SECTION 1045 PAINT FOR STRUCTURAL STEEL

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1 SECTION 1045 PAINT FOR STRUCTURAL STEEL Paint and Paint Material General. All single component paints shall be ready-mixed at the factory to comply with the specification formula for the type of paint ordered; shall be well ground to a uniform consistency and smooth texture; shall be free from dirt, water and other foreign matter; shall be of such consistency that they will have good application, covering and leveling properties; and shall dry within the specified period to a good film without running, streaking or sagging. If tinted paint is specified, the tinting material shall be thoroughly and uniformly incorporated within the body of the paint to form a shade which shall match that of a sample submitted for the purpose. Any paint which has livered or in any way hardened or thickened in the container, or in which the pigment has settled out so that the paint cannot be readily broken up with a paddle to a smooth uniform paint of good application consistency, will be rejected. The grinding equipment used in the manufacture of the paint shall meet the approval of the engineer. In no case will the use of a colloid mill, steel ball mill or high speed mill be permitted All percentages and proportions are on a weight (mass) basis unless otherwise stated Sampling. Each batch or lot of pigment and vehicle constituents for mixed paints shall be sampled and approved prior to being incorporated into a paint mixture when requested by the State Project Operations Engineer. Each batch or lot of paint shall be sampled and approved prior to use. Each batch or lot of each component of multiple -component paints shall be sampled and approved prior to use Packaging. All containers shall be approved by the engineer as to type and weight (mass) and shall be free of physical defects. The lining of the container shall not react with the paint. All containers shall be cleaned of any paint spilled during filling operations. Except when supplied in containers of less than five gallons (19 L), all mixed paint shall be packaged in strong substantial 24 gage (0.6 mm) or heavier, new metal containers having lug-type replaceable tops. They shall bear a label on which shall be clearly shown the name of the manufacturer, the kind of paint, the lot number, date of manufacture and net weight (mass) of contents. The lot number and date of manufacture shall be stamped, stenciled, or painted directly onto the container using a weatherproof, durable material Multiple-component paint shall be packaged in multiple -compartment containers or in separate containers. The components shall be packaged in such proportions that the pigment, mixed with the vehicle and activator, if used, will yield one or five gallons (4 or 19 L) of mixed paint. Each container shall bear a label on which shall be clearly shown the name of the manufacturer or brand name of paint, the lot number, date of manufacture, shelf life and, in the case of organic zinc silicate paint, the individual net weights (masses) of pigment and vehicle. The lot number and date of manufacture shall be stamped, stenciled, or painted directly onto the container using a weatherproof, durable material. The label on the vehicle container shall also include complete instructions for use of the paint.

2 Determination of Quantities. Quantities of paint shall be determined by volume. One gallon (liter) shall equal 231 cubic inches (0.001 m 3 ) at 77 F (25 C) Blank Blank Blank High Solids Inorganic Zinc Silicate Coating Description. High solids inorganic zinc coating shall be a solvent base multiple component material which, when mixed and applied in accordance with the requirements of Sec 712, cures without the use of a separate curing solution. High solids inorganic zinc coating shall comply with the requirements of AASHTO M 300, Type IA. The volatile organic compound (VOC) content shall not exceed 3.50 pounds/gallon (420 g/l). If thinning is necessary for application, the maximum VOC shall not exceed 3.50 pounds/gallon (420 g/l) Manufacturer and Brand Name Approval. Prior to approval and use of high solids inorganic zinc, the manufacturer shall submit to Project Operations a certified test report from an approved independent testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specifications. The certified test report shall also contain the exact ratio, by weight (mass), of each component of the coating used for the tests, the lot tested, the manufacturer's name, brand name of coating and date of manufacture. Upon approval by the engineer of this certified test report, further resistance tests will not be required, except as hereinafter noted, of that manufacturer for that brand name of coating. New certified test results shall be submitted any time the manufacturing process or the coating formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Project Operations High Solids Epoxy System G Intermediate Coating Description. The coating shall be a two-component, modified epoxy primer with an amine/amide type curing system compatible as an intermediate coat over high solids inorganic zinc primer and suitable for topcoating with polyurethane Pigment. The pigment shall be a minimum of 43 percent by weight (mass) of the coating Vehicle. The vehicle shall be a maximum of 57 percent by weight (mass). The vehicle shall consist of an epoxy resin Mixed Coating. Color Provide a contrast with the primer and the finish coat.

3 Weight (Mass) per Gallon (Liter), lbs (kg), min, ASTM D 10.0 (1.20) 1475 Solids, percent by weight (mass) ASTM D 1644 for 72 hours at 100 F (37.8 C) min. 79 Pigment, percent by weight (mass), min., Federal Test 43 Method 4021 Viscosity, Krebs-Stormer, 77 F (25 C) KU Volatile Organic Content*, max., lb/gal (g/l) 3.50 (420) Fineness of Grind, Hegeman Gage, min. 4 Sag Resistance, Leneta Anti-Sag Meter, mils (µm) wet, min. 8 (203) Pot Life at 70 F (21 C), hours, min. 4 Dry to Touch, hours, max. 3 Dry to Handle, hours, max. 6 *Maximum when thinned for application Manufacturer and Brand Name Approval. Prior to approval and use of the specified coating system, the manufacturer shall submit to the State Project Operations Engineer a one-gallon (4 L) unit of each coat of the coating system proposed. The manufacturer shall also submit a certified test report from an approved independent testing laboratory showing specific test results obtained on the specified coating system for Relative Humidity Resistance ASTM D 1735 or D 2247, 3000 hours, Salt Fog Resistance ASTM B 117, 3000 hours and Accelerated Weathering ASTM G 23 Method 1, Type EH (Carbon Arc), 4000 hours. ASTM G 26, Method 2, Xenon Arc or G 53 QUV (Fluorescent UV-Condensation Type using Type A lamps) may be used as an alternate to Carbon Arc All coats of the system to be tested shall be applied to steel test panels which have been prepared according to AASHTO M 300. Each coat of the system shall be from the same manufacturer. Test panels for salt fog exposure shall be scribed as specified in ASTM D 1654 and, when rated according to ASTM D 1654, each panel shall receive a rating of 7 or greater. Test panels shall not exhibit more than slight rusting, undercutting, discoloration, fading, blistering, chalking, loss of gloss, or change in color. Accelerated weathering resistance testing shall be performed on test panels that have received finish coats in the specified color(s) for which approval is being requested. After 4000 hours testing for accelerated weathering resistance, each color of the finish coat shall show a difference in color of no greater than 3.0? E, when compared to the control panel. Color change measurements shall be made in accordance with Section 6.2 CIE 1976 L*a*b* of ASTM D All resistance testing shall be performed on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to the State Project Operations Engineer The manufacturer shall provide documentation that the specified coating system has performed satisfactorily for three years. The document shall include the name, address and telephone number of the proprietary agency and location of the structures. Upon approval of the coating by the engineer, further submittals for preliminary approval will not be required of that manufacturer for that brand name of coating, except as hereinafter noted. A new sample, new testing data and new test panels shall be submitted any time the manufacturing process or the batching proportions are changed. The engineer may withdraw manufacturer and brand name approval when sampling and testing of material offered for use indicates nonconformance to any of the requirements herein specified. All data submitted for preliminary approval will be considered confidential to MoDOT Polyurethane System G Finish Coating.

4 Description. The coating shall be a two-component, aliphatic acrylic polyurethane suitable for use over Sec , High Solids Epoxy Intermediate Coating. The coating shall cure to a semi-gloss to high gloss, abrasion resistant surface and shall provide an easily cleanable finish Pigment. The pigment shall be a minimum of 29 percent for gray and a minimum of 24 percent for brown by weight (mass) of the total coating. The pigment shall consist of titanium dioxide, color retentive tinting pigments, extender pigments and UV stabilizers Vehicle. The vehicle shall be a maximum of 71 percent for gray and a maximum of 76 percent for brown by weight (mass) of the total coating. The vehicle shall consist of an aliphatic acrylic polyurethane Mixed Coating. Color, Federal Standard 595b Gray Brown Weight (Mass) per Gallon (Liter), lbs (kg), min., ASTM D 10.0 (1.20) 9.3 (1.14) 1475 Solids, percent by weight (mass) ASTM D 1644 for 72 hours at 100 F (37.8 C), min Solids by Volume, min, ASTM D Pigment, percent by weight (mass), min., Federal Test Method 4021 Viscosity, Krebs-Stormer, 77 F (25 C), KU Volatile Organic Content*, lb/gal (g/l), max (420) 3.50 (420) Fineness of Grind, Hegeman Gage, min. 6 6 Sag Resistance, Leneta Anti-Sag Meter, mils (µm) wet, min. 8 (203) 8 (203) Pot Life at 70 F (21 C), hours, min. 4 4 Dry to Touch, hours, max. 4 4 Dry to Handle, hours, max. 8 8 *Maximum when thinned for application Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Sec Waterborne Acrylic System H Intermediate and Finish Coating Description. The intermediate coating shall be a single component waterborne acrylic compatible as a coating over high solids inorganic zinc primers. The finish coating shall be a single component waterborne acrylic suitable for use over a waterborne acrylic intermediate coating. The finish coating shall cure to a tough, abrasion resistant surface which performs well in weathering exposures. The gray finish coat shall cure to a semi-gloss finish, and the brown finish coat shall cure to a low-gloss finish Pigment. The pigment shall be a minimum of 18 percent for gray and a minimum of 15 percent for brown by weight (mass) of the total coating. The pigment shall consist of titanium dioxide, color retentive tinting pigments and extender pigment Vehicle. The vehicle shall be a maximum of 82 percent for gray and a maximum of 85 percent for brown by weight (mass) of the total coating. The vehicle shall consist of acrylic resin suitable for use in exterior coatings.

5 Mixed Coating. Color - Intermediate Coat Provide a contrast between primer and finish coat. Color - Finish Coat Federal Standard 595b Gray Brown Weight (Mass) per Gallon (Liter), lbs (kg), min., ASTM D (1.20) 9.3 (1.11) Solids, percent by weight (mass), min., ASTM D Solids, percent by volume, min., ASTM D Pigment, percent by weight (mass), min., ASTM D Percent Non-volatile Vehicle, by weight (mass) of coating, min Viscosity, Krebs-Stormer, 77 F (25 C), KU Volatile Organic Content, lb/gal (g/l), max (420) 3.50 (420) Fineness of Grind, Hegeman Gage, min. 7 7 Sag Resistance, Leneta Anti-Sag Meter, mils (µm) wet, min. 8 (203) 8 (203) Dry to Handle, hours, max Manufacturer and Brand Name Approval. Prior to approval and use of waterborne acrylic intermediate and finish coats, the manufacturer shall obtain manufacturer and brand name approval in accordance with Sec Aluminum Epoxy-Mastic Primer Description. The coating shall be a one-coat system aluminum epoxy-mastic primer designed for adhesion to rusty steel, aged galvanized steel and other uses. Aluminum epoxy-mastic primer will not be allowed for use in contact with fresh concrete. The epoxymastic shall be a two-component, modified epoxy-primer containing metallic -aluminum flake Pigment. The primary pigment shall be metallic -aluminum Vehicle. The vehicle shall be an epoxy-type. The curing agent shall have suitable insensitivity to moisture to allow trouble -free application Mixed Coating The coating shall be supplied as a two-component material with a 1:1 volume mix ratio, and shall be well-ground, not caked, skinned or badly settled in the container. The mixed coating, when applied in one coat, shall be capable of achieving 5 mils (127 µm) dry film thickness without runs or sags.

6 The mixed coating properties shall be as follows: Item Requirement Shelf Life, months, min. 12 Weight per gallon,lb,min. 77 F (25 C)(Mass per liter, kg, 10.5 (1.26) min.) Solids, percent by weight (mass), min. 88 * Pot life, 75 F (24 C), hours, min. 2 Dry to touch, hours, max. 24 Dry hard, days, max. 5 ** Volatile Organic Content, lb/gal (g/l), max (420) * When tested in accordance with ASTM D 1644, Method A for 72 hours at 100 F (37.8 C). ** When air-cured at a temperature of 75 F (24 C) or above to a hard, tough film by evaporation of solvent and chemical reaction Resistance Tests. Test panels of steel meeting the requirements of ASTM D 609 and having dimensions of 2 inches x 5 inches x 1/8 inch (50 mm x 125 mm x 3 mm) shall be prepared by sandblasting all surfaces to a white metal condition in accordance with Structural Steel Painting Council SP5 (SSPC-SP5-82). The cleaned panels shall then be exposed to outdoor weather for thirty days or until uniform rusting occurs. They shall then be hand cleaned with a wire brush in accordance with SSPC-SP2-82. A 6-mil (152 µm) dry coating of the epoxy-mastic shall then be applied in one coat in accordance with the manufacturer's current printed instructions. The coating shall be cured as recommended by the manufacturer. Fresh Water, Salt Water, and Weathering and Salt Fog resistance tests as detailed herein shall be performed on one or more test panels. The material will not be approved if any individual test panel fails any of the resistance tests specified herein Fresh Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2 inch (50 mm) legs and shall be immersed in fresh tap water at 75 ± 5 F (24 ± 2 C). The panels shall show no rusting, blistering, or softening beyond 1/16 inch (2 mm) from the scribe mark, when examined after thirty days. Discoloration of the coating will be allowed Salt Water Resistance. Panels shall be scribed down to base metal with an "X" of at least 2 inch (50 mm) legs and immersed in 5 percent sodium chloride at 75 ± 5 F (24 ± 2 C). The panels shall show no rusting, blistering, or softening beyond 1/16 inch (2 mm) from the scribe mark upon examination after seven, fourteen and thirty days. Discoloration of the coating will be allowed. The sodium chloride solution shall be replaced with fresh solution after each examination Weathering and Salt Fog Resistance. Panels shall be tested in the weatherometer in accordance with ASTM G 53 QUV (Fluorescent UV-Condensation Tape using Type A Lamps) for 300 hours using a test cycle consisting of 4 hours light followed by 4 hours condensation. After this period, the panels shall be removed and scribed with an "X" of at least 2 inch (50 mm) legs down to base metal. The test panels shall then be tested in accordance with ASTM B 117. After 1000 hours of continuous exposure, the coating shall show no loss of bond, nor shall it show rusting or blistering beyond 1/16 inch (2 mm) from the center of the scribe mark Packaging and Labeling. The epoxy-mastic coating shall be packaged in two containers. The components shall be prepackaged such that mixing at a 1:1 ratio, by volume, utilizes a complete container of each component. Each container shall be labeled in

7 accordance to Sec The label on the vehicle container shall also include complete instructions for the use of this paint. The container shall be coated on the inside, if necessary, to prevent attack by the paint components Field Application The epoxy-mastic shall be applied over an SSPC-SP2, SSPC-SP3 or SSPC-SP6 surface preparation, including removal of all rust scale, loose rust, loose mill scale and loose or non-adherent paint. Oil and grease shall be removed in accordance with SSPC-SP1 Solvent Cleaning The epoxy-mastic shall be applied by spray, brush or roller in accordance with the manufacturer's printed instructions except as herein modified. The contractor shall furnish the engineer a complete set of the manufacturer's printed instructions at least two weeks prior to beginning surface preparation The epoxy-mastic shall not be applied when either the temperature of the metal or the air is below 50 F (10 C), the temperature is expected to drop to 40 F (5 C) or below before the coating has cured, or the steel surface temperature is at or below 5 F (-15 C) above the dew point as determined in accordance with MoDOT Test Method T The epoxy-mastic shall be applied in one coat to a 5-mil (127 µm) dry film thickness Approval and Prequalification Manufacturer and Brand Name Approval. Prior to approval and use of the epoxy-mastic primer, the manufacturer shall submit to Project Operations a one-gallon (4 L) sample of the coating and a certified test report from an approved independent testing laboratory showing specific test results conforming to all quantitative and resistance test requirements of these specif ications. The certified test report shall also contain the exact ratio, by weight, of the pigment component to the vehicle component of the epoxy-mastic used for the tests, the lot tested, the manufacturer's name, brand name of the epoxy-mastic, and date of manufacture. In addition, the manufacturer shall submit a complete set of tested panels which have undergone each required resistance test. The set of panels submitted shall include one untested control panel that has been prepared according to Sec Upon approval by Project Operations of this certified test report, further resistance tests will not be required, except as hereinafter noted, of that manufacturer for that brand name of epoxy-mastic primer. New certified test results shall be submitted any time the manufacturing process or the epoxymastic formulation is changed, and may be required by the engineer when sampling and testing of material offered for use indicates nonconformance to any of the requirements specified herein Final Acceptance. Final acceptance of the epoxy-mastic primer will be based on a manufacturer's certification submitted by the contractor to the engineer and upon results of tests made on samples of the material. The engineer will sample and test each lot of each component prior to approval or use of the material Gray Epoxy-Mastic Primer Description. This specification covers a one-coat gray epoxy-mastic primer system designed for adhesion to rusty steel, aged galvanized steel and other uses, including uses in contact with freshly poured Portland cement concrete. The epoxy-mastic shall be a two component modified epoxy containing gray pigmentation and shall comply with the requirements specified herein.

8 Pigment. The pigmentation shall be any pigment or combination of pigments formulated to offer the intended protective properties to the cured coating and shall be totally non-reactive to the constituents contained in both cured and uncured Portland cement concrete Vehicle. The vehicle shall be an epoxy type. The curing agent shall have suitable insensitivity to moisture to allow trouble -free application Mixed Coating The provisions of Secs shall apply The mixed coating properties shall be as follows: Item Requirement Color, Federal Standard 595b Gray Weight per gallon,lb,min. 77 F (25 C) (Mass per liter, kg, 11.0(1.32) min.) Solids, percent by weight (mass), min. 88 * Pigment, percent by weight (mass), min. 40 Viscosity, (Krebs-Stormer, 25 C) KU Volatile Organic Content, lb/gal(g/l), max. 3.50(420) Pot life, 75 F (24 C), hours, min. 2 Dry to touch, hours, max. 24 Dry hard, days, max. 7 ** Shelf Life, months, min. 12 * When tested in accordance with ASTM D 1644, Method A for 72 hours at 100 F (37.8 C). ** When air-cured at a temperature of 75 F (24 C) or above to a hard, tough film by evaporation of solvent and chemical reaction Resistance Tests. Test requirements and approval criteria shall be in accordance with Sec Packaging and Labeling. Packaging and labeling shall be in accordance with Sec Field Application. Field application shall be in accordance with Sec Approval and Prequalification Manufacturer and Brand Name Approval. Manufacturer and brand name approval shall be in accordance with Sec Final Acceptance. Final acceptance will be in accordance with Sec

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