SPECIAL SPECIFICATION 7682 Cleaning and Painting Corpus Christi Harbor Bridge

Transcription

1 1993 Specifications CSJ SPECIAL SPECIFICATION 7682 Cleaning and Painting Corpus Christi Harbor Bridge 1. Description. This Special Specification defines the scope of the work and shall govern the minimum acceptable requirements for all aspects surface preparation and coatings work associated with repainting the Corpus Christi Harbor Bridge including the steel girder spans and the truss spans. 2. General. Defining responsibility for Hazards and Compliance with Health and Pollution Regulations. The Contractor is advised that existing coatings may contain lead and other hazardous constituents. The Contractor shall comply with all applicable OSHA requirements for protection of worker health and safety. The Contractor and subcontractors shall contain, handle, label, store, classify, dispose and document all the materials used and waste generated from this project in accordance with all applicable Federal, State, and Local laws and regulations and this specification. Hazardous waste generated from cleaning and painting activities shall be handled, labeled, stored, and disposed in accordance with Universal Waste Rule for Paint and Paint Related Waste regulation under 30 TAC Chapter 335. Non-hazardous waste generated from cleaning and painting activities shall be labeled and disposed as Special Waste in accordance with 30 TAC Chapter 330, or as directed by the Engineer. Prior to classification as non-hazardous through testing or process knowledge, handle and store all waste generated from cleaning and painting in accordance with the Universal Waste Rule. Liquid wastewaters (steam, wash water, or wash water mixers) used for removing contaminants as required by SSPC SP-1 shall be contained and stored as appropriate. Dispose of wastewaters as a solid waste under Texas Commission on Environmental Quality (TCEQ) waste regulations or as an industrial wastewater in accordance with the Texas Pollutant Discharge Elimination System program. Control air emissions in accordance with TCEQ Permit By rule (PBR), 30 TAC Section Routine Maintenance, Start-up and Shutdown of Facilities, and Temporary Maintenance Facilities, and in accordance with General Air Quality Rules in 30 TAC Chapter 101 and this specification. 3. Paint System(s). The paint system(s) will consist of a minimum of three coats (Primer + Intermediate + Top Coat), plus a stripe coat where specified, supplied from the same manufacturer. Each coating will be applied individually at the required dry film thickness. Submit paint system(s) for approval. Dependent upon the paint system chosen and

2 approved, special environmental controls (temperature, dew point and/or relative humidity) inside the containment system may be required during surface preparation, coating application and curing. One system may be used for the truss structure and another system for the steel girder structures for a total of two paint systems. Use the same system for all components within each structure type. A. Source of supply. Only one paint manufacturer will be allowed to supply the coatings for the entire project. The approved coatings for the paint system(s) to be supplied for this project are as specified below. 1. International Coatings Interzinc 315 Prime Coat, 4-10 mils DFT, Color Red Interseal 670 HS Intermediate Coat, 4-8 mils DFT, Color Green Interfine 979 Top Coat, 3-7 mils DFT 2. Ameron International Amercoat 68B Prime Coat, 4-10 mils DFT, Color Red Amerlock 400 Intermediate Coat, 4-8 mils DFT, Color Green PSX 700 Top Coat, 3-7 mils DFT 3. Sherwin Williams Zinc Clad III HS or 810e Prime Coat, 4-10 mils DFT, Color Red Macropoxy 646 Intermediate Coat, 4-8 mils DFT, Color Green Polysiloxane XLE Top Coat, 3-7 mils DFT 4. Sherwin Williams Galvapac (B65G11) Prime Coat, 4-10 mils DFT, Color Red Fast Clad Urethane Intermediate Coat, 5-8 mils DFT, Color Green Fast Clad Urethane Top Coat, 5-8 mils DFT B. Materials. The paint system selected for use by the Contractor shall be tested and approved by the Department (TxDOT) to ensure compliance with requirements of this specification and manufacturers product data. Zinc Epoxy primer shall meet DMS Coatings not listed above shall not be used on this project. All materials for testing shall be supplied by the Contractor. The Department will do all sampling of materials. The stripe coat shall be the same coating as the prime coat and shall be color gray. The color of the top coat will be as directed by the Engineer. 4. Equipment. Cleaning and painting equipment shall be of adequate capacity and have sufficient gauges, filters, agitators, regulators and moisture separators to ensure delivery of

3 clean dry air at the proper pressure and volume to permit satisfactory performance of the work. All equipment and accessories shall be maintained in good working order. Painting equipment shall be adequate for the type of paint being used and shall be equipped with spray heads adequate to provide a smooth, uniform coat of paint. Equipment used for spray painting shall have adequate provisions for separation of moisture from any air stream in contact with the paint. All spray equipment shall evidence good maintenance and be essentially free of old dried coatings on the exterior surfaces. Inside surfaces to which paint is likely to come in contact shall be completely free of any and all dried coatings or other foreign matter. Equipment not in compliance with the above will be unacceptable for use. All spray tips, fluid nozzles and air caps shall not show abuse. If abuse is evident by such characteristics as dents, wire brush marks or scratches, these parts will be unacceptable for use. Any spray equipment that cannot be adjusted to produce a spray pattern of uniform distribution will not be considered as suitable. If airless spray equipment is used, working regulator and air pressure or fluid pressure gauges shall be used. If conventional air spray equipment is used, independent fluid pressure and atomization pressure regulators and gauges shall be used. Fluid and air hoses for conventional air spray equipment shall be a minimum of 1/2 inch I.D. with a maximum length of 75 feet. Fluid hoses for airless spray equipment shall be a minimum of 5/16 inch I.D. and a maximum length of 75 feet. During painting operations, paint pots shall not be more than 20 feet above or below level of spray application of paint. Fluid hoses shall not be allowed to sag more than 10 feet below the level of the bottom of the paint pot or actual spraying operations whichever is the lowest point. All hoses shall be serviceable and shall not show cracks or deterioration. Paint pots or other suitable containers from which the paint is dispensed shall be equipped with agitators which shall be in operation at all times that paint is in the pot. Containment equipment, rigging, scaffolding, containment screens, ventilation system etc. shall meet the approval of the Engineer. The approval of the Engineer does not relieve the Contractor of responsibility for the safety or correctness of equipment, rigging, scaffolds, etc. Environmental control equipment maybe required, at the Engineers request or as dictated by the paint system selected, to prevent rust bloom or flash rust, or to maintain suitable ambient conditions for surface preparation, coating application and curing. 5. Inspection Access. Provide safe access to all parts of the work for hands on inspection. All platforms, rigging and equipment shall meet current OSHA standards and shall be designed, signed and sealed by a Professional Engineer registered in Texas. 6. Steel to be Painted. Clean and paint all exposed steel except for the steel specifically specified on the plans not to be cleaned and painted. Steel members include but not limited to, all main members, bearing apparatus, diaphragms, bracing, walkways, bolts, rivets, angles, inside of the steel boxes, ladders, and hand rail. 7. Construction

4 A. Qualification. Certification is required by the cleaning and painting contractor, and subcontractors. Submit proof of certification and certification of all proposed subcontractors before beginning work. 1. Field Cleaning and Painting. Maintain the following certification for the duration of the project. The Department will stop work if the Contractor s certification is revoked or will prohibit a subcontractor from working if the subcontractor s certification is revoked. a. SSPC-QP1. For paint application and removal of coatings not containing hazardous materials. b. SSPC-QP2. For removal of coatings containing hazardous materials. B. Cleaning and surface preparation. Prepare surfaces prior to applying paint. 1. General Preparation. Surfaces to be painted shall be completely free of oil, grease, moisture, dirt, salt contamination, sand, overspray, welding contamination (slag and/or acid residue); loose or flaking mill scale, rust or paint; and be free of any other conditions that will prevent the paint from forming a continuous, uniform, tightly adhering film. All steel splinters (hackles) raised or evident during cleaning shall be removed. Re-blast areas from which hackles were removed. Use the Tape Test on all surfaces to be painted, to determine if they are contaminated with loose particles. Prior to other cleaning operations and before painting, greaselike contaminants and contaminates shall be completely removed per the requirements of SSPC SP-1 using clean petroleum solvents or other methods approved by the Engineer. This requirement is be applicable for cleaning and to all coats of paint. a. Tape Test. Press a strip of filament tape onto the surface by rubbing with moderate thumb pressure 4 times, leaving approximately 2 inches of one end of the tape free from the surface. Grasp the free end and remove the tape from the surface with a sharp pull. The surface will be considered to be contaminated and not adequately cleaned if the removed tape exhibits particles cling to the tape. 2. Class of Cleaning. Use an approved abrasive recycling system with an approved recyclable abrasive. Do not use steel shot. The abrasive will be considered recyclable if it is separated from the dust and paint debris before being reused. An approved non-recyclable abrasive may be used for the steel girder spans. a. Class A Blast-Cleaning. Remove all visible rust, paint, mill scale, and other forms of contamination, so that the blasted surface appears near white when viewed with the unaided eye (corrected to vision). Meet the surface preparation requirements of SSPC-SP 10. b. Special Cleaning for Pack Rust. Pack rust and crevice corrosion shall be removed or dislodged using hand tools or power hand tools. Jobsite standard shall be established jointly by the Contractor and the Engineer at the pre-job meeting or during initiation of work

5 Cleaning shall produce an anchor profile on the surface of mils. C. Containment. The Contractor is required to contain all materials used or waste generated from the surface preparation and painting operations. These may include, but not limited to, all or some of the following: Petroleum solvents or other solvents used to remove grease-like contaminants; rusted or loose materials such as paint chips; blasting abrasives; wash water from hand applications or pressure applications; detergent wash water; overspray resulting from the painting operations; rags, brushes, sponges, paper or cloth bags, filters, protective clothing or other materials used during these operations. The Contractor must submit a plan to the Engineer detailing the procedure, techniques, and equipment that will be used to contain all the material used and wastes generated and how it will keep public and private property and the environment from being adversely affected by the cleaning and painting operations. The containment plan must be designed, signed, sealed, and include the date of submittal by a Texas licensed professional Engineer. The analysis should include the Live Load (wind and personnel) and Dead Load (all equipment). Verify that the forces and stresses induced on the members from these loads do not cause them to be overstressed. Approval of the containment plan is required before any work begins. If any waste escapes from the containment structure, work must cease until the waste is cleaned up and the leak site is repaired. All costs for modifying or adjusting inadequate containment system shall be at the Contractor s expense. 1. Rigging, Scaffolding, Containment, Etc. The containment system and structure should be capable of containing all blast refuse and designed to meet the following minimum requirements: *floor structure-rigid; floor support structure-rigid or flexible; able to support blast refuse, workers, equipment, and inspectors; be able to be retracted upward when suspended under bridge over ship channel; *containment material-flexible; *joints-fully sealed; *entryway-airlock or resealable; *penerability- air penetrable or air impenetrable walls; *watertight floor; *exhaust air filtration system capable of creating negative pressure inside the enclosure; causing the sides of the containment to have a concave appearance; *ability to withstand wind speeds appropriate for the project area; wind speeds could be substantially higher during hurricane season; *access to all parts of the work. At a minimum, all debris accumulated in the containment shall be collected daily. Accumulated debris shall not be left in containment overnight. In place of a full containment structure, a modified containment system may be proposed when using abrasive-blasting equipment equipped with negative pressure that will contain all blast refuse. It will be necessary to demonstrate the equipment's ability to contain all blast refuse for approval

6 Provision shall be made for moving, raising and/or nesting the work platform(s) and containment devices to provide passage of ships through the navigable waterway below the bridge. Rigging, scaffolds, etc., shall not be placed on or hung from an uncured painted surface. Protect cured coated surfaces from damage from the containment equipment. All coating damage, as a result of rigging and scaffolding shall be repaired as directed by the Engineer. 2. Environmental Emissions Control. a. Air Emissions. Unacceptable emissions shall be cause for project shut down until corrections to the containment are made. Prevent the release of air contaminants in quantities creating a nuisance condition or traffic hazard. Do not allow visible emissions from the containment to exceed random cumulative duration of more than one percent of the work day (SSPC Guide 6, level 1 emissions). Note: Workday determination constitutes only the time during which cleaning and surface preparation and subsequent clean up is performed. b. Water Quality. The Contractor is advised that the release of airborne particulate into or adjacent to water bodies in a manner that causes pollution of any of the water in the State could be considered an unauthorized discharge in violation of the Texas Water Code. Contain and collect any visible floating solids that reach the water. 3. Ambient Conditions Inside Containment. Environmental controls such as dehumidification and/or clean, dry, indirectly heated and forced air may be employed in the containment to maintain suitable ambient conditions for surface preparation and coatings application and curing. a. Final surface preparation on the bare substrate shall not be conducted when the surface temperature is less than 5 degrees above the dew point temperature or the surrounding air. b. Paint shall not be applied unless the steel surface temperature is at least 5 degrees above the dew point and the relative humidity is below 85%, unless authorized in writing by the Engineer. c. Lighting inside the containment shall be according to SSPC Guide 12, Guide for Illumination of Industrial Painting Projects. D. Waste Sampling and Testing. This paint debris shall be tested to determine its classification (hazardous or non-hazardous) and the type disposal that will be required. Representative samples shall be taken from each waste stream. Sampling of test specimens shall not be done without the Engineer being present to witness. The samples shall be labeled with the name of the collector, contract number, drum numbers from which the sample were taken, bridge ID number, and date of generation. An independent and approved certified laboratory will perform the testing. Test the waste using EPA Test Method 1311, Toxicity Characteristic Leaching Procedure (TCLP), to determine existing metal. The laboratory shall send the original report with the test result to the Area Engineer

7 E. Labeling and Storage. Maintain proper USDOT labeling for materials used. Label waste containers with a description of the materials contained and waste classification (for example UW Paint and Paint Related Waste or Nonhazardous Paint Removal Debris ), in accordance with applicable regulations. Provide a plan for a well drained and secure storage area for the Engineers approval. This should include, storage location, size, fencing, type of containers and preparedness, prevention and contingence plan for the steps to be taken in the event of an unplanned release or emergency. Any evidence of improper storage as determined by the Engineer shall be cause for immediate shutdown of the project until corrective action is taken. The Engineer shall have control over access to the storage area. Waste generated shall not be placed on unprotected ground and shall be shielded to prevent dispersion by wind or rain water. F. Disposal. Dispose of hazardous waste, non-hazardous waste and wastewaters according to regulations stated in Article 2. Refer to TCEQ regulatory guidance RG- 370, Managing Paint and Paint-Related Waste Under the Universal Waste Rule for additional information. Manifest each waste shipment with an appropriate waste shipment identifying the generator, registered transporter(s), and final disposal facility. Within 30 days of transportation of waste off site, the Contractor shall furnish to the Engineer, records of disposal including, but not limited to: signed waste manifests, scale tickets, and invoices. The generator and registered transported shall sign the manifest. The scale ticket(s) given by the landfill must have the following information: waste description, date of delivery, quantity, generation site, landfill name and address. Disposal of all waste, hazardous and non-hazardous, is considered subsidiary to this Item. G. Painting. 1. General. Follow manufacturer s specifications for coating requirements (application, thinning, recoat time, temperature, humidity, dew point etc). Approval by the Engineer of the cleaned surface is required prior to applying each coating. Each paint coating shall be applied to clean, dry, firm surfaces complying with the requirements of this specification and manufacturers product data recommendations. Each coat shall dry to form a smooth, continuous, tightly adhering film of uniform thickness and appearance, free of sags, runs, pinholes, holidays, and overspray. Care shall be taken to ensure that all surfaces to which paint is applied are free of all forms of contamination. All coats shall be applied by spray except that any method of application approved by the Engineer may be used to paint inaccessible areas. Do not apply paint to any surface with discernible moisture. The coatings can only be applied when the steel surface temperature is 5ºF above the dew point or when the relative humidity is less than 85%, as determined by a sling psychrometer in accordance with ASTM E 337, unless authorized by the Engineer. If in the opinion of the Engineer, there is an objectionable amount of dust in the atmosphere, the Contractor shall take necessary precautions to prevent dust and dirt from coming in contact with freshly painted surfaces or with surfaces before the paint is applied

8 If abrasive blast cleaned steel begins to exhibit flash rust within 4 hours after the blast cleaning operation has been performed, it will be necessary to spot test the steel surfaces for salt contamination (using Chlor-Rid Test Kits or other Engineer approved methods). If salt contamination is detected, the Engineer shall be contacted to determine corrective action. Corrective action to prevent salt contamination is considered subsidiary to this Item. Acceptable values for contamination will be set by the Engineer. Representative adhesion testing will be performed by the Department or it s representative to ensure adequate adhesion and application. Adhesion requirements will be based on the coatings manufacturers specifications. Care shall be taken when painting steel that is in contact with concrete to insure full coverage of the steel with a minimal amount of paint onto the concrete surface. In no case shall the paint extend more than four (4) inches onto the concrete surfaces. When painting is complete, the only visible paint on concrete surface shall be the finish coat. Excessive and/or objectionable paint on concrete surfaces shall be removed, at the Contractor's expense, in a manner approved by the Engineer. 2. Workmanship. All painting shall be done by skilled workers. Application of modern specialized coatings requires painters knowledgeable about the characteristics of the various coatings, solvents and substrates. The painter also must be capable of adjusting equipment and application techniques as dictated by the type of paint, weather conditions, environment, size and shape of surface being painted. Any painter who, in the opinion of the Engineer, does not adjust the equipment so that the coatings are applied in a uniform full wet coat free of runs, sags, holidays or overspray will not be considered to be a skilled and experienced painter. Spray applications of coatings shall be essentially 90 degrees to the surface and from 10 to 18 inches from the surface in order to apply a full wet coat of paint free of overspray, runs, sags and holidays. Any spray painter who does not consistently spray in this manner and/or extends the spraying stroke such that paint is being applied to the surface at an angle of less than 80 degrees shall not be allowed to spray paint. 3. Application. Application of all coatings shall be done according the manufacturers recommendations and following items. After an abrasive blast cleaned surface has been approved for painting, and before the formation of any rust bloom or flash rush occurs, apply the first coat of primer to the surface. The primer application shall be followed immediately by brush striping or working the wet coating into crevices, gaps and back-to-back steel mating surfaces. Striping at rivets, bolts, nuts, fasteners and edges is not required; however, diligent spray application from several angles is required to adequately coat these difficult shapes. The dry film thickness and standard for the striping shall be jointly establish by the Contractor and Engineer at the beginning of the project. Within the time frames recommended by the manufacturer for curing and/or recoating, the Contractor shall then apply the remainder of the approved coating system (after workmanship of each coat has been approved). All coatings are to have a smooth and uniform

9 appearance. Gloss level shall be in accordance with coating manufacturers technical data sheets. Any touch-up necessary to achieve the minimum dry film thickness required on any of the coats shall be in accordance with the coating manufacturer's recommendations and the approval of the Engineer. Final acceptance of the applied paint system occurs at the end of the project. Any defective areas such as pinholes, blisters, mud cracking, bubbling, peeling, contamination, flash rust, rust bloom, and spot, pinpoint, and general rusting of rust grade 9 as defined in SSPC VIS 2 (greater than 0.03% in any 9 square inch area) shall be removed and recoated at the Contractor s expense. 4. Inspection. Consultant (3 rd Party) and Department inspectors will be on site to enforce contract compliance according to Item 5, Control of Work. Specific Hold Points will be established by the Engineer to allow the Department or designated representative to verify the quality of the work. No work shall be permitted to proceed until the required inspection of an area has been completed or when the Engineer has approved otherwise. As a minimum, all coated surfaces will be visually inspected for the following items, and repairs completed before application of subsequent coats: Dry Film Thickness Uniformity Runs and Sags Bubbling Mechanical Damage Holidays (missed areas) Contaminants Blistering Loss of Adhesion/Delamination Missed Areas A Tooke gage, a destructive dry film thickness instrument, may be used if low dry film thickness of one or several of the coats of paint is suspected. Complete coating repair of the area where the destructive test is performed is considered subsidiary to this Item. 5. Paint Improperly Applied. To uncover evidence of improperly applied paint, the Engineer may, at any time during construction, explore underneath the surface of any paint coats already applied. Whenever unsatisfactory conditions are found, the Engineer may require any and all necessary remedial measures as follows: All paint which has been applied improperly, applied to improperly cleaned surfaces, fails to dry and harden properly, fails to adhere tightly to underlying metal or other paint film, or does not evidence a normal, workmanlike appearance in conformance with these specifications, shall be repaired or completely removed and replaced at the expense of the Contractor. When the final field coat does not have a uniform color and appearance throughout the structure, it shall be corrected by the use of whatever additional coats or other corrective measures found to be necessary. Freshly applied paint, which has not yet set, shall be removed with the use of suitable solvents. Removal of dried paint films shall be by a method approved by the Engineer

10 Paint improperly applied shall be repaired at no additional cost to the State and is considered subsidiary to this Item. Repair of coatings where destructive paint inspection occurred is considered subsidiary to this Item. 8. Measurement. This item will be measured by the lump sum for the entire structure as shown on the plans. When units are shown on the plans such as square feet of surface area, they are for the Contractor's information only. 9. Payment. When indicated as a bid item on the plans, the work performed and material furnished in accordance with the Item and measured as provided under "Measurement" will be paid for at the unit price bid for "Cleaning and Painting Corpus Christi Harbor Bridge". This price shall be full compensation for cleaning; containment; painting; for furnishing all labor, supervision, equipment, tools, materials, incidentals, scaffolding, and protection of traffic; and for handling, labeling, storing, delivery and disposal of the materials used and waste generated; and for sampling and testing of waste generated, delivery and disposal of all hazardous and non-hazardous waste; and repair defective work as specified herein, and as necessary to complete the work. Any defective work that needs to be corrected or completely removed and replaced shall be considered subsidiary to this Item