Bridge Maintenance Painting Projects Design and Management Considerations
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1 Bridge Maintenance Painting Projects Design and Management Considerations A Presentation to the 2018 Louisiana Transportation Conference Baton Rouge, Louisiana
2 Are we still making progress?
3 Things are definitely changing It looks like we are.
4 Over the past 45 years bridge painting has certainly changed
5 Determine Bridge Coating History Basic Coating Project Design Considerations Conduct Existing Coating System Sampling and Testing Evaluate Project Site Conditions Determine Required and Allowable Access and Available Clearances Scope or Type of Project Containment System Requirements Review of 2016 Standard Specifications Design Options Impact of Structural Repairs on Coating Projects Address the Causes or Results of Corrosion
6 Determine Bridge Coating History Original coating age and any maintenance painting Coating types used and number and thickness of coats Extent and nature of corrosion and type or cause of coating failure Large bridge structures may have different coating histories Determine service environment Review any inspection or coating assessment reports
7 Conduct Existing Coating Sampling and Testing Determine presence and level of any typical hazardous components lead, cadmium, and chromium. Test for non-visible contaminants to determine - chloride, ferrous, nitrate, and sulfate presence and level Visible contamination Oil, tar, asphalt, concrete, grease, dirt, debris and any industrial dusts Coating adhesion, thickness, and number of coats Determine if mill scale is present under existing coatings
8 Known Contamination Conditions
9 Ground conditions Identify sensitive receptors Public access and other plants or facilities Railroad crossings on or under the project Electrical transmission lines Drainage conditions on ground and structure Review Right -of-way drawings Identify potential waste storage and work yard areas on site Lighting components, cameras and other sensors Utility conduits carried on structure and buried across the site Galvanized elements in need of painting Project Site Conditions
10 Ground Improvements
11 Sensitive Receptors
12 Sensitive Receptor Areas- businesses, residences and public areas close to the bridge should be identified and more frequent visual emission assessments and housekeeping checks conducted. Perform 24 hour high volume air sampling located near the sensitive receptors to verify they are not being negatively impacted as a result of the contractor s activities. Housekeeping is Paramount - thorough vacuuming of lead dust and abrasives from steel members and containment tarps prior to containment dismantling is essential to keeping a safe work environment.
13 Cameras, Signal Lights,
14 Utility Conduits
15 Access and Containment Typically, the two biggest costs for projects involving abatement of hazardous paint on complex structures are access and containment. Access for both workers and containment equipment and types of containment.
16 Allowable bridge vehicular traffic lane closures Prepare traffic control plans Determine Available Access and Required Clearances Prepare Traffic Management Plan (TMP) when required Existing and required vehicular roadway clearances Existing and required railroad clearances Meet with US Coast Guard to establish allowable infringement of marine horizontal and vertical clearances and any other restrictions Any access restrictions to area under project
17 Access from Roadway
18 Minimum Lane Closure Work Zone Requirements
19 Access from Roadway
20 Access from Ground
21 Railroad Clearances
22 Railroad Clearances
23 Wind Turbine Blades
24 Containment Clearance
25 Typical Coating Project Types Spot Cleaning and Painting Zone Cleaning and Painting Spot / Zone Cleaning and Full Overcoating Full Repaint (Total Removal and Replacement) Full Repaint and Structural Repairs Combinations of some of the above
26 Spot Painting
27 Spot Painting
28 Overcoating
29 Zone Cleaning and Painting and Structural Repairs
30
31 Post Blast Inspection - Fastener Deterioration
32 Zone Cleaning and Painting
33 Zone Cleaning and Painting
34 Huey P Long Bridge Segment 6 - Main Bridge Floor System
35 Movable Deck Platform System
36 Zone Cleaning and Painting Containments
37 Railroad Deck Containments
38 Huey P Long Segment 7 Main Bridge Truss Above Deck
39 Full Removal and Repainting
40 Movable Containment Tunnel Structure
41 Movable Containment Tunnel Structure
42 Required many containments Full Repaint and Structural Repairs
43 Large Containments Full Repaint and Structural Repairs
44 Tight Roadway Clearances = Rigid Containment Material
45 Partitioned Truss Containments
46 New 2016 Louisiana Standard Specifications
47 Materials Section 811 Painting and Protective Coatings Specification Project Designer Options Coating system selection Defaults to Zinc Paint System on AML Anti-Skid material selection Defaults to Manufacturer Recommendation Caulk material selection- Defaults to Manufacturer Recommendation Submittals Identify party to receive Defaults to Project Engineer Specify if Critical Path Method (CPM) schedule is required Cleaning and Painting Identify all galvanized or metalized items to be painted
48 Surface Preparation Section 811 Painting and Protective Coatings Specification Project Designer Options Specify required surface preparation standard Default is SSPC SP 10 abrasive blast cleaning Specify if aluminum or stainless steel elements such as roadway lighting, decorative lighting metalwork, utility conduits, non-metallic conduits or cables are to be painted Default is to cover and protect Specify disconnection time for electrical items Default is negotiate with utility Cost for de-energizing or protection to be included in Item unless specified otherwise
49 Surface Preparation Cont. Section 811 Painting and Protective Coatings Specification Project Design Options Specify if soluble salt detection and removal are not required Default is to conduct per standard specification requirements Specify surface profile requirements if other than default SP 10 abrasive blast cleaning Application Specify if prime stripe, intermediate and topcoat are to be applied to new steel before erection Default is after erection Specify if additional type or frequency of QC testing is required Default is per standard specifications Specify if penetrating sealer is required No default (Spec change to require sealer is pending)
50 Cleaning and Painting Other Items Section 811 Painting and Protective Coatings Specification Project Design Options Specify paint system for steel piles, sheet, pipe or H-piles Default is coal tar epoxy Specify cleaning and paint for lumber or timber to be painted Default is selection by Project Engineer Specify machinery surfaces to be painted No default Galvanizing and Metalizing If galvanizing of hardware by other than ASTM A153 or ASTM B695 is required it must be specified If other than thermal spray coating composed of 85% aluminum and 15% zinc is required it must be specified
51 Cleaning and Painting Containment Systems Section 817 Temporary Works Specification Project Design Options Specify class and type of containment system - Default is Class IA Specify required vertical and horizontal highway, railroad and waterway clearances Default is to maintain existing
52 Mechanically galvanized fasteners required for structural repairs Fasteners for Structural Repairs Solvent cleaning the bolt and bolt field and compliance with ASTM 6386 is required by current 2016 specifications
53 Structural Repairs In the past faying surfaces were coated with lead paint that is not removed by blast cleaning. Rivet removal and coating removal from faying surfaces are OSHA Lead regulation trigger tasks requiring respiratory protection and personal exposure assessments Structural repairs including rivet busting, plate clipping and power tool cleaning of former faying surfaces. TSP-lead air samples over the project limit can result from these activities. Engineering controls, respiratory protection and personal air monitoring should be employed when performing structural repairs on projects where the original coating system contained heavy metals even if they occur post blast cleaning.
54 Structural Repairs - Lead Paint on Existing Faying Surfaces
55 Structural Repairs Post Blast Inspections
56 Structural Repairs - Post Blast Inspections
57 Gusset Plate Clips
58 Gusset Plate Clips
59 Gusset Plate Clips
60 Structural Repairs
61 Structural Repairs
62 Structural Repairs
63 Structural Repairs
64 Surface Preparation of New Mechanically Galvanized Fasteners
65 Mechanically Galvanized Fastener Surface Preparation
66 Affects of Dirt and Ponding Water on Corrosion of Tower Base Anchor Bolts
67 Affects of Dirt and Ponding Water on Corrosion of Tower Base Anchor Bolts
68 Tower Anchor Bolt Replacement
69 Field Changes Chockfast Epoxy to Fill Annular Spaces
70 Dirt and Debris Accumulations at Tower Column Bases
71 Heavy Past Pitting and Ponding Water in Tower Bases
72 Field Changes Chockfast Epoxy to Fill Tower Bases
73 Field Change - Epoxy Poured to Fill Pitting at Tower Bases
74 Field Change - Epoxy Poured to Fill Pitting at Tower Bases
75 Field Change - Epoxy Poured to Fill Pitting at Tower Bases
76 Finished Condition- Replacement Angle and Epoxy Filled Pitting at Tower Bases
77 Water Ponding in Past Pitting Lower Chord Horizontal Diaphragms
78 Field Change Fiberglass Chord Perforation Covers
79 Member Corrosion and Drainage Issues
80 Poor Drainage at Truss Vertical Sealing Diaphragms
81 Poor Drainage and Dirt Accumulations = Pitting and Perforations
82
83 Poor Drainage and Dirt Accumulation
84 Poor Drainage and Dirt Accumulation
85 Partnering is a True Measure of Success Recognize That Everyone s Job Is Critical All Organizations Need to Succeed Open and Honest Communication Identify the Issue, Resolve it Immediately Make a Commitment and Hold Up Your End of the Deal Keys to Successful Projects
86 Thank You! Questions?
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