DCP3F TECHNICAL SPECIFICATIONS

- BRIDGES AND RAILWAY

STRUCTURES

11 Protection of Steel Work from Corrosion

11.1 General
1 Weathering steel (ASTM A709 Grade 50W) and for Other steel (Such as Secondary Members), shall be
protected with coating relevant to Corrosion category C5 according to BS EN ISO 12944, complying with
AREMA Chapter 15-8 for application and repair. HSFG Fasteners used for Main Members and secondary
members respectively, after torqueing and tightening, shall be painted with the same coating system to
match the surface.
2 The Contractor will procure a specialist advisor to determine the required system to provide a steelwork
protection coating with a minimum period between maintenance of 15 years for the exposure
conditions on the Site.
3 Surface preparation for protective coatings, such as abrasive blasting or wire brushing, will be carried
out after fabrication of major elements has taken place, and the appropriate coating will be applied as
soon as possible after preparation in accordance with
within 4 hours.
4 Surface preparation and cleaning will remove loose rust and mill scale and spatter, slag, or flux deposits
and will be as per the following specifications and standards:
a) SSPC- mmercia or SSPC-

b) SSPC- -up and repair work.

c) Priming: Immediately after surface preparation, apply primer according to manufacturer's written
instructions and at rate recommended by SSPC. Stripe paint corners, crevices, bolts, welds, and sharp
edges.
5 Coating will be applied in the shop in accordance with relevant Specifications
6 On site painting will be kept to a minimum adjacent to necessary site joints.
7 These areas will be made good and painted in accordance with the manufacturer's recommendations.
8 Type of paint coating as Epoxy based Zinc rich Primer coat, Epoxy Rich MiO intermediate coat and
Polyurethane Top Coat will be in accordance with relevant specifications as recommended by the paint
manufacturer complying durability, safety and environmental requirements of the project.
9
10 An independent protective coating inspector will be appointed by the Steel Work Subcontractor to
inspect and test the protective coating systems.
11 These independent inspections will be carried out in the shop and on site after transport and after
erection.
12 -referenced on the as- built
record drawings.
13 The Contractor will provide warranties that the protection system as constructed will provide 15 years of
maintenance-free performance.
14
or fibre / concrete or similar cladding.
15 The system of fire protection will be adequate to remain effective and undamaged under the action of
vibrations arising from rail traffic.

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16 The Fireproof Coating shall be in accordance with Association for Specialist Fire Protection, ASFP _
Technical Guidance Document TGD-11.

11.2 Surface Preparation

11.2.1 Pre degrease surface preparation
1 Surface preparation of all welds, corners, etc. shall be undertaken to ensure a compatible surface
finish is achieved for coating prior to surface degreasing and grit blasting.
2 Surface cleaning and removal of all debris associated with welding and construction or other such
contaminants shall be undertaken prior to surface degreasing and grit blasting.
3 Full visual inspection by the third-party inspector and acceptance to proceed will be required for the
above actions prior to surface degreasing.

11.2.2 Surface Degreasing

1 All steel surfaces shall be degreased using suitable solvent free emulsifying detergent and clean
potable water.
2 Degreasing shall commence at the highest part of the structures and proceed to the lowest part of
the structures to prevent contamination of the degreased areas.
3 The surface shall be allowed to dry.
4 Full visual inspection by the third-party inspector and approval to proceed will be required for the
above actions prior to dehumidification.

11.2.3 Abrasive Grit Blast Cleaning

1 Abrasive blasting cleaning will be undertaken using hard sharp angular grit/shots or garnets with
suitable methods to achieve desired surface cleanliness and profile before applying primer coat.
2 The final surface of the steel immediately prior to application of the first coat in any coating system
shall comply with SSPC-SP 6 or SSPC-SP 10 as per recommendation of the paint manufacturer
3 If vacu-blasting is used, then metallic abrasives may be used, and only metallic abrasives shall be re-
cycled.
4 The Contractor shall provide any necessary methods of containment to ensure abrasive used for
blast cleaning and debris is contained local to the area being prepared. In particular spent abrasive
should not be allowed to fall into any water courses or affect any other part of the working areas.
5 If necessary, the containment shall also offer the area of external works adequate protection from
rain and wind.
6 The containment shall control the local environment throughout the coating operations and include
the initial drying and curing of the applied coatings. This requirement is only applied when
considered viable and as agreed with the Project Manager.

11.2.4Equipment Requirements
Suitable oil, water and air filtration equipment shall be installed between the air compressor and the blasting
equipment to ensure no contamination occurs.

11.2.5Metal Defects
Any weld spatter, rough weld caps, sharp edges or other metal defects exposed after surface preparation on
all surfaces shall be removed.

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STRUCTURES

11.3 Coating Systems

11.3.1 General
1. The Contractor shall submit and obtain acceptance from the Engineer the proposed colours prior to the
works. Where two or more coats are to be used, a different colour shade shall be used for each coat.
2. egarding minimum and maximum over-coating intervals shall be
strictly followed.
3. The Contractor may propose alternative coating systems to those specified, provided the proposal
complies with the requirements of this Specification and is accepted by the Engineer.
4. The Coating system supplied shall conform to the requirements of this Specification and shall have
certification from third party coating inspector appropriate to the service environment and required
durability as given in Durability Assessment Report.
5.
color, the specification with which the paint complies, whether for interior or exterior use, and whether
for a priming coat, an undercoat or a finishing coat. No materials of any description shall be added to the

and paints of different types or of different manufacturers shall not be mixed.

6. Each batch shall be dated on delivery and shall be used strictly in order of delivery. Wherever possible,
coating materials to be from one manufacturing batch.
7.
recommendation shall be replaced.
8. Paint shall be stored in sealed containers in a store where it will not be exposed to extremes of
temperature. The temperature of the store shall be kept between 4 ºC and 27 ºC unless the storage
conditions recommended by the manufacturer allow temperatures outside this range. Any special storage
conditions recommended by the manufacturer shall be observed.
9. The Contractor shall obtain all components of the paint system from one manufacturer.

11.3.2Application Conditions
Coatings shall not be applied under the following conditions for external works.
When the ambient temperature falls below 5°C, when steel temperature falls below 5°C or the relative
humidity rises above 85%.
When the ambient temperature is less than 3°C above the dew point.
When the steel or ambient temperatures are above the temperature recommended by paint
manufacturer.
When rain, snow, fog, or mist could affect the work area
In a dust laden atmosphere
When the amount of moisture likely to be deposited on the surface by condensation or rain immediately
before and after coating, may have a harmful effect on the coating.
When wind-borne dust may have a harmful effect on the coating.
Every effort shall be made to maintain the conditions above throughout the coating system application.

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Blasting operations and painting processes shall be segregated.

11.3.3Coating Application
1 All components of the coating materials shall be prepared in strict accordance with the coating

2 Mixing equipment shall be clean and dry and not contaminate the coating material in any way. No
mixed coating material shall be used beyond its specified pot life or when it is clearly thickening.
3 Prior to use, the base component of 2-pack materials shall be thoroughly mixed using a slow rotating
power mixer before the hardener is added. The hardener shall be added with constant slow rotating
mixer recommended by the coating supplier and the composite mixed until homogeneous.
4 Application can be by brush, roller or spray, as recommended by paint manufacturer.
5 All coats shall be applied without thinning unless recommended by the paint manufacturer and
approved by the Engineer.
6 Coatings shall only be applied to clean, dry surfaces that have been prepared to and meet the
requirements of this Specification unless otherwise agreed by the Engineer. A new coat shall not be
applied over another coat that has any contamination present. Particular notice shall be taken to
ensure no coat is applied over another that is affected by amine bloom.
7 Wet film thickness gauges shall be used regularly to check adequate wet material is applied to
achieve the DFT.
8 Each coat, at whatever thickness applied, shall be free from surface defects, particularly cratering,
pin-holing, blistering, revelling, sagging, bittiness, and cissing.
9 The finished system shall be of an even and uniform appearance.
10 The minimum and maximum over-coating times recommended by the coating manufacturer shall be
complied with and will be temperature dependent.
11 As per AREMA Chapter 15, Page 15-8-37, DFT Shal be measured as per SSPC PA2
12 All gauges shall be calibrated before use, the Engineer shall be provided with calibration records.
Any newly applied coating that is damaged shall be fully re-instated in accordance with this
Specification.

11.3.4Stripe coats
The Contractor shall brush apply an additional stripe coat of at least one high build coat to all angles, welds,
edges, Fasteners and all areas that are difficult to coat

11.3.5Handling and Storing Coated Steelwork

1 Use methods and equipment which will minimise chafing, chipping, and other damage to coated
components.
2 Ensure an adequate drying/curing period for each coat before handling.
3 Use suitable packing, lashings, lifting harnesses, nylon slings, rubber protected chains and chocks,
etc.

11.4 Coating on Joints and Fixings

11.4.1High strength friction grip (HSFG) bolted joints
1 The Contact surface of the HSFG Bolted parts i.e. faying surfaces between splice plates shall blast-
cleaned and coated to achieve Class B Coating through a Class B coating system as per

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STRUCTURES

requirements of Research Council on Structural Connections (RCSC) Class B, Appendix A (Slip

coefficient and resistance to tension creep) or unsealed pure zinc or 85/15zinc/aluminium thermal-
sprayed coatings with a thickness less than or equal to 16 mils as per AASHTO LRFD CL 6.13.2.8, to
achieve Slip Coefficient 0.5 as per Section 1.4; Table 15.1.11a of AREMA Chapter 15.
2 The splices shall be checked as slip-critical per AASHTO LRFD 6.13.2.1.1. The contact Surfaces (faying
surface) of the bolted parts are assumed to be CLASS B according to AASHTO 6.13.2.8.
3 Contractor shall propose the Painting system to achieve Class B slip Factor to Engineer for review
and approval before use.
4 The Faying surface under the bolt head, Nut and Washer in contact with steel plate shall be same as
per Clause 3.4.1.1
5 HSFG Bolts, Nuts and Washers shall be supplied in Black condition without any coating.
6 Surface Preparation for Faying surface: unpainted blast-cleaned surfaces to SSPC-SP 6 or better

11.4.2Welded joints
1 The Contractor shall ensure that areas within 200mm of known site welds shall not be painted until
all welding and testing is completed. Where this is not practicable the Contractor shall ensure that
the paint coat is removed by grinding and each coat is stepped back to enable preparation of fusion
faces for welding.
2 Welds and surfaces which have been affected by welding shall receive the preparation and
protective systems which are applied to the parent surfaces.
3 The joints having been made and passed inspection, the parent and joint materials, exposed parts of
bolts, nuts and washers, weld and weld affected areas shall be prepared and painted.
4 All bolted joints shall be sealed against the ingress of moisture. Before painting commences gaps at
joints shall be plugged with approved filler. The perimeter of all joints shall be sealed with
subsequent coats of paint.

11.5 Inspection
1 The Contractor shall be responsible for carrying out all inspection and quality control testing in
accordance with this Specification and Approved Inspection and Test Plan. Personnel undertaking
inspection and quality control testing shall be suitably trained and hold applicable and current
certification. Certification to Level II under the Institute of Corrosion Scheme or equivalent is
required.
2 Inspection and quality control activities shall be adequate to ensure all surfaces are prepared and all
coatings applied to comply with this Specification and t
recommendations.
3 Inspection and quality control activities shall include but not be limited to:
a) Surface preparation including surface profile amplitude measurement
b) Mixing of coatings
c) Application of coatings
d) Monitoring of ambient conditions
e) Appearance and DFT of applied cured coatings
f) Recording of batch numbers of materials used
g) Recording of results of inspections and monitoring

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h) Adhesion Test for Pull Off Strength of Coatings using portable Adhesion Testers on sample
panels.
4 All site records will be kept in legible hard copy format and shall be computerised daily and available
for review by the Engineer.
5 The Contractor shall permit coating manufacturers to inspect the work in progress, including surface
preparation, and to take samples of their products if required. The Contractor shall not comply with
any directions or requests given by the coating manufacturer's representative unless and until
confirmed in writing by the Engineer.
6 The Contractor shall notify the Engineer of projected dates for start of surface preparation and
coating.

11.6 Protection
1 The Contractor shall protect freshly applied surface coatings from damage. Protect surfaces adjacent
to those being prepared and coated.
2 Stack coated components clear of the ground, separated by timber chocks, and so that ponding does
not occur.

11.7 Remedial Work

1 Early degradation of coatings (that is prior to the defects date) by blistering, peeling, flaking, cracking
and lack of adhesion must be made good by complete removal, preparation, and reapplication of all
coats.
2 Inadequate dry film thickness or surface defects shall be remedied by rubbing down and applying
further coat(s), as recommended by the coating manufacturer.
3 Mechanical damage to new coatings must be made good by local cutting back of coatings,
preparation, and re-application of all coats to leave a neat, continuous, and smooth finish.
4 Where damage to coatings or subsequent surface preparation has exposed bare metal, it must be
thoroughly cleaned, prepared, and primed within two hours.

11.8 Coating Application on Trial Panels

1 Prior to applying the system in the works, trial applications shall be carried out by the Contractor.
The trials will demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating.
2 The coating application procedure trials applicable to the steelwork are to be the initial element of
works on the Site and the Contractor must allow adequate time for these procedure trials.
3 Representatives of the coating manufacturer shall attend the trials and the surface preparation and
application of the coating shall be carried out under their direction.
4 The coated element(s), when accepted will form the standard against which the corresponding
coating in the works will be judged.
5 No changes to the materials and/ or methods of application used in the painting trials shall be
permitted during the main works unless agreed by the Engineer.

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