Bridge Maintenance Painting Projects Design and Management Considerations

Bridge Maintenance Painting Projects Design and Management Considerations A Presentation to the 2018 Louisiana Transportation Conference Baton Rouge, Louisiana

Are we still making progress?

Things are definitely changing It looks like we are.

Over the past 45 years bridge painting has certainly changed

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

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

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

Known Contamination Conditions

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

Ground Improvements

Sensitive Receptors

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.

Cameras, Signal Lights,

Utility Conduits

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.

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

Access from Roadway

Minimum Lane Closure Work Zone Requirements

Access from Roadway

Access from Ground

Railroad Clearances

Wind Turbine Blades

Containment Clearance

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

Spot Painting

Overcoating

Zone Cleaning and Painting and Structural Repairs

Post Blast Inspection - Fastener Deterioration

Zone Cleaning and Painting

Huey P Long Bridge Segment 6 - Main Bridge Floor System

Movable Deck Platform System

Zone Cleaning and Painting Containments

Railroad Deck Containments

Huey P Long Segment 7 Main Bridge Truss Above Deck

Full Removal and Repainting

Movable Containment Tunnel Structure

Required many containments Full Repaint and Structural Repairs

Large Containments Full Repaint and Structural Repairs

Tight Roadway Clearances = Rigid Containment Material

Partitioned Truss Containments

New 2016 Louisiana Standard Specifications

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

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

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)

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

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

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

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.

Structural Repairs - Lead Paint on Existing Faying Surfaces

Structural Repairs Post Blast Inspections

Structural Repairs - Post Blast Inspections

Gusset Plate Clips

Structural Repairs

Surface Preparation of New Mechanically Galvanized Fasteners

Mechanically Galvanized Fastener Surface Preparation

Affects of Dirt and Ponding Water on Corrosion of Tower Base Anchor Bolts

Tower Anchor Bolt Replacement

Field Changes Chockfast Epoxy to Fill Annular Spaces

Dirt and Debris Accumulations at Tower Column Bases

Heavy Past Pitting and Ponding Water in Tower Bases

Field Changes Chockfast Epoxy to Fill Tower Bases

Field Change - Epoxy Poured to Fill Pitting at Tower Bases

Finished Condition- Replacement Angle and Epoxy Filled Pitting at Tower Bases

Water Ponding in Past Pitting Lower Chord Horizontal Diaphragms

Field Change Fiberglass Chord Perforation Covers

Member Corrosion and Drainage Issues

Poor Drainage at Truss Vertical Sealing Diaphragms

Poor Drainage and Dirt Accumulations = Pitting and Perforations

Poor Drainage and Dirt Accumulation

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

Thank You! Questions?