Category:1045 Paint for Structural Steel: Difference between revisions

This article establishes procedures for inspecting, sampling and reporting paint and paint constituents. Refer to Sec 1045 for MoDOT’s specifications.

Discussions on non-standard colors of structural steel paint and color of structural steel paint policies are available.

For Laboratory testing and sample reporting procedures, refer to 1045.6 Laboratory Testing Guidelines for Sec 1045.

1045.1 Apparatus

All sample containers and equipment used in sampling paint and paint constituents shall be clean and free of all contaminants. The apparatus required shall consist of:

(a) Appropriate size and type of sample container as given in the following subsections for the type of paint to be sampled.

(b) Appropriate thief or sampling device to obtain a representative sample.

(c) Packaging and labeling materials as described in 106.5.2.2 Transportation of Samples and 106.5.3 Sampling Supplies.

1045.2 Procedure

Samples shall be taken by, or under the direct supervision of, the inspector, using all possible caution, skill and judgment to insure that a representative sample is obtained.

When sampling paint and paint constituents, take precautions to ensure that the samples are not contaminated or altered by any material not representative of the lot being sampled. Some paints or liquid constituents exhibit a tendency to settle or separate upon standing. Because of this, it is important to ensure that containers to be sampled, no matter the size container, is uniform prior to obtaining a sample. Mark all sample containers with the type of material, lot number, and the inspector's identification number. It is essential that samples of constituents be marked with the chemical names as called for in the given specification. Unless specifically requested, obtain only one random sample from each lot, batch, day's pack or other unit of production. In cases where several small lots are uniformly mixed in a larger mixer or tank, the mixed material shall be considered as one lot.

Whenever possible, obtain samples from original, unopened containers for all types of materials. When constituent containers have no markings distinguishing between units of production, take samples from different containers or storage units in the ratio of two samples for each 10,000 pounds (4500 kg) or portion thereof and blended in equal quantities to form a composite sample. Submit constituent samples only when requested by the Laboratory.

Packaging must comply with the applicable requirements of Sec 1045.

1045.2.1 Vehicle Constituents

When samples are requested by the Laboratory, ensure that the contents of the container or tank to be sampled has been thoroughly mixed. Fill the sample container, leaving approximately one inch (25 mm) space for expansion. Secure friction top lids with clips or other fastening devices before shipment. Observe shipping regulations when preparing samples for shipment.

1045.2.2 Pigments

When the Laboratory requests samples, open the package or storage container and take a sample at random from the contents.

1045.2.3 Mixed Paints

Sample containers are one quart (1 L), friction top cans and should be filled, leaving approximately one inch (25 mm) space for expansion. The inspector may mark and submit an original, unopened container of paint to the Laboratory in cases where the containers are small, such as quarts (L) or gallons (L). When an original container of paint cannot be sent to the Laboratory and there are no facilities for mixing or shaking the material mechanically, the inspector must ensure a representative sample by the following steps:

(a) Pour off the top liquid into a clean, suitable container having a volume equal to or larger than the one being sampled.

(b) Stir the settled portion of the paint with a paddle, gradually reincorporating the poured off liquid in small quantities until all has been returned.

(c) Mix the paint by pouring it back and forth between the two containers several times.

(d) Obtain a sample promptly so that settling does not occur before the sample is obtained.

NOTE: This process is referred to as “boxing” the material.

When samples are taken during the filling of containers, obtain a composite sample by combining samples taken at the beginning, middle, and near the end of the operation.

Mechanically mix paint in holding tanks or 55 gallon (208 L) drums to ensure uniformity and sample promptly after mixing.

1045.2.4 Submission of Samples

Paint and some paint constituents require special handling. See 106.5.2.2 Transportation of Samples and 106.5.3 Sampling Supplies for packaging, labeling and marking instructions. Enter a Basic Sample Data report into SiteManager (see AS-3510) for each sample of material submitted to the Laboratory. Include all pertinent information necessary to the sample, such as: kind of paint or constituent, batch or lot number, project number, purchase order or "general construction" for warehouse stock, inspector, source, quantity, intended use, contractor, destination, manufacturer's name and address.

1045.2.5 High Solids Inorganic Zinc Silicate Coating

Refer to the applicable requirements of Sec 1045 for requirements pertaining to prequalification. The list of paints that are qualified by manufacturer and brand name appears as Qualified High Solids Inorganic Zinc Silicate Paints. Sample each batch or lot of each component. A sample consists of one pint (500 mL) of inorganic silicate vehicle, one pint (500 mL) of metallic zinc powder and four ounces (120 mL) of activator component. Note that the activator is not to be sampled in metal containers and will be required only when sampling 3-component, high-solids primer. Submit the samples to the Laboratory through a SiteManager record, including the brand name, the batch or lot number of each component and the net weight (mass) shown on the container of each component.

1045.2.6 Polyurethane System G Final Coating

Refer to the applicable requirements of Sec 1045 for requirements pertaining to prequalification. The list of paints that are qualified by manufacturer and brand name appears as Qualified Epoxy\Polyurethane Paints. Sample each batch or lot of each component. A sample consists of each component in the approximate volume proportions recommended by the manufacturer such that the mixed sample will consist of at least one quart (1 L). Submit the samples to the Laboratory through a SiteManager record, including the brand name, the batch or lot number of each component, and the net weight (mass) shown on the container of each component.

1045.2.7 High Solids Epoxy Intermediate Coat

Refer to the applicable requirements of Sec 1045 for requirements pertaining to prequalification. The list of paints that are qualified by manufacturer and brand name appears as Qualified Epoxy\Polyurethane Paints. Sample each batch or lot of each component. A sample consists of one pint (500 mL) of each component. Submit the samples to the Laboratory using a SiteManager record, including the brand name, batch or lot number of each component, and the net weight (mass) as shown on the container of each component.

1045.2.8 Waterborne Acrylic System H Intermediate and Finish Coating

Refer to the applicable requirements of Sec 1045 for requirements pertaining to prequalification. The list of paints that are qualified by manufacturer and brand name appears as Qualified Waterborne Acrylic Paints. Sample each batch or lot of each intermediate or finish coat. A sample consists of one quart (1 L) in a friction top can. Submit the sample to the Laboratory through a SiteManager record, including the brand name, the batch or lot number of each component, and the net weight (mass) shown on the container.

1045.2.9 Aluminum Epoxy Mastic Primer

Refer to Sec 1045 for requirements pertaining to prequalification. Aluminum epoxy mastic primer is not suitable for use in contact with freshly poured concrete. Brands that have been qualified are listed in Qualified Aluminum Epoxy Mastic Paint. Sample each batch or lot submitted for use. A sample consists of one pint (500 mL) of each component in friction top cans. Submit the sample to the Laboratory through a SiteManager record, including the brand name, batch or lot number(s) of each component, and the weight (mass) shown on each container.

1045.2.10 Gray Epoxy Mastic Primer

Refer to Sec 1045 for requirements pertaining to prequalification. Gray epoxy mastic primer may be used in lieu of aluminum epoxy mastic. The list of paints that have been qualified by manufacturer and brand name are listed in Sec 1045. Each batch or lot submitted for use shall be sampled. A sample consists of one pint (500 mL) of each component in friction top cans. Submit the sample to the Laboratory through a SiteManager record, including the brand name, batch or lot number(s) of each component, and the weight (mass) shown on each container.

1045.2.11 Calcium Sulfonate

Refer to Sec 1045 for requirements pertaining to prequalification. The list of paints that are qualified by manufacturer and brand name appears as Qualified Calcium Sulfonate Overcoat Systems. Sample each batch or lot of penetrating sealer, primer or finish coat. A sample consists of one quart (1 L) in a friction top can. Submit the sample to the Laboratory through a SiteManager record, including the brand name, the batch or lot number, and the weight (mass) shown on each container.

1045.3 Sample Record

The Laboratory will issue the reports.

1045.4 Non-Standard Colors of Structural Steel Paint

The color of structural steel paint shall be gray (Federal Standard # 26373) or brown (Federal Standard # 30045) except when otherwise approved by the District Engineer and the following conditions are met:

1045.4.1 Approved Systems

Only the currently approved systems from currently approved manufacturers will be considered.

1045.4.2 Approval of Colors

When colors other than currently approved colors are requested, the requester shall include all required data from at least 2 paint manufacturers as follows:

1045.4.2.1 Manufacturer's Nomenclature

The manufacturer's system nomenclature and code numbers for each coat of the system shall be provided.

1045.4.2.2 Performance Data

Certified performance data shall be submitted to Construction and Materials. All testing shall be performed by an independent testing laboratory on samples formulated to the color being requested and applied to properly prepared steel test panels. Performance data submitted shall include the following:

1045.4.2.2.1 Polyurethane Finish Coating

Accelerated Weathering per ASTM G23 Method 1, Type EH (Carbon Arc) for 4000 hours. ASTM G26, Method 2, Xenon Arc or ASTM G53 QUV (Fluorescent UV-Condensation Type using Type A lamps) may be used as an alternate to Carbon Arc. After 4000 hours testing for accelerated weathering resistance, the finish coat, in the color for which approval is requested, shall show a difference in color of no greater than 4 ΔE, when compared to the control panel. Color change measurements shall be performed in accordance with Section 6.2 CIE 1976 L*a*b* of ASTM D 2244.

Apply the finish coat to properly prepared test panels that have received a prime coat of a currently approved high-solids inorganic zinc silicate primer and an intermediate coat of a currently approved high solids epoxy. Apply all coats of the system to properly prepared steel test panels. See Sec 1045.3.4.1 for requirements for test panel preparation. Each coat of the system shall be from the same manufacturer. Perform all testing on duplicate sets of test panels and, upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction and Materials.

1045.4.2.2.2 Waterborne Acrylic Finish Coating

Accelerated Weathering per ASTM G23 Method 1, Type EH (Carbon Arc) for 4000 hours. ASTM 26, Method 2, Xenon Arc or ASTM G53 QUV (Fluorescent UV-Condensation Type using Type A lamps) may be used as an alternate to carbon arc. After 4000 hours testing for accelerated weathering resistance, the finish coat, in the color for which approval is requested, shall show a difference in color of no greater than 4 ΔE, when compared to the control panel. Color change measurements shall be performed in accordance with Section 6.2 CIE 1976 L*a*b* of ASTM D 2244.

Apply intermediate and finish coats to properly prepared test panels that have received a prime coat of currently approved high-solids inorganic zinc silicate primer and an intermediate coat of currently approved color-contrasting waterborne acrylic coating. Apply all coats of the system to be tested to properly prepared steel test panels. See Sec 1045.3.4.1 for requirements for test panel preparation. Each coat of the system shall be from the same manufacturer. Perform all testing on duplicate sets of test panels, and upon completion of the prescribed exposure testing, the manufacturer shall submit one set of the exposed panels to Construction and Materials.

1045.4.3. Specifications for physical properties

Submit certified physical property data to Construction and Materials. All testing shall be performed by an independent testing laboratory on samples formulated to the color being requested. Physical property data submitted shall include the following:

1045.4.3.1 Polyurethane Finish Coating

The following physical property data shall be provided:

Color, Federal Standard 595b

Viscosity, 77 ºF (25 ºC), KU

Volatile Organic Content, lb/gal

Fineness of Grind, Hegeman Gage

Sag Resistance, Leneta Anti-Sag Meter

Pot Life at 77 ºF (25 ºC), hrs., Dry to Touch, hrs., Dry to Handle, hrs.

1045.4.3.2 Waterborne Acrylic Finish Coating

The following physical property data shall be provided:

Color, Federal Standard 595b

Viscosity, 77 ºF (25 ºC) KUVolatile Organic Content, lb/gal.

Fineness of Grind, Hegeman GageSag Resistance, Leneta Anti-Sag Meter

Dry to Handle, hrs.

1045.4.4 Samples

Provide a one-gallon (4 L) sample of each color requested to Construction and Materials.

1045.5 Policy on Color of Structural Steel Paint

This policy was approved 9/10/96 by the Design Committee and updated 7/1/03.

The color of structural steel paint shall be gray (Federal Standard #26373) or brown (Federal Standard # 30045) except when approved by the District Engineer and the following conditions are met:

1) An agreement with a local entity sponsoring the color is made indicating the local entity shall:

a) Pay for all costs associated with providing necessary test data.

b) Pay for all costs associated with the finish coat in excess of typical costs associated with standard colors.

c) Pay for future costs for applying the finish coat in excess of typical costs associated with standard colors as a condition of continuing the unique color. (The agreement should stipulate that the color will be maintained in the future as mutually agreeable by both parties. The additional cost to the local entity would be determined at that time. Since we require a previously approved "system" be used, the prime coat will be the same as a standard system and should not fail prematurely. If the color fades prematurely and the local entity wants it repainted, they would pay proportionately. If the color fades and the local entity does not want to pay their share, the district would decide when future repainting occurs.)

2) Only approved systems from currently approved manufacturers will be considered

3) The district or local entity shall provide certified performance data from an independent testing laboratory on samples formulated with the finish coat of the desired color from two paint manufacturers. Following is the data required:

a) Physical property and performance of the finish coat as indicated in FS 1045 of the

Materials Manual.

b) Duplicate test panels which have undergone accelerated exposure testing as described above, as well as an unexposed control panel shall be submitted to –

Construction and Materials

1617 Missouri Boulevard

Jefferson City, Missouri 65109.

4) All required data as detailed in 1045 Paint for Structural Steel shall be submitted to Construction and Materials, at least three months prior to the plans due date for letting. Changes after letting shall be submitted to Construction and Materials, at least three months prior to date of desired change order.

5) Provide a copy of the agreement as listed in Item 1 to the Bridge Unit, at least three months prior to the plans due date for letting.