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S 8.1 - 2006
This document is a standard developed by the AASHTO/NSBA Steel Bridge Collaboration. The
primary goal of the Collaboration is to achieve steel bridge design and construction of the
highest quality and value through standardization of the design, fabrication, and erection
processes. Each standard represents the consensus of a diverse group of professionals
It is intended that Owners adopt and implement Collaboration standards in their entirety to
facilitate the achievement of standardization. It is understood, however, that local statutes or
preferences may prevent full adoption of the document. In such cases Owners should adopt these
documents with the exceptions they feel are necessary.
Disclaimer
The information presented in this publication has been prepared in accordance with recognized
engineering principles and is for general information only. While it is believed to be accurate,
this information should not be used or relied upon for any specific application without
competent professional examination and verification of its accuracy, suitability, and
applicability by a licensed professional engineer, designer, or architect.
The publication of the material contained herein is not intended as a representation or warranty
of the part of the American Association of State Highway and Transportation Officials
(AASHTO) or the National Steel Bridge Alliance (NSBA) or of any other person named herein,
that this information is suitable for any general or particular use or of freedom from
infringement of any patent or patents. Anyone making use of this information assumes all
liability arising from such use.
Caution must be exercised when relying upon other specifications and codes developed by other
bodies and incorporated by reference herein since such material may be modified or amended
from time to time subsequent to the printing of this edition. The authors and publishers bear no
responsibility for such material other than to refer to it and incorporate it by reference at the
time of the initial publication of this edition.
Voting Members
Officers:
Regional Representatives:
Nonvoting Members
i
Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
All rights reserved.
AASHTO HIGHWAY SUBCOMMITTEE ON BRIDGES AND STRUCTURES
2006
Malcolm T. Kerley, Virginia Chair
James A. Moore, New Hampshire Vice Chair
M. Myint Lwin, Federal Highway Administration, Secretary
Firas I. Sheikh Ibrahim, Federal Highway Administration, Assistant Secretary
ALABAMA, William F. Conway, John F. Black, OHIO, Timothy J. Keller, Jawdat Siddiqi
George H. Connor OKLAHOMA, Robert J. Rusch, Gregory D. Allen
ALASKA, Richard A. Pratt OREGON, Bruce V. Johnson
ARIZONA, Jean A. Nehme PENNSYLVANIA, Thomas P. Macioce, Harold C.
ARKANSAS, Phil Brand Rogers, Jr.
CALIFORNIA, Kevin Thompson, Susan Hida, Barton PUERTO RICO, Jaime Cabr
Newton RHODE ISLAND, David Fish
COLORADO, Mark A. Leonard, Michael G. Salamon SOUTH CAROLINA, Barry W. Bowers, Jeff
CONNECTICUT, Gary J. Abramowicz, Julie F. Sizemore
Georges SOUTH DAKOTA, John C. Cole
DELAWARE, Jiten K. Soneji, Barry A. Benton TENNESSEE, Edward P. Wasserman
DISTRICT OF COLUMBIA, Donald Cooney TEXAS, William R. Cox, David P. Hohmann, Ronald
FLORIDA, William N. Nickas, Marcus Ansley, Andre D. Medlock
Pavlov U.S. DOT, M. Myint Lwin, Firas I. Sheikh Ibrahim,
GEORGIA, Paul V. Liles, Jr., Brian Summers Hala Elgaaly
HAWAII, Paul T. Santo UTAH, Todd Jensen
IDAHO, Matthew M. Farrar VERMONT, William Michael Hedges
ILLINOIS, Ralph E. Anderson, Thomas J. Domagalski VIRGINIA, George M. Clendenin, Prasad L.
INDIANA, Anne M. Rearick Nallapaneni, Julius F. J. Volgyi, Jr.
IOWA, Norman L. McDonald WASHINGTON, Jugesh Kapur, Tony M. Allen, Bijan
KANSAS, Kenneth F. Hurst, James J. Brennan, Loren Khaleghi
R. Risch WEST VIRGINIA, Gregory Bailey, James W. Sothen
KENTUCKY, Allen Frank WISCONSIN, Finn Hubbard
LOUISIANA, Hossein Ghara, Tony M. Ducote WYOMING, Gregg C. Fredrick, Keith R. Fulton
MAINE, James E. Tukey, Jeffrey S. Folsom ALBERTA, Tom Loo
MARYLAND, Earle S. Freedman, Robert J. Healy NEW BRUNSWICK, Doug Noble
MASSACHUSETTS, Alexander K. Bardow NOVA SCOTIA, Mark Pertus
MICHIGAN, Steve P. Beck, Raja T. Jildeh ONTARIO, Bala Tharmabala
MINNESOTA, Daniel L. Dorgan, Kevin Western SASKATCHEWAN, Howard Yea
MISSISSIPPI, Mitchell K. Carr, B. Keith Carr GOLDEN GATE BRIDGE, Kary H. Witt
MISSOURI, Shyam Gupta, Paul Kelly, Paul Porter N.J. TURNPIKE AUTHORITY, Richard J. Raczynski
MONTANA, Kent M. Barnes N.Y. STATE BRIDGE AUTHORITY, William J.
NEBRASKA, Lyman D. Freemon, Mark Ahlman, Moreau
Hussam Fallaha PENN. TURNPIKE COMMISSION, Gary L.
NEVADA, William C. Crawford, Jr. Graham
NEW HAMPSHIRE, James A. Moore, Mark W. SURFACE DEPLOYMENT AND DISTRIBUTION
Richardson, David L. Scott COMMAND TRANSPORTATION
NEW JERSEY, Harry A. Capers, Jr., Richard W. ENGINEERING AGENCY, Robert D. Franz
Dunne U.S. ARMY CORPS OF ENGINEERS -
NEW MEXICO, Jimmy D. Camp DEPARTMENT OF THE ARMY, Paul C. T. Tan
NEW YORK, George A. Christian, Donald F. Dwyer, U.S. COAST GUARD, Nick E. Mpras, Jacob Patnaik
Arthur P. Yannotti U.S. DEPARTMENT OF AGRICULTURE -
NORTH CAROLINA, Greg R. Perfetti FOREST SERVICE, Rosana Barkawi
NORTH DAKOTA, Terrence R. Udland
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
All rights reserved.
AASHTO / NSBA Steel Bridge Collaboration
Task Group 8, Coatings
Eric Kline, KTA-Tator, Chair
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
All rights reserved.
Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Table of Contents
Introduction..................................................................................................................................... 1
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Introduction
This guide represents a consensus on best industry practice for shop application of zinc rich
primers to previously uncoated bridge steel and includes the proper preparation of the steel
surfaces and the mixing, application, and cure of coatings. To simplify the application
parameters for a system based on zinc-rich primers on new steel bridges, a series of charts have
been developed. These charts provide a convenient summary listing the detailed requirements for
surface preparation, environmental conditions, coating application, curing, and verification
testing. The guide addresses a three-coat system consisting of primer, intermediate coat, and
topcoat, but is appropriate for application of a two-coat system or primer only.
This document establishes and defines the functions, operations, requirements, and activities
needed to achieve consistent quality in steel bridge painting. It is based on a cooperative
approach to achieving quality, where both the Owners and Contractors representatives work
together with a clear understanding of their roles and responsibilities, resulting in steel bridges
completed in an efficient manner while meeting all contractual requirements. Its acceptance
does not in any respect preclude anyone, whether he has adopted the standard or not, from
manufacturing, marketing, purchasing, or using products or procedures not addressed in this
standard.
Environmental, containment, and safety issues referenced herein are outside the scope of this
guide and should be addressed in other documents.
This guide uses mandatory (imperative) language to assist owners and specifiers with
development of contract language.
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 1
Definitions
1.1 Applicator (Shop)
Person or contractor who applies a coating.
1.2 Breaking the Corner (Corner Commentary:
Chamfering)
A process by which a sharp corner is flattened The breaking (flattening) of a sharp corner is
by passing a grinder or other suitable device sketched below:
along the corner, normally in a single pass.
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 2
Reference Standards
Unless otherwise noted in the contract, the latest edition of the following standards and
regulations in effect at the time of contract letting form a part of this guide. A copy of applicable
reference standards shall be available at the painting facility.
2.1 American Association of State Highway and Transportation Officials (AASHTO)
2.1.1 AASHTO M 160, Standard Specification for General Requirements for Rolled Steel
Plates, Shapes, Steel Pilings, and Bars for Structural Use
2.1.2 AASHTO M 300, Standard Specification for Inorganic Zinc-Rich Primer
2.1.3 AASHTO R 31, Standard Practice for Evaluation of Coating Systems with Zinc-Rich
Primers
2.2 American Society for Testing and Materials (ASTM)
2.2.1 ASTM A 6, Specification for General Requirements for Rolled Structural Steel Bars,
Plates, Shapes, and Sheet Piling
2.2.2 ASTM D 3359, Standard Test Methods for Measuring Adhesion by Tape Test
2.2.3 ASTM D 4138, Standard Test Method for Measurement of Dry Paint Thickness of
Protective Coating Systems by Destructive Means
2.2.4 ASTM D 4285, Standard Test Method for Indicating Oil or Water in Compressed Air
2.2.5 ASTM D 4414, Standard Practice for Measurement of Wet Film Thickness by Notch
Gages
2.2.6 ASTM D 4417, Standard Test Methods for Field Measurement of Surface Profile of Blast
Cleaned Steel
2.2.7 Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers
2.2.8 ASTM D 4752, Standard Test Method for Measuring MEK Resistance of Ethyl Silicate
Zinc-Rich Primers by Solvent Rub
2.3 SSPC: The Society for Protective Coatings
2.3.1 SSPC-Paint 29, Zinc Dust Sacrificial Primer, Performance-Based
2.3.2 SSPC-Paint 30, Weld-Through Inorganic Zinc Primer
2.3.3 SSPC-PS 12.00, Guide to Zinc-Rich Coating Systems
2.3.4 SSPC-QP 1, Standard Procedure for Evaluating Painting Contractors (Field Application
to Complex Industrial Structures
2.3.5 SSPC-AB 1, Mineral and Slag Abrasives
2.3.6 SSPC-AB 2, Cleanliness of Recycled Ferrous Metallic Abrasives
2.3.7 SSPC-AB 3, Ferrous Metallic Abrasive
2.3.8 SSPC Guide 13, Guide for the Identification and Use of Industrial Coating Material in
Computerized Product Databases
2.3.9 SSPC-PA 1, Shop, Field, and Maintenance Painting of Steel
2.3.10 SSPC-PA 2, Measurement of Dry Coating Thickness with Magnetic Gages
2.3.11 SSPC-Paint 20, Zinc-Rich Coating, Type IInorganic, and Type IIOrganic)
2.3.12 SSPC-QP 3, Standard Procedure for Evaluating Qualifications of Shop Painting
Contractors
2.3.13 SSPC-SP 1, Solvent Cleaning
2.3.14 SSPC-SP 2, Hand Tool Cleaning
2.3.15 SSPC-SP 3, Power Tool Cleaning
2.3.16 SSPC-SP 10/NACE No. 2, Near-White Blast Cleaning
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 3
General
3.1 Qualification
When the contract requires painting more than
1,500 square feet of steel surface, the
organization(s) performing coating application
must demonstrate qualification by obtaining
SSPC QP 1 certification for field painting or
either SSPC-QP 3 certification or the AISC
Sophisticated Paint Endorsement (SPE) for shop
painting. This qualification must be maintained
throughout the painting portion of the project. If
it expires or is revoked for any reason, notify
the owner, who may require that a qualified
organization complete the coating portion of the
project.
3.2 Quality Control
Conduct and document quality control
inspection of the cleaning and painting
operations including, at a minimum,
measurements of ambient conditions, surface
profile, surface cleanliness, coating material
acceptability, dry film thicknesses, and visual
inspection for coating continuity and defects.
Record the data and make it available for the
Owners review.
3.3 Written Procedures
Maintain written standard procedures, submitted
to the Owner upon request, covering such items
as verifying and maintaining paint manufacturer
data, measuring and recording dry film
thickness and cure time, protection and
treatment of faying surfaces, and other
information needed to successfully document
and apply all coats of paint.
3.4 Miscellaneous
Surfaces to be painted and the coating system to
be used shall be as indicated on plans and/or
contract documents. Unless otherwise noted,
paint is not required on flange surfaces that will
be embedded in concrete, or inside bolt holes,
although overspray is permitted on flange
surfaces and inside bolt holes.
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 4
Material Acceptance
4.1 Paint
4.1.1 Verify that all paint materials satisfy Commentary:
composition and testing requirements, are The issues surrounding the testing and
in conformance with the owner-approved selection of actual coating materials are
Qualified Products List or other applicable not addressed in this document because
requirements, and will not exceed the AASHTO maintains a testing protocol
manufacturers specified shelf life before and database of testing results as part of
use. AASHTO NTPEP (National
Transportation Product Evaluation
Program) initiative.
4.1.2 Instruct the coatings supplier to provide
batch samples of all coating material
components to the Owner as required or
requested.
4.1.3 Materials will be rejected if the material
arrives at the application site in other than
original, unopened containers; if a
container has a break in the lid seal or a
puncture; or if the coating materials have
begun to polymerize, solidify, gel, or
deteriorate in any manner.
4.2 Abrasive Media Condition
Verify that abrasive cleaning material meets the
requirements of SSPC-AB 1, Mineral and Slag
Abrasives; SSPC-AB 2, Cleanliness of Recycled
Ferrous Metallic Abrasives; or SSPC-AB 3,
Ferrous Metallic Abrasive. The condition and
cleanliness of recycled abrasives shall be
confirmed in accordance with the applicators
approved quality control program as per SSPC-QP
3 and/or AISC Sophisticated Paint Endorsement.
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 5
Surface Preparation
5.1 Material Anomalies
5.1.1 Corner Condition Remove all sharp Commentary:
corners prior to painting with either Some corner softening (flattening) occurs
organic or inorganic zinc-rich primer by during blast cleaning; however, blast
creating a small chamfer. With inorganic cleaning alone will not sufficiently break a
zinc rich primers, corners less acute than sharp corner. Corners in the as-rolled
the definition of sharp need no further condition are not normally in need of any
treatment prior to final cleaning treatment. See further discussion in
(profiling) and painting. Sharp corners Section C1.2.
may usually be removed by a single pass
with a grinder. For organic zinc-rich
primer-based systems, all corners
resulting from sawing, burning, or
shearing operations must be broken or a
primer stripe coat shall be applied to
those corners.
5.1.2 Preparation of Thermal Cut Edges
Before blast cleaning, condition (by
lightly grinding) thermal cut edges
(TCEs) to be painted, if conditioning is
necessary to achieve proper blast
cleaning profile.
5.1.3 Base Metal Surface Irregularities
Remove all visually evident surface
defects in accordance with ASTM A 6
or AASHTO M 160 prior to blast
cleaning steel. When material defects
exposed by blast cleaning are removed,
restore the blast profile either by blast
cleaning or by using mechanical tools in
accordance with SSPC-SP 11 or SP 15.
5.1.4 Weld Irregularities or Spatter Remove Commentary:
or repair all sharp weld prominences, While the removal of all weld spatter is
and all heavy, sharp, or loose weld recommended, it is recognized that absolute
spatter. Occasional individual particles compliance would present difficulties, often
of rounded tight weld spatter may leading to unnecessary rework. As a
remain, but widespread, sharp, or practical matter, occasional tightly adhered
clustered particles of tight weld spatter spatter may remain as long as paint coverage
must be removed. and adhesion are not adversely affected
5.2 Pre-Cleaning
Remove all oil, grease, and other adherent
deleterious substances, including bolt lubricant
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
concerning the lubricant removal and alkaline household cleaner such as ammonia.
the cleanliness necessary for Care should be taken to ensure that no
intermediate coat adhesion. Perform residue from the cleaner remains after
periodic evaluation to ensure that cleaning that may affect subsequent coating
lubricant and excess dye are adequately adhesion; typically ammonia will evaporate
removed. by the time the coating is applied. Any dye
coloring remaining on galvanized nuts after
weathering or the required surface
preparation is not believed to be detrimental
to subsequent coating performance or
appearance. A white cloth wipe test with no
color transfer can be used to confirm that all
lubricant and non-absorbed dye has been
removed, leaving only the residual stain
on the surface.
5.4.5 When zinc-coated twist-off tension-
control or lock-pin-and-collar fasteners
are used, completely seal the sheared
end of each fastener with non-silicone-
type sealing compound conforming to
the provisions in Federal Specification
TT-S-230, Type II.
Apply the sealant to the non-rusted
surface on the same day that the bolt is
installed. The sealant shall be
compatible with the subsequently
applied coating.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
5.5 Summary
Table 5.2 summarizes the requirements for pre-cleaning, cleaning, profile, and surface
cleanliness of structural steel.
Table 5.2 Surface Preparation Summary Table
Basis for
Requirement Acceptance Minimum Maximum Frequency/Extent
1. Pre-Clean Visual SSPC-SP 1 N/A 100%
2. Degree of Cleaning Visual PDS N/A 100%
once every shift for automated
3. Profile operations and twice per shift per
Test PDS PDS
(ASTM D 4417) nozzle, and whenever the operating
media mix is changed
4. Surface Cleanliness per owner 1
Test N/A Varies
(SSPC-Guide 15)2 requirements
Test
Black Iron SP 1, SP 10 SP 1, SP 10 100%
6. Fasteners
Mechanically
or Hot Dip SP 1 SP 1 100%
Galvanized
1 Only needed on heavily rusted or pitted steel as described in SSPC-VIS 1 Conditions C and D.
2 The test methods indicated in SSPC-Guide 15 vary in their sensitivity and the particular test
method used should be selected by the Owner.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Section 6
Paint Application
6.1 General
6.1.1 Apply coatings in accordance with the
Contract requirements, SSPC-PA 1, and
the manufacturers instructions.
6.1.2 Conduct and document an on-going
quality control inspection of the
materials, prepared surfaces, and the
prime, intermediate, and topcoat
painting per Tables 6.1 to 6.3 (presented
at the end of Section 6).
6.1.3 Record the daily storage temperature
range for coating materials and verify
conformance with the coating
manufacturers product data sheet. Use
inventory control to ensure that
components are used within the shelf life
prescribed by the manufacturer. Record
the coating batch numbers from the
mixed components, the amount and type
of thinner used, and the date applied in
the application log.
Verify that the coating has been applied
to provide a continuous, uniform film of
the specified thickness; is well bonded to
the metal or previously applied coating;
is free of laps, streaks, sags, or other
visually evident defects; and was applied
within the manufacturers specified pot
life.
6.1.4 Areas that fail any required test(s) shall
be subject to the nonconformance
disposition procedure outlined in
Section 3.6.
6.1.5 Tables 6.1, 6.2 and 6.3 show information
related to ambient conditions; surface
cleanliness; and mixing, application, and
cure. The charts show the specific
source of relevant control information,
as well as minimum and maximum
tolerances. Also indicated are inspection
frequency requirements.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
Footnotes:
1 Based on weather conditions, more or less frequent testing may be stipulated by the Owner
2 Owner approval may be based on sampling and testing or the manufacturers certification
acceptance that batch compositions conform to previously approved standards. Primer for
faying (contact) surfaces of high strength bolted connections (for slip-critical, frictional
transfer of load) must satisfy RCSC requirements for a Class B rating, based on certified
tests by the coating manufacturer or applicator.
3 All items in each lot that were coated with the same batch of paint must be identified. Small
items may be identified by bundle or shipping container number.
4 Every pot mixed should be verified. QC must document acceptance by initials or signature,
and form must include time/date and batch component numbers.
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Guide Specification for Application of Coating Systems with Zinc-Rich Primers to Steel Bridges
5 Upon addition of the activator. Does not apply to single or multiple component coatings not
utilizing a catalyst or other activator that reacts to modify the mixed coating and/or limit pot
life.
6 Cure testing of primer is required prior to shop application of intermediate or stripe coat, or
if adding extensive organic zinc primer to increase initial DFT. (Not required for spot
priming.) See manufacturers thinning requirements if repriming previously coated surface.
For field-applied intermediate coat, the cure test is not required, but adequate primer cure
must be verified before handling and shipping. For inorganic zinc, if the PDS does not have
a specified cure test, then ASTM D 4752 shall apply.
7 Stripe coat(s) may be applied either before or after the full coat to ensure adequate coverage
on outside corners, edges and other areas specified in the applicators coating plan. Note that
striping IOZ is not normally recommended.
8 Based on difference between average DFT of coats applied and previous readings for similar
areas. For example, webs, stiffeners, flanges, cross frames, and bearings may each have
different averages due to application patterns.
9 All repairs shall meet the requirements of Section 3.6. The recoat window shall follow the
guidelines of this guide, the coating manufacturers recommendations, and good painting
practice as dictated by SSPC.
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Copyright 2006 by the AASHTO/NSBA Steel Bridge Collaboration.
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AASHTO Document No: NSBASCBS-2-OL
Printed December, 2006