3.10

Application of Paint

24.3.10.1 General

The Contractor shall apply each coat to the wet film thickness as recommended by the paint
manufacturer to obtain the specified dry film thickness. The application rate of each coat shall be
verified by the Contractor with a wet film paint thickness gauge immediately after applying paint to
the surface. The application rate shall be confirmed by measuring the dry film thickness after the
solvent has evaporated from the surface.

The oldest of each kind of paint shall be used first. Paint shall be applied by brushing or spraying or
a combination of these methods. Daubers or sheepskins may be used when no other method is
practicable for proper application in places of difficult access. Dipping, roller coating, or flow coating
shall be used only when specifically authorized by the Engineer.

Open seams at contact surfaces of built-up members which would retain moisture shall be caulked
with red lead paste or other approved material before the second undercoat of paint is applied.

Paint shall not be applied when the surrounding air temperature and surface temperature is below
10°C. Paint shall not be applied when the temperature is expected to drop to 0°C before the paint
has dried. Paint shall not be applied to iron and steel at a temperature over 32°C unless the paint is
specifically formulated for application at the proposed temperature, nor shall paint be applied to iron
and steel which is at a temperature that will cause blistering or porosity or otherwise will be
detrimental to the life of the paint.

Paint shall not be applied in fog or mist, or when it is raining or when the relative humidity exceeds
85 percent. Paint shall not be applied to wet or damp surfaces.

Any applied paint exposed to excess humidity, rain, or condensation shall first be permitted to dry.
The damaged areas of paint shall be removed, the surface again prepared and then repainted with
the same number of coats of paint of the same kind as the undamaged areas.

If stripe painting is stipulated or if the Contractor chooses to do so at his option, all edges, corners,
crevices, rivets, bolts, welds, and sharp edges shall be painted with the priming paint by brush before
the steel receives its first full prime coat of paint. Such striping shall extend for at least 25 mm from
the edge. When practicable, this stripe coat shall be permitted to dry before the prime coat is applied;
otherwise, the stripe coat shall set to touch before the full prime coat is applied. However, the stripe
coat shall not be permitted to dry for a period long enough to allow rusting of the unprimed steel.
When desired, the stripe coat may be applied after a complete prime coat.

To the maximum extent practical, each coat of paint shall be applied as a continuous film of uniform
thickness, free of pores. Any thin spots or areas missed in the application shall be repainted and
permitted to dry before the next coat of paint is applied.

Each coat of paint shall be in a proper state of cure or dryness before the application of the
succeeding coat.

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24.3.10.2 Brush Application

Brush application should always be undertaken using an appropriately sized, good quality synthetic
or  natural  fibre  brush  compatible  with  the  product  being  applied  and  acceptable  to  the  paint
manufacturer.  This  application  technique  shall  be  generally  used  for  coating  small  areas  with
decorative  paints  and  for  surface  priming,  where  good  penetration  of  rusty  steel  substrates  is
required. It is particularly suitable for the application of stripe coats and for coating complex areas
where the use of spray methods would lead to considerable losses due to overspray and associated
dry spray problems.

The Contractor shall use brushes that have sufficient bristle body and length to spread the paint in
a uniform film. Round, oval shaped brushes, or flat brushes no wider than 115mm shall be used.
The Contractor shall evenly spread and thoroughly brush out the paint as it is applied.

Paint shall be worked into all crevices and corners where possible and surfaces not accessible to
brushes shall be painted by spray, daubers, or sheepskins. All runs or sags shall be brushed out.
There shall be a minimum of brush marks left in the applied paint.

Brush application shall require considerable care when applying non-convertible coatings over one
another, e.g. vinyl on top of vinyl. In these cases, the solvents in the wet coat readily redissolve the
previously dry bottom coat. Even a mild degree of the brushing out normally given to topcoats will
cause pick-up of the previous coat and result in a very poor finish. Even, light strokes shall be used
in these circumstances, covering a particular area with one or two brush strokes, and on no account
working the bristles into the previous coat.

24.3.10.3 Spray Application of Paint

The equipment used for spray application of paint shall be suitable for the intended purpose, shall
be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure
regulators  and  gages.  The  air  caps,  nozzles,  and  needles  shall  be  those  recommended  by  the
manufacturer  of  the  equipment  for  the  material  being  sprayed.  The  equipment  shall  be  kept  in
satisfactory  condition  to  permit  proper  paint  application.  In  closed  or  recirculating  paint  spray
systems, where gas under pressure is used over the liquid, the gas shall be an inert one, such as
nitrogen.

Traps or separators shall be provided to remove oil and water from the compressed air. These traps
or separators shall be of adequate size and shall be drained periodically during operations. The air
from the spray gun impinging against the surface shall show no water or oil.

Paint ingredients shall be kept properly mixed in the spray pots or containers during paint application
either by continuous mechanical agitation or by intermittent agitation as frequently as necessary.

The pressure on the material in the pot and of the air at the guns shall be adjusted for optimum
spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary
for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be
high enough to atomize the paint properly but not so high as to cause excessive fogging of paint,
excessive evaporation of solvent, or loss by overspray.

Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials
are not deposited in the paint film. Any solvents left in the equipment shall be completely removed
before applying paint to the surface being painted.

Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray
pattern shall be adjusted so that the paint is deposited uniformly. During application, the gun shall
be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is
deposited on the surface. The trigger of the gun shall be released at the end of each stroke.

All runs and sags shall be brushed out immediately or the paint shall be removed and the surface
repainted.

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Areas inaccessible to the spray gun shall be painted by brush. If not accessible by brush, daubers
or sheepskins shall be used. Brushes shall be used to work paint into cracks, crevices, and blind
spots which are not adequately painted by spray.

24.3.10.4 Shop Painting

Shop painting shall be done after fabrication and before any damage to the surface occurs from
weather or other exposure, and shall be applied in accordance with the procedures of AISC-420-
10/SPE-QP3 and SSPC-PA 1. The surface preparation shall be in accordance with SSPC-SP 10/
NACE No. 2.

Shop coats consisting of the prime coat, intermediate and finish coats shall be applied in the
manufacturer’s plant unless otherwise specified in the Contract documents. The prime Coat shall be
applied in the shop promptly after blast cleaning, but in no case shall the prime coat be applied more
than 8 hours after blast cleaning or after visible or detrimental rusting occurs. Only Nylon web slings
or padded lifting points shall be used to move shop primed steel to prevent damage to the coating.

Surfaces damaged during shipment and handling shall be repaired using the same paint system as
applied in the shop except that the primer coat shall be repaired using an Organic Zinc Primer when
the primer Coat is repaired in the field. No paint shall be applied to areas to be welded in the field.
No Vinyl paint (wash or finish coat) shall be applied to any faying surfaces.

The manufacturer and or Contractor shall be required to guarantee his work against defective
workmanship or the use of defective materials for a period of ten years from the completion of works.

A shop coat of paint shall have a minimum dry film thickness of 38 microns. Shop contact surfaces
shall not be painted unless specified.

Unless otherwise specified, surfaces to be in contact only after field erection shall be painted except
where the paint will interfere with assembly.

Surfaces not to be in contact but will be inaccessible after assembly shall receive either the full paint
coats specified or three shop coats of the specified primer before assembly.

The areas of iron and steel surfaces to be in contact with concrete shall not be painted. Unless
otherwise indicated on the Contract plans, the areas of iron and steel surfaces to be in contact with
wood shall receive either the full paint coats specified or three shop coats of the specified primer.

If the paint would be harmful to a welding operator or would be detrimental to the welding operation
or the finished welds, the iron and steel shall not be painted within a suitable distance from the edges
to be welded. Welding through inorganic zinc paint systems will not be permitted unless approved
by the Engineer.

Antiweld spatter coatings shall be removed before painting. Weld slag and flux shall be removed by
methods at least as effective as those specified for the cleaning.

Machine-finished or similar surfaces that are not to be painted, but do require protection, shall be
protected with a coating of rust inhibitive petroleum, or other coatings which may be more suitable
for special conditions.

Erection marks and weight marks shall be copied on areas that have been previously painted with
the shop coats.

24.3.10.5 Field Painting

Iron and steel structures shall be painted in accordance with SSPC-PA 1 as soon as practicable after
erection.

The applicator shall stir, strain, and keep coating materials at a uniform consistency during
application. Where the Engineer permits thinning, the applicator shall not reduce the coating material
more than is necessary to obtain the proper application characteristics and to obtain the specified

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dry film thickness. The applicator shall not exceed the maximum thinning rate allowed by the
manufacturer. Coating materials shall be stirred at all times when adding thinner.

Where  measurement  of  the  dry  film  thickness  may  become  difficult  or  dangerous  unless  the
Contractor  maintains  or  provides  suitable  means  of  access,  wet  film  measurement  may  be
authorized. In such cases the Engineer will pre-determine and notify the Contractor of the required
wet film thickness, for each type of paint, to comply with the minimum dry film thickness specified.

Iron and steel which has been shop coated shall be touched up with the same type of paint as the
shop coat. This touch up shall include cleaning and painting of field connections, welds, rivets, and
all damaged or defective paint and rusted areas. The Contractor may at his option apply an overall
coat of primer in place of touch up or spot painting.

Surfaces (other than contact surfaces) which are accessible before erection but which will not be
accessible after erection shall receive all field coats of paint before erection.

If possible, the final coat of paint shall not be applied until all concrete work is finished. If concreting
or other operations damage any paint, the surface shall be cleaned and repainted. All cement or
concrete spatter and drippings shall be removed before any paint is applied.

Wet paint shall be protected against damage from dust or other detrimental foreign matter to the
extent practicable.

24.3.10.6 Drying of Painted Iron and Steel

The maximum practicable time shall be allowed for  paint to dry before recoating or exposure. No
drier shall be added to paint on the job unless specifically called for in the specification for the paint.
No painted iron and steel shall be subjected to immersion before the paint is dried through. Paint
shall  be  protected  from  rain,  condensation,  and  contamination,  until  dry,  to  the  fullest  extent
practicable.

24.3.10.7 Handling of Painted Iron and Steel

Painted iron and steel shall not be handled until the paint has dried, except for necessary handling
in turning for painting or stacking for drying.

Paint which is damaged in handling shall be scraped off and touched up with the same number of
coats and kinds of paint as were previously applied to the iron and steel.

Painted iron and steel shall not be loaded for shipment or shipped until it is dry.

Precautions shall be taken to minimize damage to paint films resulting from stacking members.

24.3.10.8 Measurement of Dry Film Thickness (DFT) of Paints

When a coating is applied to an iron or steel substrate, previously blast cleaned with abrasive grit or
shot, the measurement of its dry film thickness is more complicated than that of a coating applied to
a smooth steel substrate. The measurement results are influenced by the profile of the abrasive
blasted surfaces which changes from point to point, instrumentation, and dry film thicknesses to be
measured. The DFT shall be measured using a non-destructive magnetic gauge, which shall give a
value measured from the surface of the coating to the magnetic plane within the surface profile. The
magnetic plane shall be the theoretical point within the surface profile that the DFT gauge sees as
being the average position of the substrate.

Instrumentation

Dry film thickness (DFT) shall be measured using Pull-Off (Type 1) or Fixed- Probe (Type 2)
Magnetic Gages. Type 1 Gages include Tinsley, Elcometer, Microtest, and Inspector models. Type
2 Gages include Elcometic, Ninitector, General Electric, Verimeter, and Accuderm models. Other
types of non-destructive electronic devices may be used if approved by the Engineer.

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DFT gauges shall be calibrated on smooth or blasted steel panels and a correction factor for surface
profile shall be considered. BS EN ISO 2808:2007, BS 3900-C5:2007, ISO 19840:2012 and SSPC-
PA 2 are accepted standards for measuring DFT.

b. Calibration

Type  1  (Pull-off)  Magnetic  Gages  measure  the  coating  thickness  on  a  series  of
reliable  standards  covering the  expected range  of paint  thickness. The  Contractor
shall  record  the  calibration  correction  either  +  or  -  required  at  each  standard
thickness.  To  guard  against  gage  drift  during  use,  the  Contractor  shall  re-check
occasionally with one or more of the standards.

When the gage adjustment has drifted so far that large corrections are needed, the Contractor is
advised to re-adjust closer to the standard values and recalibrate.

For Type 1 gages, the preferred basic standards are small, chrome-plated steel panels that may be
available from the National Institute of Standards and Technology (NIST) in coating thicknesses from
13 to 203 microns.

Plastic shims of certified thicknesses in the appropriate ranges may also be  used to calibrate the
gages.  The  gage  is  held  firmly  enough  to  press  the  shim  tightly  against  the  steel  surface.  The
Contractor shall record the calibration correction as above.

ii.

Type 2 (Fixed Probe) Magnetic Gages. Shims of plastic or of non-magnetic metals
laid  on  the  appropriate  steel  base  (at  least  8  x  8  x  0.32  cm)  are  suitable  working
standards. These gages are held firmly enough to press the shim tightly against the
steel surface. The Contractor shall avoid excessive pressure that might indent the
plastic  or,  on  a  blast  cleaned  surface,  might  impress  the  steel  peaks  into  the
undersurface of the plastic.

As per the National Institute of Standards and Technology (NIST), standard panels shall not be used
to calibrate Type 2 gauges.

c. Measurement Procedures

To determine the effect of the substrate surface condition on the gauge readings, access is required
to some unpainted areas.

Repeated gage readings, even at points close together, may differ considerably due to small surface
irregularities. Three gage readings should therefore be made for each spot measurement of either
the substrate or the paint. The Contractor shall move the probe a short distance for each new gage
reading.  The  Contractor  shall  discard  any  unusually  high  or  low  gage  reading  that  cannot  be
repeated  consistently.  The  average  of  the  three  gage  readings  shall  be  taken  at  the  spot
measurement.

Measurement with Type 1 (Pull-Off) Gage. The Contractor shall:

•

Measure (A), the bare substrate, at a number of spots to obtain a representative

average value.

•

Measure (B), the dry paint film, at the specified number of spots.

•

Correct the (A) and (B) gage readings or averages as determined by calibration of

the gage. Subtract the corrected readings (A) from (B) to obtain the thickness of
the paint above the peaks of the surface.

ii.

Measurement with Type 2 (Fixed Probe) Gage. The Contractor shall:

•

Place a standard shim of the expected paint thickness on the bare substrate that

is to be painted. Adjust the gage in place on the shim so that it indicates the known
thickness of the shim.

•

Confirm the gage setting by measuring the shim at several other areas of the bare

substrate. Re-adjust the gage as needed to obtain an average setting
representative of the substrate.

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•

With the gage adjusted as above, measure the dry point film at three points. The

gage readings indicate the paint film thickness at the three points. The gage
readings indicate the paint thickness above the peaks of the surface profile.

•

Re-check the gage setting at frequent intervals during a long series of

measurements.

•

Make five separate spot measurements spaced evenly over each section of the

structure, 9.25 square meters in area, or of other area as may be directed by the
Engineer. The average of five spot measurements for each such section shall be
not  less  than  the  specified  thickness.  No  single  spot  measurement  (average  of
three  readings,  in  any  section)  shall  be  less  than  80  percent  of  the  specified
thickness.

•

Since paint thickness is usually specified (or implied) as a minimum, greater

thickness that does not cause defects of appearance of functions, such as mud
cracking, wrinkling, etc., is permitted unless otherwise specified.

d. Special Notes

All of the above magnetic gages, if properly adjusted and in good condition, are
inherently accurate to within +15 percent of the true thickness of the coating.

ii.

Much larger, external errors may be caused by variations in method of use of the
gages or by unevenness of the surface of the substrate or of the coating. Also, any
other films present on the steel (rust or mill scale or even a blast cleaned profile zone)
will add to the apparent thickness of the applied paint film.

iii.

The surface of the paint and the probe of the gage must be free from dust, grease
and other foreign matter in order to obtain close contact of the probe with the paint
and also to avoid adhesion of the magnet. The accuracy of the measurement may
be affected if the coating is tacky or excessively soft.

iv.

The magnetic gages are sensitive to geometrical discontinuities of the iron and steel,
as at holes, corners or edges. The sensitivity to edge effects and discontinuities
varies from gage to gage. Measurements closer than 25mm from the discontinuity
may not be valid unless the gage is calibrated specifically for that location.

Magnetic gage readings also may be affected by proximity to another mass of iron
and steel close to the body of the gage, by surface curvature, and by presence of
other magnetic fields.

vi.

All of the magnets or probes must be held perpendicular to the painted surface to
produce valid measurements.

vii.

Cleanup. Upon completion, and before final acceptance, the Contractor shall leave
the work site and adjacent areas in a neat and presentable condition satisfactory to
the Engineer.

24.4

Painting Galvanized Surfaces

The Contractor shall remove all oil, grease, or other contaminants on the surface by washing with a
mineral spirit solvent according to SSPC-SP 1. Unless otherwise specified in the Contract
documents, the Contractor shall apply one of the coating systems shown in Table 24-9, as selected
and approved by the Engineer.

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Table 24-9: Galvanized surface coating systems

Coat

Paint System

Aggressive Environment

Less Aggressive Environment

Primer

Polyamide-cured, Rust-inhibitive Epoxy

3-4 mils DFT

Vinyl Wash Primer

1-2 mils DFT

Intermediate

Epoxy Polyamide

2-3 mils DFT

Exterior acrylic latex

1-2 mils DFT

Top Coat

Aliphatic Polyurethane Acrylic

2-3 mils DFT

Exterior acrylic latex

1-2 mils DFT

Total
Thickness

7-10 mils DFT

3-6 mils DFT

Note 1: Dry Film Thickness (DFT).

Test panels shall be galvanized in accordance with ASTM A123 / A123M

– 12 prior to application of

subsequent coatings.

24.4.1

Paint System No. 10

– Polyamide Cured Rust Inhibitive

Epoxy System

Paint System No. 10 shall consist of the following:

Primer coat on galvanized surfaces:

Polyamide-cured, rust-inhibitive epoxy primer

shall comply with the following minimum requirements:

Solids

47% by volume

Rust-inhibitive pigment

44% by weight

Non-volatile vehicle (epoxy resin)

20.7% by weight

All materials shall be applied in accordance with the manufacturer's directions. All surfaces
shall be thoroughly cleaned to remove any oil, soap or other deleterious material which may
affect the bond of the primer to the galvanized surfaces.

2. Intermediate coat:

an intermediate coat of epoxy polyamide conforming to SSPC Paint

22 shall be applied.

3. Top coat:

op coat of an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36

and Paragraph 3 of Article 24.3.2.1 shall be applied.

24.4.2

Paint System No. 11

– Vinyl Wash System

Paint System No. 11 shall consist of the following:

1. Primer coat on galvanized surfaces:

Vinyl Wash primer, conforming to composition and

performance requirements of SSPC-Paint 27 standard.

2. Intermediate coat:

an intermediate coat of acrylic latex conforming to SSPC-Paint 24 shall

be applied.

3. Top coat:

op coat of acrylic latex conforming to SSPC Paint 24 shall be applied.

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24.5

Painting Steel Sheet, H, Pipe Pilings, and other
Surfaces

Unless otherwise specified in the Contract documents, steel sheet, H and Pipe pilings that will be
installed in new fill, disturbed materials or fluctuating water tables shall be painted with amine-cured
coal tar epoxy coating. The H-piles and sheet piling shall be painted 76 mm above the stabilization
slab and to a 1.5 meter minimum below new fill material, disturbed soil or the lowest elevation of
fluctuating water tables. Steel piles exposed in water shall be coated the full height exposed to water
plus a 1.5 meter embedment length. The final painting requirements shall be approved by the
Engineer.

This work shall also include other metal and concrete surfaces specified in the particular
specifications or indicated in the Contract plans to be painted with tar epoxy coating.

Steel surfaces to be painted shall be coated with a minimum of 470 microns DFT of amine-cured
coal tar epoxy. The paint shall be applied in two coats. The first coat of coal tar epoxy shall be applied
to a dry film thickness of 65 microns. The Contractor shall thin this first coat in accordance with the
manufacturer's recommendations. The covered surface shall be lightly sand blasted to achieve
proper penetration before the application of first coat. The second coat of coal tar epoxy shall be
applied to a dry minimum film thickness of 405 microns. The performance of the amine-cured coal
tar epoxy coating shall be equivalent to SSPC-Paint 16.

The heavy-duty, high solid, amine-cured, two component coal tar epoxy coating shall be shipped in
two parts that must be mixed together before use.

Amine-cured coal tar epoxy is a solvent borne paint and care must be taken to avoid inhalation of
spray mist or vapour as well as contact between the wet paint and exposed skin or eyes.

24.5.1

Surface Preparation

The Contractor shall remove weld spatter, protrusions, and laminations in steel. Welds shall be
grinded smooth in accordance with NACE RP0178-2003 (21002). All surface contaminants, oil and
grease shall be removed in accordance with SSPC-SP 1.

The Contractor shall abrasive blast with angular abrasive to an SSPC-SP 10/ NACE No. 2
cleanliness or higher. A surface profile of 2.0-4.0 mils shall be achieved.

24.5.2

Application Requirements

The manufacturer shall furnish to the Engineer a notarized statement that verifies that each individual
performance test has been completed and the results have met or exceeded the required standards.
All testing for approval of coatings shall be paid for by the Contractor.

The Contractor shall take all possible precaution measures to protect the coating from damage
during the driving operation. Coating repair strategies during installation shall be submitted by the
Contractor for the Engineer’s approval.Table 24-10 shows the required characteristics of coal tar
epoxy coating.

Table 24-10: Characteristics of coal tar epoxy coating

Component A

Minimum

Maximum

Weight (kilograms per litre)

1.46 kg/litre

1.50 kg/litre

Pigment (percentage by weight)

42%

47%

Non-volatile content (percentage by weight)

82.7%

86.2%

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Component A

Minimum

Maximum

Component B

Minimum

Maximum

Weight (kilograms per litre)

0.960 kg/litre

1.000 kg/litre

Non-volatile content (percentage by weight)

82.7%

86.7%

Mixed components

Value

Total solids (percentage by volume, in accordance with ASTM
D2697 - 03(2008))

70%

Flash point (SETA)

Appearance low sheen

Black, smooth

Mixing rate of 19 parts component A to 1 part Component B.

For field application and capable of being applied at a 405 microns DFT in one coat.

Pot life at 25°C and 80% relative humidity: 4 hours minimum.

Drying or curing time at 25°C: Dry to touch after 6 1/2 hours.

Shelf life: Six months from date of shipment, without livering or more than one third increase in
viscosity with restoration to original viscosity by not more than 10% addition of thinner.

24.6

Painting Aluminium Surfaces

24.6.1

Surface Preparation

The preparation of aluminium and aluminium alloy surfaces for painting shall be performed in
accordance with the procedures of ASTM D1730

– 09. The type of treatment shall be one or a

combination of the following types, as indicated in the Contract plans or specified in the particular
specifications, or approved by the Engineer.

A.  Type A - Solvent Cleaning.
B.  Type B - Chemical Treatments.
C.  Type C - Anodic Treatments.
D.  Type D - Mechanical Treatments.

24.6.2

Paint Systems for Aluminium Surfaces

All aluminium shall be painted with one of the following systems. The required system or choice of
systems shall be shown on the Contract plans or in the Particular Specifications.

If not indicated on the Contract plans or specified in the Particular Specifications, the paint system
applied to all aluminium surfaces shall be Paint System No. 11 Polyvinylidene Difluoride System.

The Contractor shall specify the coating film thickness especially along cut ends and sharp 90 degree
bends that shall be sufficient to prevent the ingress of moisture. The paint manufacturer shall provide
the minimum acceptable dry film thickness on the product data sheet.

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24.6.2.1

Paint System No. 11 - Polyvinylidene Difluoride Coating

The Contractor shall apply a polyvinylidene difluoride (PVDF) coating to sheet aluminium and
extrusions to provide protection and a decorative organic coating in accordance with the following
requirements and test procedures of AAMA 2605-05 and AAMA 620-02.

Table 24-11: Polyvinylidene difluoride (PVDF) requirements

Thickness

20-30 Mils DFT

Chemical Resistance (ASTM D543 - 06)

Excellent

Abrasion Resistance (ASTM D4060 - 10)

Excellent

Tensile Strength at Break (ASTM D638 - 10)

45 MPa

Coefficient of Friction (ASTM D1894 - 11e1)

0.4 Static, 0.3 Dynamic

Dielectric Strength (ASTM D149 - 09(2013))

260 Volts per mil

Hardness (ASTM D2240 - 05(2010))

80 (shore D)

24.6.2.2

Paint System No. 12 - Epoxy

The Contractor shall apply an epoxy primer corrosion inhibiting lead and chromate free conforming
to MIL-P-53022D followed by a chemical agent resistant coatings (CARC), Aliphatic Polyurethane,
Single Component, Chemical Agent Resistant Coating in accordance with MIL-C-53039D.

The epoxy primer shall be sprayed to a dry film thickness between 1.0 and 2.0 mils, and the chemical
agent resistant coating shall be applied to a minimum dry film thickness of 2.0 mils.

24.6.3

Aluminium in Contact with Dissimilar Metals

Where aluminium will contact dissimilar metals, the Contractor shall protect against galvanic action
by painting contact surfaces as follows, unless otherwise indicated in the Contract plans or specifies
in the particular specifications.

1. Where aluminium members are in contact with steel, prime both aluminium and steel

members with one coat of paint meeting Federal Specification TT-P-645B. Paint aluminium
with an additional coat of varnish containing 1 kg of aluminium pigment per gallon.

2. Where aluminium members are in contact with porous materials, masonry or concrete, apply

to the contact surfaces of the aluminium members a heavy coat of alkali resistant bituminous
paint.

3. Where aluminium members are embedded in concrete containing admixtures which are

corrosive to aluminium, or in concrete subjected to highly corrosive environments, prime the
aluminium with one coat of paint meeting Federal Specification TT-P-645B.

24.7

Painting Exposed Surfaces of Concrete Structures

Except where waterproofing or ceramic tiling is specified in the Contract documents, all concrete
surfaces shall be protected by a painting system as specified here below.

Painting works shall include all exposed items or surfaces throughout the concrete structure, except
as otherwise indicated on the Contract plans. Such surfaces shall include bridge deck
superstructures, including barriers/railings; all exposed surfaces of underpasses, tunnel walls, and
retaining walls, including barriers/railings or other structural elements; and internal surfaces where
specified on the Contract plans. Extent of this painting shall be as indicated in the Contract plans, as
directed by the Engineer, and as specified herein.

Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020) - page 12