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COPYRIGHT SSPC: THE SOCIETY FOR PROTECTIVE

COATINGS

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SSPC: The Society for Protective Coatings, 40 24th St 6th Fl, Pittsburgh PA
15222-4656 USA. All rights reserved.

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may be reproduced or distributed in any other way without the express written
permission of SSPC.

DISCLAIMER

SSPC standards, guides, specifications, and other technical documents are


developed in accordance with voluntary consensus procedures established
by SSPC Technical Committees. They are intended to represent a balance of
interests, and are believed to represent good current practice. All documents
are monitored and revised as practices improve. Suggestions for revision are
welcome.

SSPC specifically disclaims responsibility for the use or misuse of any


information contained in this document, and is not responsible for the
application, interpretation, or administration of this information. Furthermore,
no person is authorized to issue an interpretation of this information on behalf
of SSPC. The supplying of details about patented formulations, treatments,
or processes is not to be regarded as conveying any right or permission to
the user of this document to use or sell any patented invention. When it is
known that the subject matter of the text is covered by patent, such patents
are reflected in the text. Mention of specific product names does not imply
SSPC endorsement.

It should be understood by all persons using this product that SSPC does not
give any warranties, expressed or implied, nor make any representations as
to the accuracy, completeness or usefulness of the information or conclusions
contained herein, nor assume any responsibility of any nature from whatever
cause including negligence resulting from the use of this product.
SSPC-PA Guide 5
September 1, 2002
Editorial Revisions November 1, 2004

SSPC: The Society for Protective Coatings

PAINT APPLICATION GUIDE NO. 5


Guide to Maintenance Coating of Steel Structures
in Atmospheric Service

1. Scope Plan and Implement Follow-Up Activities (Section 10)

1.1 This guide covers procedures for developing a main- 3. Referenced Standards
tenance coating program for steel structures. The guide may
be used for one-time recoat programs or long-range recoat 3.1. SSPC STANDARDS AND JOINT STANDARDS1
programs.
Items preceded by an asterisk (*) are referenced in the
1.2 The guide is intended for use primarily by owners Notes or Appendices.
representatives. It is not intended to be a do-it-yourself guide, Guide 6 Guide for Containing Debris
but is representative of the processes that a coating specialist Generated During Paint Removal
(such as a Protective Coating Specialist [PCS] certied by Operations
SSPC) would follow to develop a maintenance coating plan Guide 7 Guide for the Disposal of Lead-
for specic facilities. Contaminated Surface Preparation
Debris
2. Description Guide 14 Guide for the Repair of
Imperfections in Galvanized or
2.1 A maintenance coating program is required to prevent Inorganic Zinc Coated Steel with
corrosion of steel and deterioration of other substrates. It is Organic Zinc-Rich Paint
also required to maintain an acceptable appearance of coated PA 2 Measurement of Dry Coating Thick-
structures. Decisions on frequency and extent of recoating and ness with Magnetic Gauges
type of system to be used require consideration of numerous PA Guide 4 Guide to Maintenance Repainting
factors, including both technical and economical alterna- with Oil Base or Alkyd Painting
tives. Systems
PA 1 Shop, Field, and Maintenance
2.2 This guide sets out specic steps that may be used, Painting of Steel
either individually or collectively, to identify and address SP 1 Solvent Cleaning
essential elements of a maintenance coating program. These SP 2 Hand Tool Cleaning
steps are summarized in Section 4. Preparation of a contract SP 3 Power Tool Cleaning
specication for coating work is covered in SSPC-TR 4/NACE SP 5/NACE No. 1 White Metal Blast Cleaning
80200, Preparation of Protective Coating Specications for SP 6/NACE No. 3 Commercial Blast Cleaning
Atmospheric Service (latest edition).1 Due to wide variations SP 7/NACE No. 4 Brush-Off Blast Cleaning
in procedures, a discussion of contracting methodologies and SP 10/NACE No. 2 Near-White Blast Cleaning
implementation schemes is outside the scope of this guide. SP 11 Power Tool Cleaning to Bare
Metal
2.3 MAJOR STEPS IN MAINTENANCE COATING: This SP 12/NACE No. 5 Surface Preparation and Cleaning
guide addresses six major steps in a maintenance coating of Metals by Waterjetting Prior to
program, which are dened as: Recoating
Plan and Conduct Condition Assessment Survey SP 14/NACE No. 8 Industrial Blast Cleaning
(Section 5) SP 15 Commercial Grade Power Tool
List Potential Maintenance Painting Options (Section 6) Cleaning
Evaluate Economics of Available Options (Section 7) * QP 1 Standard Procedure for Evaluat-
Select Appropriate Maintenance Painting Options and ing Painting Contractors (Field
Establish Implementation Procedures (Section 8) Application to Complex Industrial
Implement Maintenance Painting Options (Section 9) Structures)

1
Joint standards may alo be obtained from NACE International at http:/www.nace.org

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* QP 2 Standard Procedure for Evaluat- 4.1.2 List Potential Maintenance Painting Options (Step
ing the Qualication of Painting 2): Section 6 reviews the various maintenance painting options
Contractors (Field Removal of available, including: spot repair, overcoating, and complete
Hazardous Coatings from Complex recoat, as well as the rationale for selecting these maintenance
Industrial Structures) painting options and the types of information needed for the
* QP 5 Standard Procedure for Evaluating decision.
Qualications of Coating and Lining
Inspection Companies 4.1.3 Evaluate Economics of Available Options (Step
TR 4/NACE 80200 Preparation of Protective Coating 3): Section 7 provides guidance in evaluating the initial and
Specifications for Atmospheric life-cycle costs of available maintenance painting options.
Service Each decision has potential impact on the life cycle cost of
TU 3 Overcoating the coating system and must be identied and evaluated.
TU 4 Field Methods for Retrieval and
Analysis of Soluble Salts on Sub- 4.1.4 Select Appropriate Maintenance Painting Options
strates and Establish Implementation Procedures (Step 4): Section
VIS 2 Standard Method of Evaluating 8 reviews the factors and considerations necessary to establish
Degree of Rusting on Painted Steel specications for the two major maintenance painting options
Surfaces of spot repair and complete recoat, including identication
of relevant factors for coating system selection, and surface
3.2 ASTM INTERNATIONAL STANDARDS:2 preparation selection, depending on whether complete removal
and recoat, spot repair, or a combination of spot repair and
* D 3276 Standard Guide for Painting Inspectors overcoating is selected as a strategy.
(Metal Substrates)
* D 4228 Standard Practice for the Qualication 4.1.5 Implement Maintenance Painting Options (Step
of Coating Applicators for Application of 5) Section 9
Coatings to Steel Surfaces
D 610 Standard Test Method for Evaluating Degree 4.1.6 Plan and Implement Follow-Up Activities (Step
of Rusting on Painted Steel Surfaces 6): Section 10 describes procedures and review actions after
the job is completed, including documentation, short- and
3.3 FEDERAL STANDARD3 long-term condition inspections, and preventative maintenance
Code of Federal Regulations measures.
29 CFR 1926.62 Lead (Construction Industry Standard)
5. Plan and Conduct Condition Assessment
4. Planning and Use of Guide Survey (Step 1)

4.1 This document is based on, and is intended to be used 5.1 PURPOSE OF CONDUCTING CONDITION
with, the technical principles outlined in SSPC-TU 3. Planning ASSESSMENT SURVEY: Condition assessments can be used
and implementation of maintenance coating programs for steel for several purposes, i.e., to determine the need for recoating,
structures are presented in a logical sequence of six specic to determine the extent of corrosion and corrosion damage,
steps. These steps range from planning and conducting condi- to determine the performance of various coating systems, or
tion assessment to follow-up activities required for implementing to prioritize coating requirements where insufcient funds are
an on-going maintenance program. Each step is designed available to do all the desired work (see Note 11.1).
such that it may be utilized in sequence with the other steps,
or independently for those with interest in only one or a few 5.2 IDENTIFY AND INVENTORY STRUCTURES TO BE
aspects of the program. A summary of each step follows. SURVEYED: A written description of the structures requiring
maintenance coating should be obtained or prepared. The
4.1.1 Plan and Conduct Condition Assessment Survey description should include location, dimensions, type of
(Step 1): Section 5 provides a general approach for organizing substrate, conguration, process, previous surface prepara-
surveys to evaluate the condition of the structure. Three different tion and coating plans, specications, history, and any other
types of surveys (general overview, detailed visual survey, and pertinent information. Examples of the latter would include
physical inspection) are covered, along with a proposed plan proximity to sensitive areas, planned new construction or other
for assessing sub-units of a larger, more complex structure, activities nearby, and types of exposures (e.g., acid fallout).
and a description of procedures and documentation needed. (See SSPC Publication 94-18, Project Design.) It is usually

2
ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2659. Available onliine from www.astm.org.
3
FED STD 141 can be obtained from http://astimage.daps.dla.mil/online/new/

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most economical to consider all structures in similar condi- 5.3.4 Hazardous Content Assessment: Unless previous
tion within a given area for maintenance at the same general coating history and specications are known, laboratory
time. testing needs to be performed to determine if any hazardous
elements are present. These include, but are not limited to,
5.3 DETERMINE THE EXTENT OF ASSESSMENT lead, cadmium, and chromium. OSHA (Occupational Safety
REQUIRED: The survey may vary considerably in the extent and Health Administration) requirements for worker expo-
and detail of the information required. Among the types of sure and RCRA (Resource Conservation and Recovery Act)
survey to be considered are: requirements for disposal with its implied containment should
be incorporated into the contract to protect workers and lessen
5.3.1 General Coating Condition Assessment: In this potential claims. SSPC-Guide 6 and Guide 7 provide details
assessment, usually only one or two parameters are rated relevant to containment and disposal. OSHA regulation 29
(e.g., general condition or rusting). The structure is normally CFR 1926.62 details worker protection requirements for lead
observed from the ground (i.e., without scaffolding). The assess- (see SSPC publication 95-06, Project Design).
ment is at best a qualitative rating of the condition (e.g., good,
fair, poor). Only the major features of a structure or facility are 5.3.5 Structural Inspection: Coating assessment should
rated (e.g., a full span of a bridge or a side of a storage tank). be included as part of any general structural inspection for loss of
This type of assessment is usually done in a few hours or less metal, broken joints, or other structural defects. A relatively small
and is suitable for identifying overall condition of the coating. additional inspection time is required to evaluate and record
the ratings of individual structures or structural elements. This
5.3.2 Detailed Visual Assessment: This type of assess- information will normally prove extremely valuable in evaluating
ment also relies exclusively on visual observations, but these maintenance painting options, especially in developing the most
are performed more systematically than for a general assess- cost effective life-cycle maintenance strategy. Numerous public
ment. Numerous structural elements (e.g., support beams, and private entities have been successful in using scheduled
connections, edges) are separately rated according to SSPC- facility inspections, such as bridge safety inspections, as the
VIS 2, ASTM D 610, or equivalent and combined to provide rst cut in determining coating condition.
an overall structure or facility rating. Often, several condition
parameters (e.g., loss of topcoat, cracking, rust staining) and 5.4 DETERMINE THE CONDITION RATING SCHEME:
several corrosion parameters (e.g., rusting, blistering, scaling, For both visual inspection and physical testing, it is necessary
loss of metal) are recorded. With this survey, one can obtain a to use a standard rating system and format for recording data.
semi-quantitative rating of the percent of surface deteriorated. SSPC-TU 3 discusses the salient characteristics of a rating
This type of survey may be used to develop preliminary cost scheme that is based on the technical merits of coating condi-
estimates for recoating. tion and overcoating.

5.3.3 Physical Coating Testing: Physical testing, visual 5.4.1 Physical Testing: See SSPC-TU 3 for detailed guid-
assessment, and the general assessment are often performed ance in evaluating coating condition and risks of overcoating.
simultaneously. Visual assessment gives no information on the These evaluations generally require certain detailed information
lm adhesion, thickness, brittleness, or underlm corrosion. concerning the coating type and physical condition.
Physical testing is required to determine whether the coating
can be overcoated or repaired, or whether it is too weak to 5.4.2 Use of Ratings Data: In many cases, these condi-
accept another coating layer. This assessment should be tion ratings will be keyed directly to repair procedures (e.g.,
performed prior to specifying the maintenance painting options SSPC-PA Guide 4). The next two sections of this guide give
and requires direct access to the surface at several locations the procedures for developing such a scheme.
on the structure. SSPC-TU 3 provides discussion of the value
of physical testing, as well as the procedures for testing. 5.5 PLAN FOR INSPECTING STRUCTURAL
Identication of the generic type of the existing nish COMPONENTS: A sub-unit sampling plan identies the
coating is important when selecting compatible coatings for portions of the structure or facility that will be rated and the
maintenance coating, if part of the existing coating is to remain. A type of rating scheme to be used. Sub-unit sampling plans are
laboratory technique, Fourier Transform Infrared Spectroscopy needed for complex structures or where detailed information
(FTIR), is frequently used to determine the generic coating type. is required. For a process unit, (for example) the structural
This requires only a tiny sample chip of paint to identify the steel might be divided into individual tanks, piping, handrails
coating type, and is available at a nominal price. Alternatively, and ladders, and structural support. On large structures, the
patch tests of the proposed system or systems may be applied areas could be further subdivided into sections. Because of
to the existing coating to establish compatibility. differences in corrosion tendencies, it is often useful to have

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separate ratings for edges and at surfaces. The extent of 6.1.2 The data to be analyzed are those that have been
inspection depends on how detailed a survey is desired and previously collected from an overview, visual inspection, or
what resources may be available. physical inspection. If no formal survey was taken, use the
best information available (e.g., coating historical records) to
5.6 ESTABLISH PROCEDURES AND ASSEMBLE estimate the overall condition ratings.
RELATED DOCUMENTS
6.2 CONSIDER ALTERNATIVE OPTIONS: After the
5.6.1 A specic procedure should be established for a data is reviewed, the available alternative actions should be
condition assessment, which should include a budget and considered. These range from not coating to complete coating
schedule, including equipment and crews. The availability removal and recoating.
of funds will determine the extent of the survey that can be
undertaken. A schedule should be established based on the 6.3 NO MAINTENANCE REQUIRED FOR THREE YEARS
number of hours or days required to prepare the structure OR LONGER: In one possible scenario, the coating is in good
(e.g., notify other trades) or arrange for access (i.e., coordinate shape and no corrosion or deterioration requires attention. In a
schedules of other individuals). This includes identifying support second scenario, the coating may be providing some protec-
crews and equipment that may be required to assist with the tion but may be in too poor a condition to salvage. Eventually,
condition assessment. Personnel requirements must also be total coating removal will be needed, but maintenance can be
established (i.e., identify individuals who will conduct the survey delayed without any signicant harm to the structure. This option
such as in-house inspectors, engineers, outside consultants, may be considered under the following circumstances:
coating contractors, or coating manufacturers). If a condition
assessment survey is to be performed by a consultant or 6.3.1 The structure is in a mild environment and little
contractor, a written contract should be prepared. If a coating corrosion activity is expected at breaks in the coating lm over
manufacturer offers to do the assessment at no cost, the rm the next few years.
should be asked to submit a written description of the plan
for the owners review, modication, and approval. There are 6.3.2 The extent of discoloration, topcoat erosion, or
numerous contracting methods available for acquiring condi- general degradation is not very important, due to the locations
tion assessments, structural inspections, and coating work, on the structure. In general, the coating is intact and protection
including options ranging from acquiring each facet of work by is still being provided.
different contracts to using turnkey type contracts to perform
all inspection, structural repair, and coating work. When more 6.3.3 The structure is being assigned a low priority for
than one facet of work is included in a single contract, steps maintenance because of economics, aesthetics, or other
should be taken to ensure the validity of each facet prior to reasons.
proceeding to the next facet.
6.3.4 The structure is scheduled for major coating repair
5.6.2 Required standards (e.g., standards such as SSPC or complete replacement within 3 years. The additional time
VIS 2, ASTM D 610, or equivalent) as well as eld equipment is not expected to add signicantly to the corrosion metal loss
such as tape recorders, inspection forms, and a camera must or the surface preparation cost.
be available.
6.3.5 The structure is due for demolition.
5.7 CONDUCT ASSESSMENT SURVEY: The survey
should be conducted after the schedule and the standards 6.4 SPOT REPAIR ONLY: Spot repair entails surface
have been established. The owners representative should preparation and touch-up coating of localized areas of deterio-
ensure that all elements of the survey have been properly rated coating and corrosion. The surface preparation may be
performed, recorded correctly, and distributed to predetermined accomplished by hand or power tool cleaning, high- or ultrahigh
personnel. pressure waterjetting, or abrasive blasting. Several specialized
materials and procedures are available for localized surface
6. List Potential Maintenance Painting Options preparation, including composite media (sponge), sodium
(Step 2) carbonate slurries, plastic media, walnut shells, corncobs, etc.
The intact coating surrounding the degraded area should be
6.1 REVIEW SURVEY DATAAND COATING OBJECTIVES feathered and lightly sanded 2.5 to 5 cm (1 to 2 inches) onto the
AND CRITERIA intact coating to permit a smooth transition. The cleaned areas
are primed with a coating compatible with the existing coating
6.1.1 The corrective action to be taken is based on the system and spot topcoated to conform to the required DFT. In
results of the previous surveys, the short and long-term objec- this particular option, the remaining (e.g., intact) coating is not
tives of the coating program, special limitations, and other overcoated. It should be noted that the spot repair method is
relevant factors. primarily a stopgap method. It is recommended that the structure

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be re-evaluated within three to ve years. Spot repair may be 6.5.4 When corrosion and deterioration exceed 10 to 15%
considered under the following circumstances: of the total area, project economics may suggest total removal
of the coating system.
6.4.1 Repairs are hidden or in a low-visibility area and
thus unimportant to the aesthetics. 6.6 COMPLETE RECOAT OF STRUCTURE OR SUB-
UNITS (ZONES): When the overall coating condition is poor,
6.4.2 Owner maintenance crews are available for this type when the remaining life of the structure or sub-unit justies the
of work. expense, and when funds are available, a decision to recoat
the structure in its entirety is usually made. This involves
6.4.3 Structures are small, not requiring extensive scaf- removing the old coating and all of the corrosion products before
folding or hard-to-access areas. applying the primer, intermediate coats, and topcoat. Coating
a sub-unit of a structure (often called zone painting) may be
6.4.4 Corrosion and degradation are limited to isolated a variation of this alternative when funds are limited or when
areas and relatively small sections, which amount to less than the remaining portions of the structure are in good condition.
1% of the total area. This option presents a much lower risk of early coating/corro-
sion problems (such as catastrophic delamination or early rust
6.4.5 A decision has been made to upgrade small isolated back) than do the alternative options.
areas such as bearing areas, crevices, or areas subject to
leakage, condensation, or chemical splash. 6.7 OTHER REPAIR METHODS: On occasion, different
methods of cleaning and/or coating may be required for different
6.5 SPOT REPAIR AND OVERCOATING: This technique areas or zones of the structure. A higher-performing coating
involves spot repair of deteriorated coating and corroded areas system (e.g., abrasive blast cleaning followed by application
followed by the application of a full nish coating over the of a zinc-rich/epoxy/polyurethane system) may be specied
entire surface, including spot repaired areas and intact coating for high corrosion atmospheric areas of a structure, such as
areas. The intact coating surrounding the degraded area must areas subject to deicing salt, dripping, or chemical spillage),
be feathered back. The repair coating should extend at least with a lesser performing system (such as hand or power tool
2.5 to 5 cm (1 to 2 inches) onto the intact coating to allow for cleaning followed by an alkyd or a high-solids epoxy with
a smoother transition of the repair coating onto the existing good wetting) on less critical or less corrosion-prone areas.
coating and better topcoat adhesion. The topcoat should Compatible topcoats may be required to blend in with restored
be compatible with the existing coating. The existing intact or rehabilitated portions of the structure.
coating should be cleaned of surface contaminants before
total recoating. This type of system would be expected to give 6.8 ADDITIONAL SURVEY: After an analysis of the avail-
perhaps ve years or more additional life to the entire surface able data, an additional survey may be required. The initial
area by helping to prevent further deterioration of the intact survey may have been too limited to provide sufcient data
coating. Successful overcoating will often delay the need for to make remedial recommendations, or the survey may have
a full coating removal. Spot repair and overcoating may be only looked at a portion of the structure or not examined some
considered under the following circumstances: specic details required, such as the integrity of the coating
near high-corrosion prone areas. The area may be scheduled
6.5.1 An evaluation of risks in overcoating is a function of for other repair or outage work within a 2-year period and may
adhesion and existing coating thickness, as outlined in SSPC- be re-assessed at that time.
TU 3. This risk analysis must be performed if risks are to be
managed, and while it is generally thought that risks should 7. Evaluate Economics of Available Options
be held to the range of low to moderate, higher risks may (Step 3)
be acceptable to the owner under certain conditions.
7.1 The act of contemplating coating application or main-
6.5.2 The intact surface can be readily cleaned with pres- tenance is, in effect, an analysis of the economics of abating
surized air, hand tools (SSPC-SP 2), power tools (SSPC-SP 3), or slowing the effects of corrosion damage. The variables
solvent or detergent wiping (SSPC-SP 1), or power washing involved in protective coatings often require a variety of solu-
(as described in SSPC-SP 12). If low or high pressure water tions, each of which will carry unique cost-benet factors. Many
cleaning (also called power washing) is used, the maximum factors inuence the selection of coating systems. However,
water pressure required should be stated in the project speci- when considering maintenance of existing coating systems,
cation. the factors are generally restricted due to constraints imposed
by the existing coating. Still, there are generally multiple
6.5.3 If severely corroded surfaces (as described in Section options available, and it is important to consider the economic
6.6) are found, special cleaning methods and coating systems impacts of all options prior to nalizing a design. The chapter
may be required. on economics in the SSPC Painting Manual, Volume 1Good

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Painting Practice, provides comparative costs for most surface 8.2.6 The ability of the coating to tolerate residual soluble
preparation methods, generic coating systems, application, salts will directly affect the time to early rust-back. SSPC-TU 4
and special requirements for selected situations. addresses salt remediation testing. The coating to be applied
must be tolerant of the level of contaminant present.
8. Select Appropriate Maintenance Painting Op-
tions and Establish Implementation Procedures 8.3 SELECT SURFACE PREPARATION METHODS
(Step 4) AND COATING MATERIALS FOR COMPLETE RECOAT
STRATEGY
8.1 Once a course of action has been determined, it is
essential that detailed specications and supporting documents 8.3.1 Select Surface Preparation Methods: SSPC and
be prepared to achieve that course of action. other organizations have well-dened standards for most of
these requirements, which can readily be incorporated into
8.2 IDENTIFY RELEVANT FACTORS FOR COATING a specication. Available surface preparation techniques for
SYSTEM SELECTION complete recoating include conventional dry abrasive blast
cleaning (SSPC-SP 5/NACE No. 1, SSPC-SP 10/NACE No.
8.2.1 The selection of the coating system is inuenced 2, SSPC-SP 6/NACE No. 3, SSPC-SP 14/NACE No. 8, and
not only by the type of recoating (e.g., spot repair or complete SSPC-SP 7/NACE No. 4), wet abrasive blast cleaning, vacuum
recoat) but also by special factors such as restrictions due to blasting, and high- and ultrahigh pressure water jetting (SSPC-
environmental, health, and safety regulations; budgets; expo- SP 12/ NACE No. 5). It is important to specify the degree of
sure environment; weather; or conguration and contaminants. cleanliness and the surface prole (for blast cleaning), the
Thus, before choosing the coating system, it is useful to identify degree of salt or contaminant remediation, and the need for
these pertinent factors. solvent cleaning and/or water washing prior to blast cleaning.
Waterjetting can neither alter nor create prole, but can expose
8.2.2 Abrasive blast cleaning may require containment existing prole.
controls due to air quality concerns or the need to avoid dust or
abrasive rebound in sensitive areas. The presence of hazards An important consideration when blast cleaning is the
such as lead-based coatings on a structure will require special collection and disposal of blasting debris. SSPC-Guide 6
collection and containment devicesthe type of device being provides guidance on the selection of the type of containment
largely determined by the extent of lead- based coating to based on the type of surface preparation being performed. It can
be removed. Site-specic regulations on the volatile organic also be used to provide guidance on the level of containment
compound (VOC) content may exclude the use of previously that is necessary for a job. Guidance is provided on ventilation,
used coatings. air ow, and dust emissions. Guide 7 provides guidance on
the disposal of hazardous surface preparation debris once it
8.2.3 Weather or conguration can also limit the selection has been contained and collected.
of coating systems. Many coatings (e.g., conventional epoxies,
water-borne acrylics) are best applied above 10C (50F). If the surface preparation techniques discussed herein
Other coatings are sensitive to high humidity or low humidity cannot be used, it may be necessary to clean to a less desir-
(e.g., inorganic zinc-rich primers). In certain congurations, able surface condition and to apply a coating system (primer,
spray application may not be permitted because of high wind intermediate, and topcoat) over a surface that is not completely
or overspray on sensitive equipment or automobiles. rust and coating free. In such instances, the primer must be
tolerant of the surface condition. Certain power tools are also
8.2.4 The exposure environment is a major determinant of capable of removing existing rust and coating (SSPC-SP 11
the type of coating system. Typically, exposure environments or SSPC-SP 15) but generally at much lower production rates.
are classied according to the presence of soluble salts, pollu- Coating system life expectancy is likely to decrease if the level
tion, sunlight exposure, rain/humidity, or chemicals. of surface preparation is lowered.

8.2.5 The existing condition of the structure must be 8.3.2 Select Coating Materials: The selection of the
known. For spot repair or overcoating, the compatibility of the coating system often involves two phases: rst, identifying the
new coats over existing ones should be veried by a patch generic types (e.g., epoxy/zinc-rich/polyurethane); and second,
test, as shown in SSPC-TU 3. If the patch coating shows no identifying the criteria for selecting materials. The specica-
adverse physical effects (e.g., lifting of the existing coating) or tion may utilize generic compositions, a qualied product list
appearance effects (e.g., bleeding) on the existing coating, it of proprietary materials, or other approaches. In the coating
should be considered compatible with it. In addition, the patch specication, the owner should describe the procedures for
test, when evaluated over a period of six months or more, can qualication and acceptance criteria for the coating materials.
provide important data on the physical compatibility (stress) For qualication, the supplier may be required to furnish
of the new coating over the old. evidence of previous use of the coatings on similar structures,

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or laboratory tests of physical properties, accelerated corrosion (SSPC-SP 3), commercial grade power tool cleaning (SSPC-
and weathering properties, and application properties. These SP 15), special (proling) power tool cleaning (SSPC-SP 11),
properties should be certied by the manufacturer or an inde- and vacuum or wet blasting methods. These methods may be
pendent laboratory. For new technology coatings, extensive used easily with vacuum assists for containment.
service data may not be available. The owner may also require
some verication that the material delivered to the job site is 8.4.1.4. After spot cleaning, the cleaned areas are coated
the same as that which was originally qualied. Some general with a primer that extends over the feathered edges of the
guidelines on acceptance sampling and testing are given in the intact coating to overlap them 2.5 to 5 cm (1 to 2 inches) onto
SSPC Painting Manual, Volume1Good Painting Practice. the sound, intact coating. This will minimize edge lifting and
will provide a better appearance.
8.3.3.1 An important part of the specication is the coating
lm thickness. Both a minimum and a maximum dry lm thick- 8.4.2 Select Coating Materials for Spot Repair or Spot
ness should be specied (see SSPC-PA 2). Repair with Overcoating.

8.3.3.2 The application methods are normally governed 8.4.2.1 The selection of the coatings will be determined
by the materials selected and are stipulated by coating manu- by the need for compatibility with the existing surfaces. Most
facturers on their data sheets. SSPC-PA 1 provides guidance coatings are suitable for application to the bare metal areas
for applicators that will supplement the manufacturers appli- (i.e., spot-repaired areas), so the main concern is compat-
cation instructions. If there is a contradiction between the two ibility with the previous coating. See SSPC-TU 3 for detailed
recommendations, that of the coating manufacturer should instructions for performing and evaluating patch testing.
take precedence.
8.4.2.2 The selection of the coating materials for spot repair
8.4 SELECT SURFACE PREPARATION METHODS is guided by the same considerations as for full recoat. For spot
AND COATING MATERIALS FOR SPOT REPAIR OR SPOT repair of small areas, a brushable primer is advantageous. It is
REPAIR AND OVERCOATING also important that the primer be compatible with the existing
intact coating because it is necessary to have the spot repair
8.4.1 Determine Techniques and Standards for Repair, overlap the intact coating. As an example, an organic zinc-
Surface Preparation, and Recoating rich coating is normally used instead of an inorganic zinc-rich
coating for spot repair of a damaged inorganic zinc coating with
8.4.1.1 When making spot repairs, it is necessary to deter- an organic nish coat, because the inorganic zinc-rich coating
mine the precise areas requiring repair. Areas where coating does not bond sufciently to either organic or inorganic coat-
can be removed by moderate scraping with a dull putty knife ings. Additional information on repair of damaged galvanized
will require spot repair. Residual loose material will prevent or inorganic zinc coatings is given in SSPC-Guide 14.
proper spot repair.
8.4.2.4 The coatings selected for the full topcoat must be
8.4.1.2 One important decision to be made is whether compatible with both the spot primer and the existing intact
abrasive blast cleaning will be used for spot repair mainte- coating.
nance. Abrasive blasting may be used for brush-off cleaning
(SSPC-SP 7/NACE No. 4) or industrial blast cleaning (SSPC- 8.4.2.5 The requirements for application, lm thickness,
SP 14/NACE No. 8). To provide a higher level of cleaning with material qualications, and acceptance criteria are the same
the total removal of rust and coating, SSPC-SP 6/NACE No. as those for applying a full recoat system. For spot repair,
3 or greater may be specied for spot repair areas. Brush off however, it is essential that the requirements for determining
blasting may be used to remove loose coating or rust. It or some which areas are to be repaired should be clear and denitive.
other surface treatment may be necessary to obtain acceptable Discussion of these items should be included in the pre-bid
adhesion between the existing intact coating and the repair or and pre-job meetings.
overcoating system. Great care must be exercised when spot
blasting to avoid over-blast damage to adjacent intact coating 8.5 PREPARE SPECIFICATION
that does not need to be blasted. Spot blasting is generally not
recommended for areas of repair of less than 1 square foot or 8.5.1 The job specication provides the basis for the cost
when the total repair is less than 5 to 10 percent of the total and execution of the work. It is essential that the job speci-
surface area, unless a lesser degree of cleaning cannot be cation provide a complete description of the desired work by
tolerated. prescribing specic procedures, processes, and materials or
by describing the work product. The specication must also
8.4.1.3 Alternatives to open spot blasting include hand provide criteria for acceptance or rejection of work as well as
tool cleaning (SSPC-SP 2), conventional power tool cleaning remedies for unacceptable work.

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8.5.2 A job specication should be prepared using the 10.4 ENSURE PROPER DOCUMENTATION AND FILING
general format of the Construction Specication Institute OF HISTORICAL INFORMATION: Before the job is ofcially
(CSI). Chapter 3 of The Inspection of Coatings and Linings: accepted, it is necessary that all documentation be completed.
A Handbook of Basic Practice for Inspectors, Owners, and The record of the daily inspection logs and the records of the
Speciers provides a description of the CSI format and its parts coatings procured, used, discarded, or disposed of should be
or specic owners format requirements. Additional information properly stored in the owner les. It should be veried that
for preparing a job specication for protective coating work can the retained samples of the coating are properly labeled and
be found in SSPC-TR 4/NACE 80200, Preparation of Protective stored for future reference.
Coatings Specications for Atmospheric Service. Appendix
A provides additional information that should be considered 10.5 INSTITUTE PREVENTATIVE MAINTENANCE
during preparation of the job specication. MEASURES: In some cases, regular removal of contaminants
can eliminate potential problems before they become severe.
9. Implement Maintenance Painting Options Examples are chemical spills that might occur or concentrations
(Step 5) of de-icing salts. In some cases, moderate design changes can
be made that will eliminate water or other chemicals collecting
Clean and coat the structure.
in crevices or other areas vulnerable to corrosion attack.

10. Plan and Implement Follow-up Activities


11. Notes
(Step 6)
11.1. Numerous public and private entities have been
10.1 BENEFITS OF FOLLOW-UP: An important part of a
successful in using scheduled facility inspections, such as
maintenance coating program is to monitor the performance of
bridge safety inspections, as the rst cut in determining coating
the applied coatings system, for both short-term and long-term
condition. Depending on the processes used for such inspec-
effects. In the short term, certain inspections and follow-ups
tions, it is feasible to train facility inspectors to perform surveys
are necessary to ensure that the contractor has fullled the
that range from General Overview Condition Assessment to
requirements of the contract. For the long-term, there are
Detailed Visual Inspection, as described in Section 5.3. It
certain benecial measures that can be taken to minimize the
requires a relatively small additional inspection time to evaluate
onset of corrosion and information that can be collected that
and record the ratings of individual structures or structural
will facilitate future decisions on maintaining the structure.
elements. This information will normally prove extremely valu-
able in evaluating maintenance painting options, especially
10.2 ESTABLISH NEED FOR PERIODIC INSPECTION:
in developing the most cost effective life-cycle maintenance
Inspection should be made of the structure within 6 to 12
strategy.
months after application especially in cases where there are
surfaces such as edges or bolts that will delaminate or rust
12. Disclaimer
within a short period due to difcult surface preparation or
application, or especially severe service conditions. If these
12.1 This guide is designed to describe, review, or analyze
areas are discovered and are corrected within the rst year,
new or improved technology and does not meet the denition
the time interval until the next maintenance may be extended.
of a standard as dened by SSPC. A guide differs from a stan-
Some agencies require a one-year touchup provision as part
dard in that it is not suitable for referencing in a specication
of a contractors obligations in the contract to cover such
or procurement document.
contingencies. Other warranted work should also be inspected
prior to expiration of the warranty.
12.2 While every precaution is taken to ensure that all
information furnished in SSPC guides is as accurate, complete,
10.3 ESTABLISH SCHEDULES FOR CONDITION
and useful as possible, SSPC cannot assume responsibility
ASSESSMENT: In addition to periodic inspection, a structure
nor incur any obligation resulting from the use of any materials,
should be scheduled for a periodic condition assessment.
coatings, or methods described herein, or of the guide itself.
Depending on the type of structure and the environment, the
rst condition asssessment would normally be conducted
12.3 This guide does not attempt to address problems
about 5 years after the original application and every 3 years
concerning safety associated with its use. The user of this
thereafter. Specic rating sheets or parameters to be inspected
specication, as well as the user of all products or practices
should be made available to inspection personnel. The condi-
described herein, is responsible for instituting appropriate
tion assessment should be similar to the survey data required
health and safety practices and for ensuring compliance with
in Section 5 of this guide.
all governmental regulations.

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13. Bibliography Trimber, Kenneth A. Industrial Lead Paint Removal Handbook,


2nd ed. Pittsburgh, PA: KTA-Tator, Inc., 1993. (SSPC
The following reference materials may contain useful Publication 93-02).
supplementary information:
Trimber, Kenneth A. and Daniel P. Adley, CIH, CSP. Project
Appleman, Bernard R., Advances in Technology and Standards Design: Industrial Lead Paint Removal Handbook,
for Mitigating the Effects of Soluble Salts, Journal of Volume II. Pittsburgh, PA: KTA-Tator, Inc., 1995. (SSPC
Protective Coatings & Linings, Vol. 19, No. 5, (May, 2002), Publication 95-06).
pp. 42-47.
Appendix A. Other Considerations in Preparing
Appleman, Bernard R. Coating Over Soluble Salts: A Contract Documents and Executing Mainte-
Perspective. Journal of Protective Coatings & Linings, nance Coating Projects
Vol. 4, No. 10, (October 1987), pp. 68-82.
The items below are intended to provide the owners
Castler, L. Brian, Jayson L. Helsel, Michael F. MeLampy, and representative with a summary of items to be considered when
Eric Kline, Comparative Painting Costs. Steel Structures preparing contract documents and following up as the project
Painting Manual, Vol. 1: Good Painting Practice, Chapter evolves.
8. Pittsburgh, PA: SSPC, 2002.
A.1 BENEFITS OF WELL-PREPARED CONTRACTS: A
Environmentally Acceptable Materials for Corrosion Protection well-planned and designed contract will benet both the owner
of Steel Bridges, Appendix 1 from Environmental and the contractor as follows:
Guidelines for Painting Practices. Washington DC: FHWA,
1997. (FHWA Report RD-96-058). Reduce the cost of the work to the owner.
Provide clear expectations of work to be
Guide to Bridge Painting, FHWA TS-89-14. Washington DC: performed.
Highway Administration, 1989. (SSPC Publication 89- Eliminate unnecessary contingencies for the
04). contractor.
Provide for a smooth, trouble-free workow without
Inspection of Coatings and Linings: A Handbook of Basic costly interruptions.
Practice for Inspectors, Owners, and Speciers. Richard Identify and anticipate possible problems, avoid them
W. Drisko, and Judy Neugebauer, eds. Pittsburgh, PA: when possible, and provide means to resolve them
SSPC, 1997. (SSPC Publication 97-07). when they occur.
Complete the work safely.
PDCA Safety & Loss Control Manual., Fairfax, VA: Painting & Provide measurement and payment criteria.
Decorating Contractors of America, 1984.
A.2 ESTABLISH QUALIFICATION REQUIREMENTS
Protective Systems for Steel Bridges, Section 16.4, Bridge FOR CONTRACTORS
Inspectors Training Manual 90, produced by Michael
Baker, Jr., Inc. Washington DC: FHWA, 1991. FHWA- A.2.1 Pre-Qualication of Contracting Firms: Many
PD-91-015. agencies have adopted guidelines or procedures for screening
or pre-qualifying contractors based on references or actual job
SSPC Painting Manual, Volume 1Good Painting Practice evaluations. SSPC, through its Painting Contractor Certication
(Fourth Edition). Pittsburgh, PA: SSPC, 2002. (SSPC Program (PCCP), has established a program for certifying
Publication 02-14). contractors. The QP 1 program is for eld paint application,
the QP 3 program is for shop application rms, and the QP 2
SSPC Painting Manual, Vol. 2Systems & Specications (Eighth program is for the removal of hazardous coatings. In addition,
Edition), Selection of Coating Systems by Environmental numerous owners require that a contractor be bonded to cover
Zone. Pittsburgh, PA: SSPC, 2000. (SSPC Publication the estimated cost of the work.
00-10).
A.2.2 Qualications for Applicators and Blasters:
SSPC-TU 1: Technology Update: Surface Tolerant Coatings. Some state and other agencies require that the applicators
Pittsburgh: SSPC, 1997. (SSPC Publication 97-20). demonstrate their abilities to attain specied quality of cleaning
and coating application. ASTM D 4228, Standard Practice for
Qualication of Coating Applicators for Application of Coatings
to Steel Surfaces may be used to qualify applicators.

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A.2.3 Union or Labor Requirements: Some jurisdictions owner should identify locations, pressures, amounts, ttings,
may be restricted to union shops. voltages, and other pertinent operating details. The contractor
should identify any owner-furnished items or services.
A.3 PROTECTION OF EXISTING PLANT FACILITY AND
EQUIPMENT: Identify all the steps that should be taken by A.8 WARRANTY/GUARANTEE: The most common
the contractor and/or owner to protect the existing plant facility warranty for coating work is a one-year warranty against defec-
and equipment from the planned operations. Establish hold tive materials and job quality. Extended period performance
points to verify that the proper protection is in place prior to warranties are becoming more common, and, when utilized,
proceeding with operations. Identify on plans or in the scope should be formulated to correlate with the specic coating
of work if the coating is or may be hazardous. systems selected. When warranties are utilized, it should be
clearly stated who is to be responsible for the warranty and
A.4 SAFETY REQUIREMENTS: All employers must what conditions will trigger the warranty repair, any required
prepare a safety plan, including both facility owners and contrac- inspection schedules, what is expected of the warranty repairs,
tors. When contractors are working at a particular facility, their etc.
site-specic safety plan must incorporate the relevant issues.
The safety plan used is likely to be an amalgamation of the stan- A.9 PERSONNEL AND COATING CONSUMPTION
dard safety plan of both the owner and the contractor. Depending RECORDS: Information regarding personnel resources and
upon the particular situation, the plan may be prepared by coating quantities can be benecial in preparing cost estimates
the facility owner, the contractor, or by both working together, for similar work. Tracking mechanisms should be dened in
but it should be understood and approved by both parties. All the contract documents. Also, owners should request copies
employers must provide personal protective equipment (PPE), of contractor inspection reports and daily logs for their les.
including specic equipment such as respirators, and training
in its use. Safe working conditions are the responsibility of A.10 TYPE OF CONTRACT: The SSPC Painting Manual
the employer. Such responsibility is more easily dened at a Volume 1Good Painting Practice provides a detailed descrip-
xed facility where all the workers are employed by the same tion of the types of contracts, bids, and proposals.
company than at a complex construction site where there are
many different companies working together. Nevertheless, A.11 ESTABLISH PROCEDURES FOR OWNER-
all safety precautions must be made, and it is the employers CONTRACTOR RELATIONS
responsibility to ensure that safety issues are recognized, and
the risks are minimized. Any details not completely understood A.11.1 Identification of Owner and Contractor
should be resolved in the pre-construction conference and at Representatives: The contractor and owner should each
subsequent other conferences. All HAZCOM requirements, appoint an authorized representative to whom all required
including labeling and material safety data sheets, must be notications are given, through whom contract changes are
met. The SSPC Painting Manual Volume 1Good Painting processed, and who is responsible for contract coordination
Practice provides additional guidance on safety issues in the and resolution of non-conformances and other problems.
coating industry. Ensure that all personnel are familiar with responsibilities and
procedures and that the authorities of engineer, inspector, eld
A.5 HAZARDOUS WASTE: The owner shall notify the supervisor, and coating manufacturers representative are
contractor if lead, cadmium, chromium-containing paints or dened. In particular, identify the person who is responsible
other hazardous materials are to be removed. The contractor for inspection and that persons afliation (e.g., owners repre-
should identify the requirements to remove lead, chromium, sentative, third party, or other). Review procedures established
or cadmium-containing paints, or other toxic materials. The for handling and disposing of waste.
owner should also indicate the extent of responsibility of the
contractor for generating, containing, collecting samples, A.11.2 Interface with Plant Operation: The contract
testing, and disposing of hazardous waste. should identify all plant operations and operations of other
contractors that will be ongoing in the work area. The contract
A.6 ACCESS FOR INSPECTION: The contractor should should outline how the coating work will interface with these
provide for reasonable access to the work for the owners operations and what precautions will be necessary. Special
inspectors, including use of the contractors scaffolding, work efforts should be made so that conicting operations, such as
platforms, and safety apparatus. welding and spray coating, do not occur simultaneously in the
same area.
A.7 OWNER-FURNISHED ITEMS AND SERVICES: It is
often necessary and/or economically benecial to the owner to A.12 PREPARE CONTRACT AND SCHEDULE: It is
make various items and services available to the contractor. useful to prepare a list of the various activities required in
These may include: laydown/storage areas, electric power, securing the contracts and the time allotted for each of these.
potable water, restrooms, etc. For any utilities provided, the Typical elements of this schedule are as follows:

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a. Prepare Contract Documents


b. Notice Inviting Proposals A.16 PROCURE COATINGS ACCORDING TO
c. Pre-Bid Conference SPECIFICATION: Either the owner or the contractor may
d. Pre-Bid Demonstration/Inspection procure the coatings. In either case, it is necessary to verify
e. Proposal Due Date that the coatings meet the specication. The owners inspector
f. Post-Bid Meetings and Clarications should verify that the agreed-upon coating materials supplied
g. Negotiations, if allowed to the job site are properly labeled, that proper certications
h. Contract Award have been obtained, and that samples are retained for testing
i. Pre-Job Conference/Demonstration by the owners laboratory, an independent laboratory, or for
j. Contract Start Date future reference. Any exceptions or replacements should be
k. Contract Termination Date noted. Pre-sampling, testing, and approval prior to shipment
l. Owner Acceptance Date can help assure that approved material arrives on the job. This
m. Warranty Date can help prevent job delays.
n. EEO requirements
A.18 Quality Assurance/Quality Control: Quality
Specic sample clauses for these and other details required Assurance (QA) and Quality Control (QC) are important
in obtaining contracts may be found in SSPC-TR 4/NACE parts of any maintenance program. The purpose of the
80200. QA/QC program is to ensure that the processes and work
products are in conformance with the specied criteria. The
A.13 ARRANGE AND CONDUCT PRE-BID CSI specication format includes QC under Part 3. Execution.
CONFERENCE: All prospective or qualied bidders are invited The CSI approach requires the contractor to execute the QC
to attend a meeting with the owners representative to review the program. The contractor is responsible for quality control. The
bid package. This review would normally include an explanation processes need to be veried, which requires the contractor to
of the surface cleaning and application requirements, the nature perform various inspection functions related to the QC effort.
of the structure, its condition, access to the structure, special The owner is responsible for quality assurance and should
restrictions (e.g., on blast cleaning safety requirements), and be functioning to provide this assurance role. In other words,
answer any questions the contractor might have. Ordinarily, the owner should assure that the contractor is providing the
an actual visit to the structures or facility to be coated should necessary quality control. (This concept is often misinterpreted
be required. Many contractors are reluctant to attend pre-bid as meaning the QC program will be executed by the owner,
meetings because of the cost and time, or simply because they utilizing in-house personnel or independent third party inspec-
do not want to let their interests be known. For major and critical tors, with the contractor providing no quality control effort.)
projects, experienced owners often make pre-bid attendance Qualied personnel are essential to the execution of the QC
mandatory because it eliminates problems that occur when as well as the QA program. Qualied inspector qualication
contractors are not familiar with the structure or the terms of programs, such as NACE Internationals CIP4 or equivalent
the specications. Some public agencies do not permit such for individual inspectors, or SSPC-QP 5 for coating and lining
meetings because they feel that the additional travel expense inspection companies, are excellent tools for obtaining qualied
is unfair to contractors from remote locations. inspectors. The inspectors can be utilized in either a quality
control role or a quality assurance role. The content of the QC
A.14 REVIEW BID AND AWARD CONTRACT: This program as described in the specication is also important.
operation is usually strictly governed by owner legal policies The QC program must include appropriate methods and tools
and requirements. The contractor who has met the previous with suitable references. Inspection frequency, distribution, and
requirement with the lowest bid is generally awarded the data analysis methods must also be described. The correct
contract in the competitive bidding system. amount of inspection is important. Inadequate inspection may
not identify serious deciencies. There are numerous guides,
A.15 PRE-JOB CONFERENCE: This meeting is held such as Inspection of Coatings and Linings: A Handbook of
between the owner and the contractor hired to do the job. Basic Practice for Inspectors, Owners, and Speciers, and
Owners may need to include representatives from their internal ASTM D 3276, which may be used to develop project-specic
safety and environmental departments in these meetings. coating inspection plans. Over-inspection may increase the
The contractor should bring the eld superintendent and the cost of the coating project while returning little or no additional
company principal or company representative. The purpose of benets.
this meeting is to review in detail the specic work assignments,
schedules, needs for coordination, and procedures for formal
and informal communication. The conference must include a
review of the work area pointing out safety hazards, facilities,
and equipment that require protection or special care, and
safety and emergency systems available.

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