0150-0137 Addendum No. 2 Contract Special Provisions.pdf

0150-0137 ADDENDUM NO. 2

OCTOBER 2, 2026

REHABILITATION OF BRIDGE NO. 00906

U.S. ROUTE 202 OVER SHEPAUG RIVER

FEDERAL AID PROJECT NO.: N/A

STATE PROJECT NO. 0150-0137

TOWN OF WASHINGTON

ADDENDUM NO. 2

SPECIAL PROVISION

REVISED SPECIAL PROVISION

The following Special Provision is hereby deleted in its entirety and replaced with the attached like-named Special Provision:

• ITEM #0603310.01A - ABRASIVE BLAST CLEANING AND FIELD METALLIZING

OF STRUCTURE (SITE NO. 1)

CONTRACT ITEM

NEW CONTRACT ITEM

ITEM NO. DESCRIPTION UNIT QUANTITY

0822100.03 TEMPORARY TRAFFIC BARRIER

(BOLTED)

L.F. 372 L.F.

PLANS

REVISED PLANS

The following Plan Sheets are hereby deleted and replaced with the like-numbered Plan Sheets:

02.01.A1 03.17.A1 04.02.A1 04.26.A1

The Bid Proposal Form has been revised to reflect these changes.

The Detailed Estimate Sheets do not reflect these changes.

There will be no change in the number of calendar days due to this Addendum.

The foregoing is hereby made a part of the contract.

05/15/2026

0150-0137 ITEM #0603310.01A

ADDENDUM NO. 2

ITEM #0603310.01A - ABRASIVE BLAST CLEANING AND FIELD

METALLIZING OF STRUCTURE (SITE NO. 1)

Description: Work under this item shall consist of surface preparation and field metallizing of the steel components as shown on the plans. The coating system for bridges under this specification shall be comprised of 85/15 zinc aluminum thermally sprayed metallizing primer, an epoxy sealer coat, and a urethane topcoat. The thermal spraying process consists of melting the metal described herein and then spraying said metal onto a properly prepared surface by means of compressed air.

All structural steel, including the beams, steel components of the bearings, and diaphragms shall be abrasive blast cleaned and metallized within the limits indicated on the plans.

The top of the top flange shall NOT be metallized but shall be coated with an inorganic zinc-rich primer from the NEPCOAT Qualified Products List. No sealer shall be applied over the zinc-rich primer.

Utilities, elastomeric bearing pads and signs shall be protected during coating work and shall not be metallized.

Sequence of Work: The Contractor shall prepare the surfaces specified in the Plans in accordance with the following sequence:

1. Prepare Surfaces. The Contractor shall prepare the surface of the existing steel to meet the requirements specified in “Surface Preparation of this specification. The containment and collection of surface preparation debris shall be paid for under the item “Class 1 Containment and Collection of Surface Preparation Debris (Site No. 1)”.

2. Remediate Soluble Salts. The Contractor shall remediate soluble salts on the existing bare steel in accordance with “Soluble Salt (Chloride) Remediation” of this specification.

3. Apply zinc-rich primer. The contractor shall apply the primer to the prepared surfaces of the tops of the existing beam top flanges.

4. Apply Thermally Sprayed Coating (Metalizing). The Contractor shall apply the metalizing (primer) system in accordance with “Metalizing Application” of this specification and within the limits shown on the plans.

5. Apply Sealer. The Contractor shall apply the sealer system in accordance with “Sealer and Topcoat Application” of this specification.

6. Apply Topcoat. The Contractor shall apply the topcoat system in accordance with “Sealer and Topcoat Application” of this specification.

Materials:

Primer (Metallizing): The thermally sprayed primer wire feedstock shall be a zinc-aluminum alloy which shall meet the following quantitative requirements:

Metal Content (%) Iron (Fe) .020% max.

Copper (Cu) .004% max.

Cadmium (Cd) .004% max.

Lead (Pb) .004% max.

https://nepcoat.org/qualprod.htm

ADDENDUM NO. 2

Titanium (Ti) .002% max.

Aluminum (Al) 14.0% - 16.0% Zinc (Zn) Remainder

Sufficient identifiable characteristics, other than trade or brand name or designation number or symbol, shall be provided to laboratory test verification of metal identity. Each container or coil shall be properly labeled to identify the component type, supplier, size, batch number and wire lot number.

The Contractor shall provide a Certified Test Report (CTR) in accordance with 1.06.07 for the feedstock from the feedstock supplier.

Primer (Zinc Rich): The zinc-rich primer applied to the top flanges of the existing beams shall be an inorganic zinc-rich primer from the NEPCOAT Qualified Products List.

Sealer: Clear sealer shall be a low viscosity epoxy sealer which is compatible with the metallizing and the urethane topcoat, meeting the following requirements:

Solids by Volume (Min.) ............................... 99% + 1% Solids by Weight (Min.) ................................ 99% + 1% Drying Time @ 75 deg. F. to recoat .............. Overnight Pot Life @ 72 deg. F. (Min.) .......................... 4 hours

The Contractor shall select a sealer compatible with the topcoat chosen. The sealer shall be capable of penetrating into the body of the Primer to seal the interconnected surface porosity as defined in AWS C2.18-93R.

Topcoat: The topcoat shall be a high build aliphatic urethane and shall meet the following requirements:

A: Compositional Data

(1) General

Theoretical Coverage 1 mil DFT per Gallon in Square Feet – 860 Minimum Minimum Curing Time @ 75 Degrees F. Minimum

To touch ......................................................... N/A To handle ....................................................... 5 hours To recoat ........................................................ 5 hours Shelf Life Minimum – 24 months Temperature Resistance – Dry Film 150 Degrees F. Minimum

Pre-proportioned Mix Ratio – 1 Part A to 1 Part B.

(2) Properties of Mixed Components

a. % Total Solids by Weight (Min.) ......................69.0

b. % Total Solids by Volume (Min.) .....................54.0

c. Viscosity (Stormer @ 77 Deg. F) KU............ 75 to 100

d. Weight per Gallon, 1 lbs (Min.) ........................9.5

e. Mils DFT........................................................ 4 to 6

f. Pot Life @ 77 Deg. F. Hr. (Min.) .................. 3 to 6 https://nepcoat.org/qualprod.htm

ADDENDUM NO. 2

The Contractor shall select one of the following semi-gloss topcoats of the color shown on the plans from the list below:

AkzoNobel: International Interthane 870UHS Carboline: Carbothane 133 LV Sherwin Williams: Hi-Solids Polyurethane 250 or approved equal

Packaging and Labeling:

A. The sealer and topcoat materials shall be packaged in pre-proportioned separated containers such that mixing the entire contents of both containers will yield the correct mixing ratio. For spot painting, lesser amounts may be packaged to eliminate waste. Each container shall bear a label on which shall be clearly shown the name of the coating manufacturer, the name of the product, the lot and batch number, the date of manufacture and the end of shelf-life date. The label shall also include complete specific instructions for the opening, mixing, thinning, and application of the contained coating material. The container shall be designed to contain the material within.

B. Linseed Oil Alkyd Paint: Storage containers for this paint shall conform to the Code of Federal Regulations title 49, Chapter 1, Paragraph 173.510A (1), (5), and Paragraph 178.118. Each storage container shall have a protective liner and removable lid. Also, these containers shall not have any indentations or shipping damage that would allow seepage of the material contained within.

Caulking Materials: Caulking shall be as recommended by the coating manufacturer and approved by the Engineer.

Abrasives:

Abrasives shall meet the following requirements:

1. SSPC AB 1 for mineral slag abrasives

2. SSPC AB 2 for recycled ferrous metal abrasives

3. SSPC AB 3 for new steel abrasives

Control of Materials: Before any thermal spraying can be done, a Certified Test Report and a Materials Certificate will be required for the zinc-aluminum alloy, the sealer, the topcoat, and the linseed oil alkyd paint, in accordance with Article 1.06.07, confirming the conformance of these materials to the requirements set forth in these specifications. A 10 1b. sample of the steel grit to be used in the blast cleaning operations shall also be furnished to the Engineer.

Only one metallizing supplier and one sealer and topcoat manufacturer may be used for the

Project including material supplied for touch-up painting operations with no subcontractors manufacturing allowed. Intermixing of materials within and between coating systems will not be permitted. Thinning of paint shall conform to the manufacturer's written recommendations. All components of the coating system and the mixed paint shall comply with the Volatile Organic Compounds (VOC) Content Limits and Emission Standards stated in the Connecticut Department of Energy and Environmental Protection's Administration Regulation for the Abatement of Air Pollution, Sections 22a-174-41 through 41a and 22a- 174-20(s), respectively.

The top coat shall meet the color and gloss retention performance criteria of SSPC Paint 36, Level

3, for accelerated weathering. After 2000 hours of accelerated weathering in accordance with ASTM D4587, the color change (ASTM D2244) shall be less than 2.0 ∆E* with a loss of gloss (ASTM D523) less than 30. With the submittals, the Contractor shall provide the Engineer with

ADDENDUM NO. 2

proof that the finish coat complies with the above criteria.

The abrasive media for blast cleaning shall be recyclable steel grit.

Notification: Prior to use of the abrasives, SDS should be submitted by contractor for all Abrasives and reviewed by DOT Safety and DOT OEC for waste management. If any of the above or following stipulated Contract specifications differ from those of the manufacturer’s recommended procedures or ranges, the more restrictive of the requirements shall be adhered to unless directed by the Engineer in writing.

The AMS-STD-595 Color Number for the top coat shall be 26329 (blue).

Construction Methods:

Submittals:

Provide documentation verifying successful use of the specified coatings in the field, preferably on bridges. This documentation shall list the agency/owner, location, amount (s.f.), and date of application of each specific coating.

A minimum of 30 calendar days before starting any surface preparation and coating application work, the metallizing firm shall submit the following to the Engineer for acceptance:

1. A copy of the firm’s written Quality Control Program used to control the quality of surface preparation and coating application including, ambient conditions, surface cleanliness and profile, coating mixing, dry film thickness, and final film continuity.

2. Surface Preparation/Sealing Plan: A copy of the firm’s written surface preparation and application procedures. This written program must contain a description of the equipment that will be used for removal of laminar and stratified rust, for surface preparation, including the remediation of soluble salts, and for paint mixing and application, including stripe coating.

Coating repair procedures shall be included.

3. The qualifications, references and documentation of the personnel managing and performing the Quality Control Program, including a detailed description of the firm’s enforcement procedures and the authority of personnel.

4. Containment plans (paint removal/collection of debris, surface preparation, coating applications with heat). The submission of perimeter air monitoring plan to be executed by Industrial hygiene firm.

5. If the application of heat is proposed for coating application purposes, provide information on the heat containment and procedures that will be used, with data sheets for the equipment. Note: If heat is used for coating operations, the heat and containment must be maintained to provide the required temperatures for the duration of the cure period.

6. Proof of SSPC-QP1 qualifications, CAS-certification(s) and QP2 qualifications, as applicable.

7. Proof that the finish coat complies with the color and gloss retention performance criteria of

SSPC Paint 36, Level 3, for accelerated weathering.

8. Metallizing and coating product information, including coating manufacturer, product name, application instructions, technical data, MSDS, color chips, VOC levels for liquid coatings, and written application instructions including mixing requirements, proposed thinners, and manufacturer’s recommended thinner amounts for liquid coatings.

9. Abrasive product information, including abrasive manufacturer, product name, technical data, and MSDS in accordance with the Qualified Products List (QPL).

ADDENDUM NO. 2

10. Touch-up and repair procedures of any damage that occurs to the newly applied metallizing or coatings, including methods and materials.

11. Written procedures for the preparation of surfaces and the application of the metallizing, the sealer, and topcoat.

12. Hold points for surface preparation, metallizing application, adhesion testing of metallizing application and top coating thickness measurements.

13. Copies of qualification records along with continuity logs for all thermal spray operators.

14. Copies of NACE CIP Level 3 certifications, or approved equal, for all staff required to possess same. Copies of CAS (SSPC ACS/NACE No. 13) certifications, for all staff required to possess same.

15. Identification of the thermal spray equipment.

16. A work schedule that includes timelines for surface preparation, metallizing, sealing and top coating.

17. The qualifications, references and documentation of the technical advisor employed by the coating (including metalizing) manufacturer.

Metallizing Contractor Worker Qualifications: The Metallizing Contractor shall be certified by the SSPC Painting Contractor Certification Program QP-6, entitled "Thermal Spray (Metallizing) Contractor Certification Program" in the enclosed shop category or be certified in the American Institute of Steel Construction (AISC) Sophisticated Paint Endorsement (SPE) category – enclosed shop P1 or covered shop P2. A list of approved contractors can be found on the AISC website at www.AISC.org. The Contractor shall also show evidence of having successfully field metallized structural steel on a minimum of three (3) bridges or structures in the last three years.

The Metallizing Contractor shall be fully certified, including endorsements, for the duration of the time they are doing the surface preparation and coating application. The certification(s) must be kept current for the duration of the Project work. If a Contractor’s, subcontractor’s or any craft-worker’s certification expires, the firm will not be allowed to do any work on this item until the certification is reissued. Requests for extension of time for any delay to the completion of the Project due to an inactive certification will not be considered, and liquidated damages will apply.

All Contractor activities associated with the coating work described and specified herein shall be conducted in accordance with all applicable Federal (OSHA), State of Connecticut and local (based on bridge location) safety regulations and SSPC-PA Guide 3 “A Guide to Safety in Paint Application.”

Applicator Qualifications: The Contractor shall submit to the Engineer evidence indicating that the proposed metallizing applicators are fully qualified in metallizing according to ANSI/AWS C2.18-93R. to perform the work. Any proposed applicator found to be not qualified shall, at the written request of the Engineer, be removed forthwith by the Contractor

The Engineer shall require that the Contractor demonstrate proven ability and competence in the application of the metallizing and topcoat materials, in conformance with the specifications herein and with the manufacturer’s printed instructions.

Requests for extension of time for any delay to the completion of the Project due to an inactive certification will not be considered, and liquidated damages will apply. In addition, if any recoat http://www.aisc.org/

ADDENDUM NO. 2

times are exceeded, the affected areas shall be abrasive blast cleaned to SSPC-SP 10 and coatings reapplied in accordance with these specifications at no additional cost to the State. At the option of the Engineer, if such a delay will adversely impact the successful and timely completion of the Project, the Department may require the Contractor to engage another SSPC-certified firm to do the metallizing work at the Contractor’s expense.

The Metallizing Contractor and subcontractors are required to have at least one (1) Coating Application Specialist (CAS) (SSPC ACS/NACE No. 13) – certified (Level II-Interim Status

Minimal) craft-worker. CAS-certified (Level II-Interim Status-Minimal) craft-worker(s) are required for all crews/craft-workers up to four (4) crew members. For each crew larger than four (4), an additional CAS-certified (Level II-Interim Status-Minimal) craft-worker shall be present on each painting/blasting crew during blast cleaning and spray application (Atmospheric and Immersion Service) operations. A crew-member is a person who is on the job performing hand-held nozzle blast cleaning and/or spray application of protective coatings on a steel structure. The certification(s) must be kept current for the duration of the Project work. If a Contractor’s, subcontractor’s or any craft-worker’s certification expires, the firm will not be allowed to do any work on this item until the certification is reissued.

Quality Control Inspections: The Contractor shall perform first line, in-process Quality Control (QC) inspections. The Contractor shall implement a Quality Control Program accepted by the Engineer, including written daily reports, that ensures that the work accomplished complies with these specifications. Copies of these reports shall be provided daily to the Engineer. Contractor QC inspections shall include, the following:

• Suitability of protective coverings and containments

• Ambient conditions

• Surface preparation (solvent cleaning, hand/power tool or abrasive blast cleaning)

• Coating application (mixing, thinning, and wet/dry film thickness)

• Recoat times and cleanliness between coats

• Coating continuity (freedom from runs, sags, overspray, dry spray, pinholes, shadow-through, skips, misses)

• Final film acceptance

The personnel managing and performing the quality control program shall be NACE Certified

Coating Inspector(s) (successfully completed Sessions I, II, III and Peer Review) or shall provide evidence of successful inspection of three projects of similar size and scope that have been completed in the last two years. References shall include the name, address, and telephone number of a contact person employed by the bridge owner. The personnel performing the quality control tests shall be trained in the use of the quality control instruments. Documentation of training shall be provided. These personnel shall not perform surface preparation and painting.

The Contractor shall provide the Engineer, prior to contract award, a copy of the equipment manufacturer’s specifications, operating recommendations and safety precautions relating to the equipment to be used on this Project.

The Contractor shall submit a plan of protection including overspray containment, for each

ADDENDUM NO. 2

individual site, to the Engineer 30 days prior to commencing any painting operation. The minimum overspray containment enclosure shall be in accordance with SSPC Guide 6I Class 4. Tarpaulin material shall be fire retardant and impermeable to air and water. The joints shall be fully sealed except at the entryway. All mists or dust shall be filtered with collection equipment. For truss bridges a ceiling shall also be included.

The Contractor shall provide the proposed procedures for chloride remediation in the Surface

Preparation/Sealing Plan.

Notification: Contact the Materials Evaluation and Specifications Unit at DOT.Steel@ct.gov a minimum of two (7) days prior to the start of work.

The Contractor shall not begin any paint removal Work until the Engineer has accepted the submittals. The Contractor shall not construe Engineer acceptance of the submittals to imply approval of any particular method or sequence for conducting the Work, or for addressing health and safety concerns. Acceptance of the programs does not relieve the Contractor from the responsibility to conduct the Work in strict accordance with the requirements of Federal, State, or local regulations, this specification, or to adequately protect the health and safety of all workers involved in the Project and any members of the public who may be affected by the Project. The Contractor remains solely responsible for the adequacy and completeness of the programs and work practices, and adherence to them.

Environmental Constraints:

No surface preparation, metallizing, sealing, or painting shall be done when the relative humidity is above 85%, when there is falling rain, or when the surface temperature of the steel is less than 5 degrees F. above the dewpoint temperature as determined by a surface thermometer and electric psychrometer.

If steel was abrasive blasted when the temperature of the steel was less than 5 ºF (3 ºC) above the dew point, re-blast the steel when the steel temperature is at least 5 ºF (3 ºC) above the dew point.

Painting (Topcoat) of the structure will be allowed only between sunrise and sunset except as limited herein and in the specifications “Prosecution and Progress” and “Maintenance and Protection of Traffic”.

Test Equipment and Materials: The Contractor shall furnish the following new test equipment and materials for use by the QC Inspector:

1. Two (2) PTC Surface Temperature Thermometers

2. Psychron 566 Psychrometer (Battery Operated) with two (2) sets of batteries or a Bacharach

Sling Psychrometer

3. U.S. Weather Bureau Psychrometric Tables

4. Hypodermic Needle Pressure Gage for nozzle pressure tests.

5. SSPC Visual Standards VIS 1, VIS 3, and/or VIS 4, as applicable.

6. Testex Spring Micrometer

7. Testex Press-O-Film Replica Tape, one (1) roll, 100 pieces each, of coarse and extra-coarse per bridge span, or as specified by the Engineer.

8. Wet film thickness gage

9. PosiTest, Mikrotest or Elcometer Dry Film Thickness Gauge (FM) mailto:DOT.Steel@ct.gov

ADDENDUM NO. 2

10. SSPC Type 2 Dry Film Thickness Gauge per PA2

11. Metalizing Adhesion strength test equipment per ASTM D4541, Annex A4

12. NIST (NBS) Calibration Standards Range: 0 – 39 mils

SSPC AB2 recycled ferrous material should be pre-screened before use in the field for radioactivity.

Quality Assurance Inspections: The Engineer may conduct Quality Assurance (QA) observations of any or all phases of the work. The presence or activity of Engineer inspections in no way relieves the Contractor of the responsibility to provide all necessary daily Quality Control inspections of its own and to comply with all requirements of this Specification.

The Contractor shall facilitate the Engineer’s inspections as required, including allowing ample time for the inspections and providing suitable lighting (50-foot candles minimum at the surface as defined later in this specification). The Contractor shall furnish, erect and move scaffolding or other mechanical equipment to permit inspection and close observation of all surfaces to be cleaned, metallized and coated. This equipment shall be provided during all phases of the work.

The Contractor shall notify the Engineer in advance of plans to remove staging used in cleaning, metallizing and coating operations in order to allow for inspection. The QA inspection will be performed with the QA inspector’s equipment when verifying the Contractor’s test results in the field.

Safety Equipment: The Contractor shall furnish and have available to the Engineer at all times during the metallizing operation, and at no expense to the State, two NIOSH/MESA approved thermal spray air respirators and other such safety equipment so as to permit proper inspection of on-going work. The required safety equipment shall be furnished prior to the start of work and shall be returned to the Contractor upon approval of the work.

Secure scaffolding shall be used to enable safe and ready access to the work areas for inspection purposes.

Spray Equipment for Metallizing: The metallizing unit shall be an electric arc gun that has the ability to spray the specified alloy, is manufactured by an established domestic company, and shall be used in accordance with the manufacturer’s recommendations. Flame spray equipment may be used on repair or limited access areas, if operated in accordance with the manufacturer's latest written instructions. Preheating the starting area is required for flame spraying. All air and gas pressure gages and flow meters shall be in good working order. Malfunction of any one pressure gage or flow meter shall be just cause to suspend operations.

Compressed Air: All compressed air sources shall have oil and moisture separators, attached and functional, properly designed and sized to allow delivered air at the nozzle to be oil-free, moisture-free and of sufficient pressure to accomplish the associated work efficiently and effectively. The tanks on the air compressor and moisture separator shall be drained at the end of each work day.

Prior to abrasive blast cleaning, the Contractor shall prove to the inspector that the air is moisture free. Air for air driven power tools shall be properly lubricated in accordance with the respective power tool manufacturer’s instruction, but such lubrication shall not be deposited onto the bridge surface being prepared.

The Contractor shall verify that the compressed air is free of moisture and oil contamination in accordance with the requirements of ASTM D4285. The tests shall be conducted at least once every 4 hours for each compressor system in operation. Sufficient freedom from oil and moisture

ADDENDUM NO. 2

is confirmed if soiling or discoloration is not visible on the paper. If air contamination is evidenced, the Contractor shall change filters, clean traps, add moisture separations or filters, or make other adjustments as necessary to achieve clean, dry, air.

All surface preparation equipment, hoses and hoppers that the Contractor brings to the Sites shall be clean and free of any prior cleaning debris.

Abrasives: Abrasive blast media shall be grit only to derive a blast profile in the range of 3.0 –

6.0 mils with an anchor tooth profile that is sharp, clean and free of embedded friable material with minimal peening effect. Steel shot shall not be used. Verification of the profile height will be performed with extra coarse Testex Replica Tape (3.5 -7.5 mils). The impressed tape is a record to be filed with the project inspection records. Note: When measuring the profile on the tape, 2 mils shall be subtracted (non-compressible mylar thickness) from the micrometer reading.

Abrasives shall also be checked for oil contamination before use. A small sample of abrasives shall be added to ordinary tap water. Any detection of an oil film on the surface of the water shall be cause for rejection. This test shall be conducted on each load of abrasives delivered to the job site.

Abrasive media for blast cleaning shall be recyclable steel grit with a minimum Rockwell C hardness of 45. The abrasive grit, as delivered, shall exhibit no more than a 20% breakdown from the initial sieve test data after 100 uses. Prior to reuse the abrasive grit shall be cleaned of all millscale, rust, paint, and other contaminates.

SSPC AB2 recycled ferrous material should be pre-screened before use in the field for radioactivity.

An initial ten-pound (4.5 kilogram) abrasive working mix sample before blast cleaning operations begin will be required for sieve analysis and testing. During blast cleaning operations a weekly ten-pound (4.5 kilogram) abrasive sample will be taken from the mobile abrasive recycling, blast machine(s), abrasive hopper after grit recovery and classification and immediately delivered to the Laboratory. Samples will be analyzed by the Department for the abrasive mix tolerance breakdown and cleanliness. If the abrasive mix has greater than twenty percent breakdown from the initial sample then all the abrasive shall be replaced with harder (Rockwell C hardness) material at no cost to the State. Contamination of the abrasive mix shall not exceed 0.1% by weight and the total lead content of the sample shall not exceed 500 milligrams. If the contamination or lead limit is exceeded, then all abrasive blast cleaning operations shall be suspended. The abrasive classifier shall be repaired and another abrasive sample will be required for testing after reclassification of the abrasive. For test results lower than the maximum limits, abrasive blast cleaning may resume.

Test results greater than the maximum limit will require additional equipment repairs or replacement recommended by the manufacturer at no cost to the State. If additional repairs were performed then a sample will be required for testing after reclassification of the abrasive. Test results greater than the maximum limit will require replacement of the classifier unit at no cost to the State.

Observed Steel Defects: After blast cleaning operations have occurred, if significant deficiencies, such as cracks or section losses are found outside of areas shown to be repaired as part of the project, the Contractor shall immediately notify the Engineer as to their extent and include field sketches and photographs of the area so it can be determined if any additional steel repairs would

ADDENDUM NO. 2

be required.

Cracks and significant section loss shall be noted and measured by the Engineer, who shall then promptly notify in writing the Bridge Safety and Evaluation Section, Office of Engineering, dot.bridgesafety@ct.gov.

Form

Location: Bridge No.:

Span:

Girder, beam, or diaphragm affected:

Problem: Problem Location:

Protection of Persons and Property: The Contractor shall protect property, pedestrians, vehicular, and other traffic upon, underneath, or in the vicinity of the bridge, and also all portions of the bridge superstructure and substructure against abrasive blast cleaning damage or disfigurement from splatters, splashes, smirches, or spray of paint or paint materials. All coating overspray, drips, spills shall be contained. Any coating or solvent that has escaped the Contractor’s containment enclosure shall be cleaned up immediately. For bridges over water, a containment boom will be required. The length of containment boom on Site shall be at least equal to twice the length of the active work Site over the water. The submission of a perimeter air monitoring plan to be executed by Industrial hygiene firm

Notice: Chemical Stripping will not be permitted.

Surface Preparation: Steel surfaces shall be cleaned by the specified methods described in the Steel Structures Painting Council (SSPC) Specifications, Edition. The structural steel shall be abrasive blast cleaned in accordance with SSPC-SP 10 “Near White Blast Cleaning”. Laminar corrosion, steel fins or slivers shall be removed by Hand Cleaning (SSPC-SP 2) and/or Power Tool Cleaning

(SSPC-SP 3).

A standard of cleaning for SSPC-SP 10 “Near White Blast Cleaning” shall be established. The surface for the standard (or control) shall be a flat portion of the surface actually to be cleaned and shall be located by the Engineer. This standard, once approved by the Engineer, shall serve as a guide for the Project.

To supplement this standard, SSPC-VIS 1-89 and NACE TM-01-75 Grit shall be used.

For the production cleaning operations, the specifications and written definitions, the test section(s), and the SSPC visual standards shall be used in that order for determining compliance with the Contract requirements.

All edges of flame cut edges shall be abrasive blast cleaned with aluminum oxide or hand ground until the steel is smooth and shiny and then reblasted with angular grit.

A. Laminar and Stratified Rust: All laminar and stratified rust or corrosion products that have formed on any area of the existing steel surfaces and accessible rust formed along edges of connected plates or shapes of structural steel shall be removed. The tools used to remove these mailto:dot.bridgesafety@ct.gov

ADDENDUM NO. 2

corrosion products shall be identified in the submittals and accepted by the Engineer. If the surface preparation or removal of rust results in nicks or gouges, the work will be suspended.

The Contractor shall demonstrate that the necessary adjustments have been made to prevent a recurrence of the damage prior to resuming work.

B. Weld Spatter, Sharp Edges, and Holes: All slag, flux deposits, and weld spatter and steel irregularities such as fins, tears and slivers shall be removed from the surfaces to be metallized.

Any resulting burrs from such removal shall be ground smooth, including burrs around holes.

All corners and edges shall be rounded to a 0.0625-inch radius or chamfered to a 0.0625-inch chamfer.

C. Cleaning of Steel: All visible contaminants shall be removed from surfaces in accordance with SSPC-SP 1 using only solvents or detergents.

D. Compressed Air Cleanliness: The cleanliness of the compressed air shall be confirmed in accordance with ASTM D4285 at least once per shift for each compressor system.

E. Surface Requirements: The required surface preparation shall meet SSPC SP 10. Surface preparation shall not be performed under damp environmental conditions or when the surface temperature of the steel is less than 5°F above the dewpoint temperature as determined by a surface thermometer and an electric or sling psychrometer.

F. Abrasives/Profile:

1. The Contractor shall use abrasives that are free of oil, soluble salts and other similar substances that could contaminate the surface.

2. A uniform sharp angular profile with a profile of 3.0 to 6.0 mils shall be provided in accordance with ASTM D4417, Method B or C.

G. Acceptance Prior to Metallizing: The cleaned surface shall be accepted by the Engineer before application of metallizing. Failure of the Contractor to prepare and clean the surfaces to be metallized in accordance with these specifications shall be cause for rejection by the Engineer.

All surfaces that are rejected shall be re-cleaned to the satisfaction of the Engineer at no additional cost to the State.

H. Pre-Production Test Section:

1. The Contractor shall blast clean and metallize at least 9 square feet of steel surface prior to initiating the full-scale metallizing operation using the same metallizing equipment, set up, materials, and calibration and operating procedures in the test section(s) that shall be used for the production operations.

2. Additional testing may be required by the Engineer to establish the suitability of the surface preparation and the thermal spray coating. Full-scale metallizing shall not commence until the Engineer has inspected and approved the Test Section.

The Metallizing Contractor may abrasive blast and metallize at the same bridge if separate containments are provided to ensure the abrasive blasting debris and dust does not contaminate surfaces to be metallized.

All foreign materials such as dirt, dust, rust scale, sand, bird droppings, and all materials loosened by abrasive blasting operations shall also be completely removed before any metallizing, sealing, or painting operations are begun.

The cleaned surface shall be reviewed and, if meeting SSPC-SP 10 requirements, approved by the Engineer prior to proceeding to the next operation.

All abrasives and residue shall be removed from all surfaces to be metallized and coated with a vacuum system equipped with a brush type cleaning tool. All steel blast cleaned in any one day

ADDENDUM NO. 2

shall be kept dust free and metallized the same day. Failure to apply metallizing the same day will require reblasting before metallizing. No dust or abrasives from adjacent work shall be left on the metallized coat.

Before and after blast cleaning and before metallizing, all dissolvable foreign matter, such as oil, grease, and dust shall be removed in accordance with the provisions of SSPC-SP 1 “Solvent Cleaning” Method 4.1.1 only.

Failure by the Contractor to properly prepare and clean surfaces to be metallized in accordance with the specifications shall be cause for rejection by the Engineer. All surfaces which are rejected shall be cleaned and metallizing shall be reapplied to the satisfaction of the Engineer, at no additional cost to the State.

Soluble Salt (Chloride) Remediation: The Contractor shall remediate chloride levels on blast cleaned surfaces to acceptable levels. Surfaces subject to chloride contamination include steel surfaces within or beneath expansion joints, areas subject to moisture splashing, misting or seeping downward from the roadway and corrosion pitted areas.

Methods of chloride removal such as steam cleaning or pressure washing (with or without the addition of a chemical soluble salt remover as approved by the metalizing manufacturer) and scrubbing before or after blast cleaning shall be used. The Contractor may also elect to use wet abrasive methods of preparation, or combinations of the above. If wet methods are used, the steel shall be re-blast cleaned by dry abrasive blast cleaning. If steam or water cleaning methods of chloride removal are used on surfaces where the existing paint has been completely removed, and the water does not contact any lead containing coating, the water does not have to be collected.

The Contractor shall provide the proposed procedures for chloride remediation in the Surface Preparation/Sealing Plan.

The Contractor shall use Class A (cell or sleeve) methods of field chloride extraction and test procedures (e.g., silver dichromate) in accordance with SSPC Guide 15 to test representative surfaces that were previously rusted (e.g., pitted steel) for the presence of remaining chlorides.

Chloride levels shall be no greater than 7 µg/sq cm as read directly from the surface without any multiplier applied to the results. The testing shall be performed, and the results shall be acceptable to the Engineer, prior to metallizing each day.

A minimum of five tests per 1,000 sq ft (93 sq m) or fraction thereof completed in a given day, shall be conducted at Project start-up. If results greater than 7 µg/sq cm are detected, the surfaces shall be re-cleaned and retested at the same frequency. If acceptable results are achieved on three consecutive days in which testing is conducted, the test frequency may be reduced to one test per 1,000 sq ft (93 sq m) prepared each day provided the chloride remediation process remains unchanged. If unacceptable results are encountered, or the methods of chloride remediation are changed, the Contractor shall resume testing at a frequency of five tests per 1,000 sq ft (93 sq m).

Following successful chloride testing, test areas shall be re-cleaned in accordance with SSPC-SP

10.

Bend Tests: Unless directed otherwise by the Engineer, each day that metallizing will be applied, the Contractor shall perform bend testing prior to beginning production work. For each metallizing applicator, five carbon steel coupons measuring 2 inches wide × 8 inches long × 0.05 inches thick

ADDENDUM NO. 2

shall be blast cleaned using the same equipment and abrasive used for the production work. Each operator shall apply the metallizing to five coupons in accordance with the requirements of this Specification to a dry film thickness of 8.0 to 12.0 mils. The 180-degree bend testing shall be performed on all five coupons using a 0.5-inch mandrel in accordance with the requirements and acceptance criteria of SSPC-CS 23.00/AWS C2.23M/NACE No. 12. Minor cracks that cannot be lifted from the substrate with a knife blade are acceptable. If lifting occurs on any coupon, the surface preparation and/or metalizing process shall be modified until acceptable results are achieved before proceeding with production work.

Metallizing Application:

A. Quality of Surface Preparation: The Contractor and Engineer shall verify that the surface meets the specified SSPC-SP 10 surface requirements immediately prior to application of the metallized coating.

B. Surface Cleanliness: Subsequent coats shall not be applied until overspray, spent abrasive, dirt, dust, and other contaminants have been removed in accordance with SSPC-SP 1.

C. Apply metallizing to steel surfaces within 6 hours of the beginning of abrasive blasting. If the Metallizing Contractor elects to supply a heated and dehumidified enclosure, apply metallizing within 24 hours of the beginning of abrasive blasting.

D. Ambient Conditions: Metallizing shall be applied when the relative humidity is less than 85%.

Metallizing shall not be applied under damp environmental conditions or when the surface temperature of the steel is less than 5°F above the dewpoint temperature as determined by a surface thermometer and an electric or sling psychrometer.

E. Metallizing: The coating shall be applied by thermal spray employing multiple passes to achieve a uniform thickness of 0.008 to 0.012 inches (8-12 mils) unless otherwise specified.

No single pass shall deposit more than 0.004 inches.

F. Metallizing Adhesion: Adhesion strength of the metallizing shall be 700 psi minimum as measured with approved equipment per ASTM D4541, Annex A4. Measurements shall be taken on companion coupons 4 × 6 × 0.25 inches of the same steel grade as the member being coated and processed concurrently. If adhesion is less than 700 psi but greater than 560 psi, four (4) additional adhesion tests shall be made. If any of the additional adhesion tests are less than 700 psi, the coating shall be removed and re-applied. Any single adhesion test result less than 560 psi, will be justification for the Engineer to have the Contractor remove the entire coating. All corrective action will be at the Contractor’s expense.

G. Holding Time: A flash coat of metallizing 2 to 4 mil thick may be applied within the required six hours to hold the surface condition for an additional four hours. Maximum holding time is four (4) hours provided the metallized coating can be maintained free of contamination. Do not exceed the maximum holding time between each successive 2 to 4 mil thick metallized coat.

H. Quality Control of Metallizing Operation:

1. The Metallizing Contractor shall verify proper spray equipment set up, calibration, and operating procedures by performing a bend test at the beginning of each work shift that metallizing is to be applied in accordance with requirements described in the Pre- Production Test Section.

2. In addition to the bend test, a cut test shall be performed on the companion coupons, one during the production day and one at the end of each shift, to confirm that metallizing is being properly applied. The cut test consists of a single cut 1.5 inches long through the thermal spray coating to the substrate without severely cutting the substrate. A cut shall be made with a hammer and sharp chisel. The chisel cut shall be made at a shallow angle.

The bond of the metallizing is considered unsatisfactory if any part of the metallizing lifts

ADDENDUM NO. 2

from the substrate along the cut.

3. The Engineer shall be notified immediately of any unsatisfactory tests.

I. Bolted Connections and Other Areas:

1. The Contractor shall state in writing to the Engineer a list of areas they believe are inaccessible prior to the start of work at each Site. The Engineer will have the final determination as to the accessibility of those areas.

2. Areas such as bolt holes, backs of snipes and other similar areas where the standard application of a metallized coating cannot be performed shall be cleaned and free of dirt and any loose overspray, and shall receive a brush applied coating of the approved coating system.

3. Metallized coating applied to surfaces not required to be coated may remain if found to be tightly adhered, as determined by the Engineer.

Sealer and Topcoat Application:

A. The sealer shall be applied in a single mist coat followed by a full topcoat.

1. The Metallizing Contractor shall apply the sealer in accordance with the manufacturer’s recommendations, unless otherwise specified.

2. The sealer shall be applied no more than 8 hours after application of the metallizing, and in no case shall the sealer be applied over dust, rust that may have bled through (if there was not enough thickness), loose oxides or other visible contaminants that would interfere with the sealer.

3. When conventional spray equipment is used, the Contractor shall verify that the compressed air supply is clean and dry as determined by the blotter test (ASTM D4285).

4. The topcoat shall be applied to achieve a 4 to 6 mils dry film thickness and shall be applied after the seal coat has been allowed to dry as required by the recoat time in the manufacturer's written instructions, but in no case shall a coat remain exposed for longer than ten (10) calendar days prior to overcoating.

B. Coverage and Continuity: All surfaces shall be completely coated and free of voids, runs, sags or other defects. Special attention shall be given to hard-to-reach or inaccessible areas and irregular surfaces. Some configurations may require spraying from multiple directions to assure complete coverage.

C. Sealer and Topcoat Adhesion to Metallized Surfaces:

1. The Metallizing Contractor shall apply the sealer and topcoat in such a manner to assure adherence to the underlying surface. Any lifting of an underlying coat, or poor adhesion between coats or to the substrate, will require removal of the coating in the affected area to adjacent intact, adherent coating, and reapplication of the material.

2. Topcoat adhesion shall be verified using adhesion tests in accordance with ASTM D4541 as directed by the Engineer.

D. Coating Thickness

1. Wet Film Thickness: The Contractor shall verify and document the thickness of each liquid coat at the time of application using wet film thickness gages in accordance with ASTM D4414.

2. Dry Film Thickness: The dry film thicknesses of the completed coating shall be:

Metallizing 8 to 12 mils Topcoat 4 to 6 mils TOTAL SYSTEM 12 to 18 mils

The Contractor shall measure the thickness of each coat using nondestructive magnetic dry film thickness gages. The procedure shall comply with SSPC-PA2 for the calibration and use of the gages, and the frequency of thickness measurements. Spot readings both 20%

ADDENDUM NO. 2

above and 20% below the thicknesses shown above are permitted, provided the average thicknesses are within the specified tolerances.

Spray equipment, brushes and rollers used in application of coatings shall be sized sufficiently and be in proper working order to accomplish the work according to the manufacturer's written recommendations.

Storage of Paints: The Contractor shall provide a suitable facility for the storage of paint that will be in accordance with the latest OSHA and DEP regulations. This facility must provide protection from the elements and ensure that the paint is not subjected to temperatures outside the manufacturer’s recommended extremes. Storage of paint must be located in reasonable proximity to the painting locations. The Engineer shall be provided access to the stored paint at any time for inspection and to witness removal of the materials. The Contractor’s facility for the storage of paint will be subject to the approval of the Engineer. Paint shall be furnished in the manufacturer’s original sealed containers.

Ambient Conditions: Surface preparation and coating application work shall only be done inside a containment enclosure as specified herein. Surface preparation or coating work shall be performed inside the containment enclosure meeting the following:

• The relative humidity is at or below 85%.

• The substrate is not damp, or covered by frost or ice.

• The surface temperature and air temperature are between 50°F and 100°F.

• The surface temperatures of the steel and air are more than 5°F above the dew point temperature, as determined by a surface temperature thermometer and electric or sling psychrometer.

If the requirements of the coating manufacturer differ from the ranges provided above, comply with the most restrictive requirements unless directed otherwise by the Engineer in writing.

Heating Devices: The Contractor may use heating devices to obtain and maintain a condition within the containment enclosure that is suitable for surface preparation, metallizing and coating application. For metallizing and coating applications, the required conditions must be maintained for the duration of the cure period. Heating devices shall be limited to gas- or oil-fired indirect air heaters in which the combustion products are discharged separately from the forced airstream to an area outside the containment enclosure. The heating devices must be configured so as not to form condensation on cold surfaces or cause rust-back and must be automatically controlled.

Information describing the proposed heating devices and the proposed heating procedures shall be provided a minimum of 20 days in advance for Engineer acceptance.

Industrial Dehumidification: The Contractor may use industrial dehumidification equipment within an enclosure.

If the Contractor proposes to control the ambient conditions inside the containment, proposal methods and equipment for heating and/or dehumidification shall be included in the Surface Preparation, Metallizing or Sealing Plans, as applicable. Any heating and/or dehumidification proposals accepted by the Engineer shall be implemented at no additional cost to the State.

ADDENDUM NO. 2

Lighting Requirements: A minimum illumination level of 20 foot-candles shall be provided throughout the inside of the containment enclosure during surface preparation and coating application work. A minimum illumination level of 50 foot-candles shall be provided at the location of the specific work task and for inspection. All lighting fixtures and related connectors located inside the containment enclosure must be explosion proof and shall be UL listed.

Technical Advisor: It is mandatory that the Contractor obtain the services of a qualified technical…