Paint+Application+Guide+No.+5

7/27/2019 Paint+Application+Guide+No.+5

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SSPC-PA Guide 5

September 1, 2002

Editorial Revisions November 1, 2004

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1. Scope

1.1 This guide covers procedures for developinga main-

tenance coating program for steel structures. The guide may

be used for one-time recoat programs or long-range recoat

programs.

1.2 The guide is intended for use primarily by owners

representatives. It is not intended to be a do-it-yourself guide,

but is representative of the processes that a coating specialist

(such as a Protective Coating Specialist [PCS] certified bySSPC) would follow to develop a maintenance coating plan

for specific facilities.

2. Description

2.1 A maintenance coating program is required to prevent

corrosion of steel and deterioration of other substrates. It is

also required to maintain an acceptable appearance of coated

structures. Decisions on frequency and extent of recoating and

type of system to be used require consideration of numerous

factors, including both technical and economical alterna-

tives.

2.2 This guide sets out specific steps that may be used,

either individually or collectively, to identify and address

essential elements of a maintenance coating program. These

steps are summarized in Section 4. Preparation of a contract

specification for coating work is covered in SSPC-TR 4/NACE

80200, Preparation of Protective Coating Specifications for

Atmospheric Service (latest edition).1 Due to wide variations

in procedures, a discussion of contracting methodologies and

implementation schemes is outside the scope of this guide.

2.3 MAJOR STEPS IN MAINTENANCE COATING:This

guide addresses six major steps in a maintenance coating

program, which are defined as:

Plan and Conduct Condition Assessment Survey

(Section 5)

List Potential Maintenance Painting Options (Section 6)

Evaluate Economics of Available Options (Section 7)

Select Appropriate Maintenance Painting Options and

Establish Implementation Procedures (Section 8)

Implement Maintenance Painting Options (Section 9)

Plan and Implement Follow-Up Activities (Section 10)

3. Referenced Standards

3.1. SSPC STANDARDS AND JOINT STANDARDS1

Items preceded by an asterisk (*) are referenced in the

Notes or Appendices.

Guide 6 Guide for Containing Debris

Generated During Paint Removal

OperationsGuide 7 Guide for the Disposal of Lead-

Contaminated Surface Preparation

Debris

Guide 14 Guide for the Repair of

Imperfections in Galvanized or

Inorganic Zinc Coated Steel with

Organic Zinc-Rich Paint

PA 2 Measurement of Dry Coating Thick-

ness with Magnetic Gauges

PA Guide 4 Guide to Maintenance Repainting

with Oil Base or Alkyd Painting

Systems

PA 1 Shop, Field, and MaintenancePainting of Steel

SP 1 Solvent Cleaning

SP 2 Hand Tool Cleaning

SP 3 Power Tool Cleaning

SP 5/NACE No. 1 White Metal Blast Cleaning

SP 6/NACE No. 3 Commercial Blast Cleaning

SP 7/NACE No. 4 Brush-Off Blast Cleaning

SP 10/NACE No. 2 Near-White Blast Cleaning

SP 11 Power Tool Cleaning to Bare

Metal

SP 12/NACE No. 5 Surface Preparation and Cleaning

of Meta ls by Waterjetting Prior to

Recoating

SP 14/NACE No. 8 Industrial Blast Cleaning

SP 15 Commercial Grade Power Tool

Cleaning

*QP 1 Standard Procedure for Evaluat-

ing Painting Contractors (Field

Application to Complex Industrial

Structures)

SSPC: The Society for Protective Coatings

PAINT APPLICATION GUIDE NO. 5

Guide to Maintenance Coating of Steel Structures

in Atmospheric Service

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-

ing the Qualification of Painting

Contractors (Field Removal of

Hazardous Coatings from Complex

Industrial Structures)

*QP 5 Standard Procedure for Evaluating

Qualifications of Coating and Lining

Inspection Companies

TR 4/NACE 80200 Preparation of Protective Coating

Specifications for Atmospheric

Service

TU 3 Overcoating

TU 4 Field Methods for Retrieval and

Analysis of Soluble Salts on Sub-

strates

VIS 2 Standard Method of Evaluating

Degree of Rusting on Painted Steel

Surfaces

3.2 ASTM INTERNATIONAL STANDARDS:2

* D 3276 Standard Guide for Painting Inspectors

(Metal Substrates)

* D 4228 Standard Practice for the Qualification

of Coating Applicators for Application of

Coatings to Steel Surfaces

D 610 Standard Test Method for Evaluating Degree

of Rusting on Painted Steel Surfaces

3.3 FEDERAL STANDARD3

Code of Federal Regulations

29 CFR 1926.62 Lead (Construction Industry Standard)

4. Planning and Use of Guide

4.1 This document is based on, and is intended to be used

with, the technical principles outlined in SSPC-TU 3. Planning

and implementation of maintenance coating programs for steel

structures are presented in a logical sequence of six specific

steps. These steps range from planning and conducting condi-

tion assessment to follow-up activities required for implementing

an on-going maintenance program. Each step is designed

such that it may be utilized in sequence with the other steps,

or independently for those with interest in only one or a few

aspects of the program. A summary of each step follows.

4.1.1Plan and Conduct Condition Assessment Survey

(Step 1): Section 5 provides a general approach for organizing

surveys to evaluate the condition of the structure. Three different

types of surveys (general overview, detailed visual survey, and

physical inspection) are covered, along with a proposed plan

for assessing sub-units of a larger, more complex structure,

and a description of procedures and documentation needed.

4.1.2List PotentialMaintenance Painting Options (Step

2):Section 6 reviews the various maintenance painting options

available, including: spot repair, overcoating, and complete

recoat, as well as the rationale for selecting these maintenance

painting optionsand the types of information needed for the

decision.

4.1.3 Evaluate Economics of Available Options (Step

3): Section 7 provides guidance in evaluating the initial and

life-cycle costs of available maintenance painting options.

Each decision has potential impact on the life cycle cost of

the coating system and must be identified and evaluated.

4.1.4 Select Appropriate Maintenance Painting Options

and Establish Implementation Procedures (Step 4): Section

8 reviews the factors and considerations necessary to establish

specifications for the two major maintenance painting options

of spot repair and complete recoat, including identification

of relevant factors for coating system selection, and surface

preparation selection, depending on whether complete removal

and recoat, spot repair, or a combination of spot repair and

overcoating is selected as a strategy.

4.1.5 ImplementMaintenance Painting Options (Step

5) Section 9

4.1.6 Plan and Implement Follow-Up Activities (Step

6): Section 10 describes procedures and review actions after

the job is completed, including documentation, short- and

long-term condition inspections, and preventative maintenance

measures.

5. Plan and Conduct Condition AssessmentSurvey (Step 1)

5.1 PURPOSE OF CONDUCTING CONDITION

ASSESSMENT SURVEY: Condition assessments can be used

for several purposes, i.e., to determine the need for recoating,

to determine the extent of corrosion and corrosion damage,

to determine the performance of various coating systems, or

to prioritize coating requirements where insufficient funds are

available to do all the desired work (see Note 11.1).

5.2 IDENTIFY AND INVENTORY STRUCTURES TO BE

SURVEYED: A written description of the structures requiring

maintenance coating should be obtained or prepared. The

description should include location, dimensions, type of

substrate, configuration, process, previous surface prepara-

tion and coating plans, specifications, history, and any other

pertinent information. Examples of the latter would include

proximity to sensitive areas, planned new construction or other

activities nearby, and types of exposures (e.g., acid fallout).

(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-

tion within a given area for maintenance at the same general

time.

5.3 DETERMINE THE EXTENT OF ASSESSMENT

REQUIRED: The survey may vary considerably in the extent

and detail of the information required. Among the types of

survey to be considered are:

5.3.1 General Coating Condition Assessment: In this

assessment, usually only one or two parameters are rated

(e.g., general condition or rusting). The structure is normally

observed from the ground (i.e., without scaffolding). The assess-

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

rated (e.g., a full span of a bridge or a side of a storage tank).

This type of assessment is usually done in a few hours or less

and is suitable for identifying overall condition of the coating.

5.3.2 Detailed Visual Assessment: This type of assess-

ment also relies exclusively on visual observations, but these

are performed more systematically than for a general assess-

ment. Numerous structural elements (e.g., support beams,

connections, edges) are separately rated according to SSPC-

VIS 2, ASTM D 610,or equivalentand combined to provide

an overall structure or facility rating. Often, several condition

parameters (e.g., loss of topcoat, cracking, rust staining) and

several corrosion parameters (e.g., rusting, blistering, scaling,

loss of metal) are recorded. With this survey, one can obtain a

semi-quantitative rating of the percent of surface deteriorated.

This type of surveymay be used to develop preliminary cost

estimates for recoating.

5.3.3 Physical Coating Testing: Physical testing, visual

assessment, and the general assessment are often performed

simultaneously. Visual assessment gives no information on the

film adhesion, thickness, brittleness, or underfilm corrosion.

Physical testing is required to determine whether the coating

can be overcoated or repaired, or whether it is too weak to

accept another coating layer. This assessment should be

performed prior to specifying the maintenance painting options

and requires direct access to the surface at several locations

on the structure. SSPC-TU 3 provides discussion of the value

of physical testing, as well as the procedures for testing.

Identification of the generic type of the existing finish

coating is important when selecting compatible coatings formaintenance coating, if part of the existing coating is to remain. A

laboratory technique, Fourier Transform Infrared Spectroscopy

(FTIR), is frequently used to determine the generic coating type.

This requires only a tiny sample chip of paint to identify the

coating type, and is available at a nominal price. Alternatively,

patch tests of the proposed system or systems may be applied

to the existing coating to establish compatibility.

5.3.4 Hazardous Content Assessment: Unless previous

coating history and specifications are known, laboratory

testing needs to be performed to determine if any hazardous

elements are present. These include, but are not limited to,

lead, cadmium, and chromium. OSHA (Occupational Safety

and Health Administration) requirements for worker expo-

sure and RCRA (Resource Conservation and Recovery Act)

requirements for disposal with its implied containment should

be incorporated into the contract to protect workers and lessen

potential claims. SSPC-Guide 6 and Guide 7 provide details

relevant to containment and disposal. OSHA regulation 29

CFR 1926.62 details worker protection requirements for lead

(see SSPC publication 95-06, Project Design).

5.3.5 Structural Inspection: Coating assessment should

be included as part of any general structural inspection for loss of

metal, broken joints, or other structural defects. A relatively small

additional inspection time is required to evaluate and record

the ratings of individual structures or structural elements. This

information will normally prove extremely valuable in evaluating

maintenance painting options, especially in developing the most

cost effective life-cycle maintenance strategy. Numerous public

and private entities have been successful in using scheduled

facility inspections, such as bridge safety inspections, as the

first cut in determining coating condition.

5.4 DETERMINE THE CONDITION RATING SCHEME:

For both visual inspection and physical testing, it is necessary

to use a standard rating system and format for recording data.

SSPC-TU 3 discusses the salient characteristics of a rating

scheme that is based on the technical merits of coating condi-

tion and overcoating.

5.4.1 Physical Testing: See SSPC-TU 3 for detailed guid-

ance in evaluating coating condition and risks of overcoating.

These evaluations generally require certain detailed information

concerning the coating type and physical condition.

5.4.2 Use of Ratings Data: In many cases, these condi-

tion ratings will be keyed directly to repair procedures (e.g.,

SSPC-PA Guide 4). The next two sections of this guide give

the procedures for developing such a scheme.

5.5 PLAN FOR INSPECTING STRUCTURAL

COMPONENTS: A sub-unit sampling plan identifies the

portions of the structure or facility that will be rated and thetype of rating scheme to be used. Sub-unit sampling plans are

needed for complex structures or where detailed information

is required. For a process unit, (for example) the structural

steel might be divided into individual tanks, piping, handrails

and ladders, and structural support. On large structures, the

areas could be further subdivided into sections.Because of

differences in corrosion tendencies, it is often useful to have


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separate ratings for edges and flat surfaces. The extent of

inspection depends on how detailed a survey is desired and

what resources may be available.

5.6 ESTABLISH PROCEDURES AND ASSEMBLE

RELATED DOCUMENTS

5.6.1 A specific procedure should be established for a

condition assessment, which should include a budget and

schedule, including equipment and crews. The availability

of funds will determine the extent of the survey that can be

undertaken. A schedule should be established based on the

number of hours or days required to prepare the structure

(e.g., notify other trades) or arrange for access (i.e., coordinate

schedules of other individuals). This includes identifying support

crews and equipment that may be required to assist with the

condition assessment. Personnel requirements must also be

established (i.e., identify individuals who will conduct the survey

such as in-house inspectors, engineers, outside consultants,

coating contractors, or coating manufacturers). If a condition

assessment survey is to be performed by a consultant or

contractor, a written contract should be prepared. If a coating

manufacturer offers to do the assessment at no cost, the firm

should be asked to submit a written description of the plan

for the owners review, modification, and approval.There are

numerous contracting methods available for acquiring condi-

tion assessments, structural inspections, and coating work,

including options ranging from acquiring each facet of work by

different contracts to using turnkey type contracts to perform

all inspection, structural repair, and coating work. When more

than one facet of work is included in a single contract, steps

should be taken to ensure the validity of each facet prior to

proceeding to the next facet.

5.6.2 Required standards (e.g., standards such as SSPC

VIS 2, ASTM D 610, or equivalent) as well as field equipment

such as tape recorders, inspection forms, and a camera must

be available.

5.7 CONDUCT ASSESSMENT SURVEY: The survey

should be conducted after the schedule and the standards

have been established. The owners representative should

ensure that all elements of the survey have been properly

performed, recorded correctly, and distributed to predetermined

personnel.

6. List Potential Maintenance Painting Options(Step 2)

6.1 REVIEW SURVEY DATA AND COATING OBJECTIVES

AND CRITERIA

6.1.1 The corrective action to be taken is based on the

results of the previous surveys, the short and long-term objec-

tives of the coating program, special limitations, and other

relevant factors.

6.1.2 The data to be analyzed are those that have been

previously collected from an overview, visual inspection, or

physical inspection. If no formal survey was taken, use the

best information available (e.g., coating historical records) to

estimate the overall condition ratings.

6.2 CONSIDER ALTERNATIVE OPTIONS: After the

data is reviewed, the available alternative actions should be

considered. These range from not coating to complete coating

removal and recoating.

6.3 NO MAINTENANCE REQUIRED FOR THREE YEARS

OR LONGER: In one possible scenario, the coating is in good

shape and no corrosion or deterioration requires attention. In a

second scenario, the coating may be providing some protec-

tion but may be in too poor a condition to salvage. Eventually,

total coating removal will be needed, but maintenance can be

delayed without any significant harm to the structure. This option

may be considered under the following circumstances:

6.3.1 The structure is in a mild environment and little

corrosion activity is expected at breaks in the coating film over

the next few years.

6.3.2 The extent of discoloration, topcoat erosion, or

general degradation is not very important, due to the locations

on the structure. In general, the coating is intact and protection

is still being provided.

6.3.3 The structure is being assigned a low priority for

maintenance because of economics, aesthetics, or other

reasons.

6.3.4 The structure is scheduled for major coating repair

or complete replacement within 3 years. The additional time

is not expected to add significantly to the corrosion metal loss

or the surface preparation cost.

6.3.5 The structure is due for demolition.

6.4 SPOT REPAIR ONLY: Spot repair entails surface

preparation and touch-up coating of localized areas of deterio-

rated coatingand corrosion. The surface preparation may be

accomplished by hand or power tool cleaning, high- or ultrahigh

pressure waterjetting, or abrasive blasting. Several specialized

materials and procedures are available for localized surfacepreparation, including composite media (sponge), sodium

carbonate slurries, plastic media, walnut shells, corncobs, etc.

The intact coating surrounding the degraded area should be

feathered and lightly sanded2.5 to 5 cm (1 to 2 inches) onto the

intact coating to permit a smooth transition. The cleaned areas

are primed with a coating compatible with the existing coating

system and spot topcoated to conform to the required DFT. In

this particular option, the remaining (e.g., intact) coating is not

overcoated. It should be noted that the spot repair method is

primarily a stopgap method. It is recommended that the structure


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be re-evaluated within three to five years. Spot repair may be

considered under the following circumstances:

6.4.1 Repairs are hidden or in a low-visibility area and

thus unimportant to the aesthetics.

6.4.2Owner maintenance crews are available for this type

of work.

6.4.3 Structures are small, not requiring extensive scaf-

folding or hard-to-access areas.

6.4.4 Corrosion and degradation are limited to isolated

areas and relatively small sections, which amount to less than

1% of the total area.

6.4.5A decision has been made to upgrade small isolated

areas such as bearing areas, crevices, or areas subject to

leakage, condensation, or chemical splash.

6.5 SPOT REPAIR AND OVERCOATING:This technique

involves spot repair of deterioratedcoating and corroded areas

followed by the application of a full finish coating over the

entire surface, including spot repaired areas and intact coating

areas. The intact coating surrounding the degraded area must

be feathered back. The repair coating should extend at least

2.5 to 5 cm (1 to 2 inches) onto the intact coating to allow for

a smoother transition of the repair coating onto the existing

coating and better topcoat adhesion. The topcoat should

be compatible with the existing coating. The existing intact

coating should be cleaned of surface contaminants before

total recoating. This type of system would be expected to give

perhapsfive years or more additional life to the entire surface

area by helping to prevent further deterioration of the intact

coating. Successful overcoating will oftendelay the need for

a full coating removal. Spot repair and overcoating may be

considered under the following circumstances:

6.5.1 An evaluation of risks in overcoating is a function of

adhesion and existing coating thickness, as outlined in SSPC-

TU 3. This risk analysis must be performed if risks are to be

managed, and while it is generally thought that risks should

be held to the range of low to moderate, higher risks may

be acceptable to the owner under certain conditions.

6.5.2 The intact surface can be readily cleaned with pres-surized air, hand tools (SSPC-SP 2), power tools (SSPC-SP 3),

solvent or detergent wiping (SSPC-SP 1), or power washing

(as described in SSPC-SP 12). If low or high pressure water

cleaning (also called power washing) is used,the maximum

water pressure required should be stated in the project speci-

fication.

6.5.3 If severely corroded surfaces (as described in Section

6.6) are found, special cleaning methods and coating systems

may be required.

6.5.4 When corrosion and deterioration exceed 10 to 15%

of the total area, project economics may suggest total removal

of the coating system.

6.6 COMPLETE RECOAT OF STRUCTURE OR SUB-

UNITS (ZONES): When the overallcoating condition is poor,

when the remaining life of the structure or sub-unit justifies the

expense, and when funds are available, a decision to recoat

the structure in its entirety is usually made. This involves

removing the old coating and all of the corrosion products before

applying the primer, intermediate coats, and topcoat. Coating

a sub-unit of a structure (often called zone painting) may be

a variation of this alternative when funds are limited or when

the remaining portions of the structure are in good condition.

This option presents a much lower risk of early coating/corro-

sion problems (such as catastrophic delamination or early rust

back) than do the alternative options.

6.7 OTHER REPAIR METHODS: On occasion, different

methods of cleaning and/or coating may be required for different

areas or zones of the structure. A higher-performing coating

system (e.g., abrasive blast cleaning followed by application

of a zinc-rich/epoxy/polyurethane system) may be specified

for high corrosion atmospheric areas of a structure, such as

areas subject to deicing salt, dripping, or chemical spillage),

with a lesser performing system (such as hand or power tool

cleaning followed by an alkyd or a high-solids epoxy with

good wetting) on less critical or less corrosion-prone areas.

Compatibletopcoats may be required to blend in with restored

or rehabilitated portions of the structure.

6.8 ADDITIONAL SURVEY: After an analysis of the avail-

able data, an additional survey may be required. The initialsurvey may have been too limited to provide sufficient data

to make remedial recommendations, or the survey may have

only looked at a portion of the structure or not examined some

specific details required, such as the integrity of the coating

near high-corrosion prone areas. The area may be scheduled

for other repair or outage work within a 2-year period and may

be re-assessed at that time.

7. Evaluate Economics of Available Options(Step 3)

7.1 The act of contemplating coating application or main-

tenance is, in effect, an analysis of the economics of abating

or slowing the effects of corrosion damage. The variables

involved in protective coatings often require a variety of solu-

tions, each of which will carry unique cost-benefit factors. Many

factors influence the selection of coating systems. However,

when considering maintenance of existing coating systems,

the factors are generally restricted due to constraints imposed

by the existing coating. Still, there are generally multiple

options available, and it is important to consider the economic

impacts of all options prior to finalizing a design. The chapter

on economics in the SSPC Painting Manual, Volume 1Good


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Painting Practice,provides comparative costs for most surface

preparation methods, generic coating systems, application,

and special requirements for selected situations.

8. Select Appropriate Maintenance Painting Op-tions and Establish Implementation Procedures(Step 4)

8.1 Once a course of action has been determined, it is

essential that detailed specifications and supportingdocuments

be prepared to achieve that course of action.

8.2 IDENTIFY RELEVANT FACTORS FOR COATING

SYSTEM SELECTION

8.2.1 The selection of the coating system is influenced

not only by the type of recoating (e.g., spot repair or complete

recoat) but also by special factors such as restrictions due to

environmental, health, and safety regulations; budgets; expo-

sure environment; weather; or configuration and contaminants.Thus, before choosing the coating system, it is useful to identify

these pertinent factors.

8.2.2 Abrasive blast cleaning may require containment

controls due to air quality concerns or the need to avoid dust or

abrasive rebound in sensitive areas. The presence of hazards

such as lead-based coatings on a structure will require special

collection and containment devicesthe type of device being

largely determined by the extent of lead- based coating to

be removed. Site-specific regulations on the volatile organic

compound (VOC) content may exclude the use of previously

used coatings.

8.2.3 Weather or configuration can also limit the selection

of coating systems. Many coatings (e.g., conventional epoxies,

water-borne acrylics) are best applied above 10C (50F).

Other coatings are sensitive to high humidity or low humidity

(e.g., inorganic zinc-rich primers). In certain configurations,

spray application may not be permitted because of high wind

or overspray on sensitive equipment or automobiles.

8.2.4The exposure environment is a major determinant of

the typeof coating system. Typically, exposure environments

are classified according to the presence of solublesalts, pollu-

tion, sunlight exposure,rain/humidity, or chemicals.

8.2.5 The existing condition of the structure must be

known. For spot repair or overcoating, the compatibility of the

new coats over existing ones should be verified by a patch

test, as shown in SSPC-TU 3. If the patch coating shows no

adverse physical effects (e.g., lifting of the existing coating) or

appearance effects (e.g., bleeding) on the existing coating, it

should be considered compatible with it. In addition, the patch

test, when evaluated over a period of six months or more, can

provide important data on the physical compatibility (stress)

of the new coating over the old.

8.2.6 The ability of the coating to tolerate residual soluble

salts will directly affect the time to early rust-back. SSPC-TU 4

addresses salt remediation testing. The coating to be applied

must be tolerant of the level of contaminant present.

8.3 SELECT SURFACE PREPARATION METHODS

AND COATING MATERIALS FOR COMPLETE RECOAT

STRATEGY

8.3.1 Select Surface Preparation Methods: SSPC and

other organizations have well-defined standards for most of

these requirements, which can readily be incorporated into

a specification. Available surface preparation techniques for

complete recoating include conventional dry abrasive blast

cleaning (SSPC-SP 5/NACE No. 1, SSPC-SP 10/NACE No.

2, SSPC-SP 6/NACE No. 3, SSPC-SP 14/NACE No. 8, and

SSPC-SP 7/NACE No. 4), wet abrasive blast cleaning, vacuum

blasting, and high- and ultrahigh pressure water jetting (SSPC-

SP 12/ NACE No. 5). It is important to specify the degree of

cleanliness and the surface profile (for blast cleaning), the

degree of salt or contaminant remediation, and the need for

solvent cleaning and/or water washing prior to blast cleaning.

Waterjetting can neither alter nor create profile, but can expose

existing profile.

An important consideration when blast cleaning is the

collection and disposal of blasting debris. SSPC-Guide 6

provides guidance on the selection of the type of containment

based on the type of surface preparation being performed. It can

also be used to provide guidance on the level of containment

that is necessary for a job. Guidance is provided on ventilation,

air flow, and dust emissions. Guide 7 provides guidance on

the disposal of hazardous surface preparation debris once ithas been contained and collected.

If the surface preparation techniques discussed herein

cannot be used, it may be necessary to clean to a less desir-

able surface condition and to apply a coating system (primer,

intermediate, and topcoat) over a surface that is not completely

rust and coating free. In such instances, the primer must be

tolerant of the surface condition. Certain power tools are also

capable of removing existing rust and coating (SSPC-SP 11

or SSPC-SP 15) but generally at much lower production rates.

Coating system life expectancy is likely to decrease if the level

of surface preparation is lowered.

8.3.2 Select Coating Materials: The selection of the

coating system often involves two phases: first, identifying the

generic types (e.g., epoxy/zinc-rich/polyurethane); and second,

identifying the criteria for selecting materials. The specifica-

tion may utilize generic compositions, a qualified product list

of proprietary materials, or other approaches. In the coating

specification, the owner should describe the procedures for

qualification and acceptance criteria for the coating materials.

For qualification, the supplier may be required to furnish

evidence of previous use of the coatings on similar structures,


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or laboratory tests of physical properties, accelerated corrosion

and weathering properties, and application properties. These

properties should be certified by the manufacturer or an inde-

pendent laboratory. For new technology coatings, extensive

service data may not be available. The owner may also require

some verification that the material delivered to the job site is

the same as that which was originally qualified. Some general

guidelines on acceptance sampling and testing are given in the

SSPC Painting Manual, Volume1Good Painting Practice.

8.3.3.1An important part of the specification is the coating

film thickness. Both a minimum and a maximum dry film thick-

ness should be specified (see SSPC-PA 2).

8.3.3.2 The application methods are normally governed

by the materials selected and are stipulated by coating manu-

facturers on their data sheets. SSPC-PA 1 provides guidance

for applicators that will supplement the manufacturers appli-

cation instructions. If there is a contradiction between the two

recommendations, that of the coating manufacturer should

take precedence.

8.4 SELECT SURFACE PREPARATION METHODS

AND COATING MATERIALS FOR SPOT REPAIR OR SPOT

REPAIR AND OVERCOATING

8.4.1 Determine Techniques and Standards for Repair,

Surface Preparation, and Recoating

8.4.1.1When making spot repairs, it is necessary to deter-

mine the precise areas requiring repair. Areas where coating

can be removed by moderate scraping with a dull putty knife

will require spot repair. Residual loose material will preventproper spot repair.

8.4.1.2 One important decision to be made is whether

abrasive blast cleaning will be used for spot repair mainte-

nance. Abrasive blasting may be used for brush-off cleaning

(SSPC-SP 7/NACE No. 4) or industrial blast cleaning (SSPC-

SP 14/NACE No. 8). To provide a higher level of cleaning with

the total removal of rust and coating, SSPC-SP 6/NACE No.

3 or greater may be specified for spot repair areas. Brush off

blasting may be used to remove loose coating or rust. It or some

other surface treatment may be necessary to obtain acceptable

adhesion between the existing intact coating and the repair or

overcoating system. Great care must be exercised when spotblasting to avoid over-blast damage to adjacent intact coating

that does not need to be blasted. Spot blasting is generally not

recommended for areas of repair of less than 1 square foot or

when the total repair is less than 5 to 10 percent of the total

surface area, unless a lesser degree of cleaning cannot be

tolerated.

8.4.1.3 Alternatives to open spot blasting include hand

tool cleaning (SSPC-SP 2), conventional power tool cleaning

(SSPC-SP 3), commercial grade power tool cleaning (SSPC-

SP 15), special (profiling) power tool cleaning (SSPC-SP 11),

and vacuum or wet blasting methods. These methods may be

used easily with vacuum assists for containment.

8.4.1.4. After spot cleaning, the cleaned areas are coated

with a primer that extends over the feathered edges of the

intact coating to overlap them 2.5 to 5 cm (1 to 2 inches) onto

the sound, intact coating. This will minimize edge lifting and

will provide a better appearance.

8.4.2 Select Coating Materials for Spot Repair or Spot

Repair with Overcoating.

8.4.2.1 The selection of the coatings will be determined

by the need for compatibility with the existing surfaces. Most

coatings are suitable for application to the bare metal areas

(i.e., spot-repaired areas), so the main concern is compat-

ibility with the previous coating. See SSPC-TU 3 for detailed

instructions for performing and evaluating patch testing.

8.4.2.2The selection of the coating materials for spot repair

is guided by the same considerations as for full recoat. For spot

repair of small areas, a brushable primer is advantageous. It is

also important that the primer be compatible with the existing

intact coating because it is necessary to have the spot repair

overlap the intact coating. As an example, an organic zinc-

rich coating is normally used instead of an inorganic zinc-rich

coating for spot repair of a damaged inorganic zinc coating with

an organic finish coat, because the inorganic zinc-rich coating

does not bond sufficiently to either organic or inorganic coat-

ings. Additional information on repair of damaged galvanized

or inorganic zinc coatings is given in SSPC-Guide 14.

8.4.2.4 The coatings selected for the full topcoat must be

compatible with both the spot primer and the existing intact

coating.

8.4.2.5 The requirements for application, film thickness,

material qualifications, and acceptance criteria are the same

as those for applying a full recoat system. For spot repair,

however, it is essential that the requirements for determining

which areas are to be repaired should be clear and definitive.

Discussion of these items should be included in the pre-bid

and pre-job meetings.

8.5 PREPARE SPECIFICATION

8.5.1 The job specification provides the basis for the cost

and execution of the work. It is essential that the job specifi-

cation provide a complete description of the desired work by

prescribing specific procedures, processes, and materials or

by describing the work product. The specification must also

provide criteria for acceptance or rejection of work as well as

remedies for unacceptable work.


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8.5.2 A job specification should be prepared using the

general format of the Construction Specification Institute

(CSI). Chapter 3 of The Inspection of Coatings and Linings:

A Handbook of Basic Practice for Inspectors, Owners, and

Specifiers provides a description of the CSI format and its parts

or specific owners format requirements. Additional information

for preparing a job specification for protective coating work can

be found in SSPC-TR 4/NACE 80200, Preparation of Protective

Coatings Specifications for Atmospheric Service. Appendix

A provides additional information that should be considered

during preparation of the job specification.

9. Implement Maintenance Painting Options(Step 5)

Clean and coat the structure.

10. Plan and Implement Follow-up Activities(Step 6)

10.1 BENEFITS OF FOLLOW-UP: An important part of amaintenance coating program is to monitor the performance of

the applied coatings system, for both short-term and long-term

effects. In the short term, certain inspections and follow-ups

are necessary to ensure that the contractor has fulfilled the

requirements of the contract. For the long-term, there are

certain beneficial measures that can be taken to minimize the

onset of corrosion and information that can be collected that

will facilitate future decisions on maintaining the structure.

10.2 ESTABLISH NEED FOR PERIODIC INSPECTION:

Inspection should be made of the structure within 6 to 12

months after application especially in cases where there are

surfaces such as edges or bolts that will delaminate or rust

within a short period due to difficult surface preparation or

application, or especially severe service conditions. If these

areas are discovered and are corrected within the first year,

the time interval until the next maintenance may be extended.

Some agencies require a one-year touchup provision as part

of a contractors obligations in the contract to cover such

contingencies. Other warranted work should also be inspected

prior to expiration of the warranty.

10.3 ESTABLISH SCHEDULES FOR CONDITION

ASSESSMENT: In addition to periodic inspection, a structure

should be scheduled for a periodic condition assessment.Depending on the type of structure and the environment, the

first condition asssessment would normally be conducted

about 5 years after the original application and every 3 years

thereafter. Specific rating sheets or parameters to be inspected

should be made available to inspection personnel. The condi-

tion assessment should be similar to the survey data required

in Section 5 of this guide.

10.4 ENSURE PROPER DOCUMENTATION AND FILING

OF HISTORICAL INFORMATION: Before the job is officially

accepted, it is necessary that all documentation be completed.

The record of the daily inspection logs and the records of the

coatings procured, used, discarded, or disposed of should be

properly stored in the owner files. It should be verified that

the retained samples of the coating are properly labeled and

stored for future reference.

10.5 INSTITUTE PREVENTATIVE MAINTENANCE

MEASURES: In some cases, regular removal of contaminants

can eliminate potential problems before they become severe.

Examples are chemical spills that might occur or concentrations

of de-icing salts. In some cases, moderate design changes can

be made that will eliminate water or other chemicals collecting

in crevices or other areas vulnerable to corrosion attack.

11. Notes

11.1. Numerous public and private entities have been

successful in using scheduled facility inspections, such as

bridge safety inspections, as the first cut in determining coating

condition. Depending on the processes used for such inspec-

tions, it is feasible to train facility inspectors to perform surveys

that range from General Overview Condition Assessment to

Detailed Visual Inspection, as described in Section 5.3. It

requires a relatively small additional inspection time to evaluate

and record the ratings of individual structures or structural

elements. This information will normally prove extremely valu-

able in evaluating maintenance painting options, especially

in developing the most cost effective life-cycle maintenance

strategy.

12. Disclaimer

12.1This guide is designed to describe, review, or analyze

new or improved technology and does not meet the definition

of a standard as defined by SSPC. A guide differs from a stan-

dard in that it is not suitable for referencing in a specification

or procurement document.

12.2 While every precaution is taken to ensure that all

information furnished in SSPC guides is as accurate, complete,

and useful as possible, SSPC cannot assume responsibility

nor incur any obligation resulting from the use of any materials,

coatings, or methods described herein, or of the guide itself.

12.3 This guide does not attempt to address problems

concerning safety associated with its use. The user of this

specification, as well as the user of all products or practices

described herein, is responsible for instituting appropriate

health and safety practices and for ensuring compliance with

all governmental regulations.


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13. Bibliography

The following reference materials may contain useful

supplementary information:

Appleman, Bernard R., Advances in Technology and Standards

for Mitigating the Effects of Soluble Salts, Journal of

Protective Coatings & Linings, Vol. 19, No. 5, (May, 2002),

pp. 42-47.

Appleman, Bernard R. Coating Over Soluble Salts: A

Perspective. Journal of Protective Coatings & Linings,

Vol. 4, No. 10, (October 1987), pp. 68-82.

Castler, L. Brian, Jayson L. Helsel, Michael F. MeLampy, and

Eric Kline, Comparative Painting Costs. Steel Structures

Painting Manual, Vol. 1: Good Painting Practice, Chapter

8. Pittsburgh, PA: SSPC, 2002.

Environmentally Acceptable Materials for Corrosion Protectionof Steel Bridges, Appendix 1 from Environmental

Guidelines for Painting Practices. Washington DC: FHWA,

1997. (FHWA Report RD-96-058).

Guide to Bridge Painting, FHWA TS-89-14. Washington DC:

Highway Administration, 1989. (SSPC Publication 89-

04).

Inspection of Coatings and Linings: A Handbook of Basic

Practice for Inspectors, Owners, and Specifiers. Richard

W. Drisko, and Judy Neugebauer, eds. Pittsburgh, PA:

SSPC, 1997. (SSPC Publication 97-07).

PDCA Safety & Loss Control Manual., Fairfax, VA: Painting &

Decorating Contractors of America, 1984.

Protective Systems for Steel Bridges, Section 16.4, Bridge

Inspectors Training Manual 90, produced by Michael

Baker, Jr., Inc. Washington DC: FHWA, 1991. FHWA-

PD-91-015.

SSPC Painting Manual, Volume 1Good Painting Practice

(Fourth Edition). Pittsburgh, PA: SSPC, 2002. (SSPC

Publication 02-14).

SSPC Painting Manual, Vol. 2Systems & Specifications (EighthEdition), Selection of Coating Systems by Environmental

Zone. Pittsburgh, PA: SSPC, 2000. (SSPC Publication

00-10).

SSPC-TU 1: Technology Update: Surface Tolerant Coatings.

Pittsburgh: SSPC, 1997. (SSPC Publication 97-20).

Trimber, Kenneth A. Industrial Lead Paint Removal Handbook,

2nd ed. Pittsburgh, PA: KTA-Tator, Inc., 1993. (SSPC

Publication 93-02).

Trimber, Kenneth A. and Daniel P. Adley, CIH, CSP. Project

Design: Industrial Lead Paint Removal Handbook,

Volume II. Pittsburgh, PA: KTA-Tator, Inc., 1995. (SSPC

Publication 95-06).

Appendix A. Other Considerations in PreparingContract Documents and Executing Mainte-nance Coating Projects

The items below are intended to provide the owners

representative with a summary of items to be considered when

preparing contract documents and following up as the project

evolves.

A.1 BENEFITS OF WELL-PREPARED CONTRACTS: A

well-planned and designed contract will benefit both the ownerand the contractor as follows:

Reduce the cost of the work to the owner.

Provide clear expectations of work to be

performed.

Eliminate unnecessary contingencies for the

contractor.

Provide for a smooth, trouble-free workflow without

costly interruptions.

Identify and anticipate possible problems, avoid them

when possible, and provide means to resolve them

when they occur.

Complete the work safely. Provide measurement and payment criteria.

A.2 ESTABLISH QUALIFICATION REQUIREMENTS

FOR CONTRACTORS

A.2.1 Pre-Qualification of Contracting Firms: Many

agencies have adopted guidelines or procedures for screening

or pre-qualifying contractors based on references or actual job

evaluations. SSPC, through its Painting Contractor Certification

Program (PCCP), has established a program for certifying

contractors. The QP 1 program is for field paint application,

the QP 3 program is for shop application firms, and the QP 2

program is for the removal of hazardous coatings. In addition,

numerous owners require that a contractor be bonded to cover

the estimated cost of the work.

A.2.2 Qualifications for Applicators and Blasters:

Some state and other agencies require that the applicators

demonstrate their abilities to attain specified quality of cleaning

and coating application. ASTM D 4228, Standard Practice for

Qualification 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

may be restricted to union shops.

A.3 PROTECTION OF EXISTING PLANT FACILITY AND

EQUIPMENT: Identify all the steps that should be taken by

the contractor and/or owner to protect the existing plant facility

and equipment from the planned operations. Establish hold

points to verify that the proper protection is in place prior to

proceeding with operations. Identify on plans or in the scope

of work if the coating is or may be hazardous.

A.4 SAFETY REQUIREMENTS: All employers must

prepare a safety plan, including both facility owners and contrac-

tors. When contractors are working at a particular facility, their

site-specific safety plan must incorporate the relevant issues.

The safety plan used is likely to be an amalgamation of the stan-

dard safety plan of both the owner and the contractor. Depending

upon the particular situation, the plan may be prepared by

the facility owner, the contractor, or by both working together,

but it should be understood and approved by both parties. Allemployers must provide personal protective equipment (PPE),

including specific equipment such as respirators, and training

in its use. Safe working conditions are the responsibility of

the employer. Such responsibility is more easily defined at a

fixed facility where all the workers are employed by the same

company than at a complex construction site where there are

many different companies working together. Nevertheless,

all safety precautions must be made, and it is the employer s

responsibility to ensure that safety issues are recognized, and

the risks are minimized. Any details not completely understood

should be resolved in the pre-construction conference and at

subsequent other conferences. All HAZCOM requirements,

including labeling and material safety data sheets, must bemet. The SSPC Painting Manual Volume 1Good Painting

Practice provides additional guidance on safety issues in the

coating industry.

A.5 HAZARDOUS WASTE: The owner shall notify the

contractor if lead, cadmium, chromium-containing paints or

other hazardous materials are to be removed. The contractor

should identify the requirements to remove lead, chromium,

or cadmium-containing paints, or other toxic materials. The

owner should also indicate the extent of responsibility of the

contractor for generating, containing, collecting samples,

testing, and disposing of hazardous waste.

A.6 ACCESS FOR INSPECTION: The contractor should

provide for reasonable access to the work for the owner s

inspectors, including use of the contractor s scaffolding, work

platforms, and safety apparatus.

A.7 OWNER-FURNISHED ITEMS AND SERVICES: It is

often necessary and/or economically beneficial to the owner to

make various items and services available to the contractor.

These may include: laydown/storage areas, electric power,

potable water, restrooms, etc. For any utilities provided, the

owner should identify locations, pressures, amounts, fittings,

voltages, and other pertinent operating details. The contractor

should identify any owner-furnished items or services.

A.8 WARRANTY/GUARANTEE: The most common

warranty for coating work is a one-year warranty against defec-

tive materials and job quality. Extended period performance

warranties are becoming more common, and, when utilized,

should be formulated to correlate with the specific coating

systems selected. When warranties are utilized, it should be

clearly stated who is to be responsible for the warranty and

what conditions will trigger the warranty repair, any required

inspection schedules, what is expected of the warranty repairs,

etc.

A.9 PERSONNEL AND COATING CONSUMPTION

RECORDS: Information regarding personnel resources and

coating quantities can be beneficial in preparing cost estimates

for similar work. Tracking mechanisms should be defined in

the contract documents. Also, owners should request copies

of contractor inspection reports and daily logs for their files.

A.10 TYPE OF CONTRACT: The SSPC Painting Manual

Volume 1Good Painting Practice provides a detailed descrip-

tion of the types of contracts, bids, and proposals.

A.11 ESTABLISH PROCEDURES FOR OWNER-

CONTRACTOR RELATIONS

A.11.1 Identification of Owner and Contractor

Representatives: The contractor and owner should each

appoint an authorized representative to whom all required

notifications are given, through whom contract changes are

processed, and who is responsible for contract coordination

and resolution of non-conformances and other problems.

Ensure that all personnel are familiar with responsibilities and

procedures and that the authorities of engineer, inspector,field

supervisor, and coating manufacturers representative are

defined. In particular, identify the person who is responsible

for inspection and that persons affiliation (e.g., owners repre-

sentative, third party, or other). Review procedures established

for handling and disposing of waste.

A.11.2 Interface with Plant Operation: The contract

should identify all plant operations and operations of other

contractors that will be ongoing in the work area. The contractshould outline how the coating work will interface with these

operations and what precautions will be necessary. Special

efforts should be made so that conflicting operations, such as

welding and spray coating, do not occur simultaneously in the

same area.

A.12 PREPARE CONTRACT AND SCHEDULE: It is

useful to prepare a list of the various activities required in

securing the contracts and the time allotted for each of these.

Typical elements of this schedule are as follows:


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a. Prepare Contract Documents

b. Notice Inviting Proposals

c. Pre-Bid Conference

d. Pre-Bid Demonstration/Inspection

e. Proposal Due Date

f. Post-Bid Meetings and Clarifications

g. Negotiations, if allowed

h. Contract Award

i. Pre-Job Conference/Demonstration

j. Contract Start Date

k. Contract Termination Date

l. Owner Acceptance Date

m. Warranty Date

n. EEO requirements

Specific sample clauses for these and other details required

in obtaining contracts may be found in SSPC-TR 4/NACE

80200.

A.13 ARRANGE AND CONDUCT PRE-BID

CONFERENCE: All prospective or qualified bidders are invited

to attend a meeting with the owner s representative to review the

bid package. This review would normally include an explanation

of the surface cleaning and application requirements, the nature

of the structure, its condition, access to the structure, special

restrictions (e.g., on blast cleaning safety requirements), and

answer any questions the contractor might have. Ordinarily,

an actual visit to the structures or facility to be coated should

be required. Many contractors are reluctant to attend pre-bid

meetings because of the cost and time, or simply because they

do not want to let their interests be known. For major and critical

projects, experienced owners often make pre-bid attendance

mandatory because it eliminates problems that occur whencontractors are not familiar with the structure or the terms of

the specifications. Some public agencies do not permit such

meetings because they feel that the additional travel expense

is unfair to contractors from remote locations.

A.14 REVIEW BID AND AWARD CONTRACT: This

operation is usually strictly governed by owner legal policies

and requirements. The contractor who has met the previous

requirement with the lowest bid is generally awarded the

contract in the competitive bidding system.

A.15 PRE-JOB CONFERENCE: This meeting is held

between the owner and the contractor hired to do the job.Owners may need to include representatives from their internal

safety and environmental departments in these meetings.

The contractor should bring the field superintendent and the

company principal or company representative. The purpose of

this meeting is to review in detail the specific 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.

A.16 PROCURE COATINGS ACCORDING TO

SPECIFICATION: Either the owner or the contractor may

procure the coatings. In either case, it is necessary to verify

that the coatings meet the specification. The owners inspector

should verify that the agreed-upon coating materials supplied

to the job site are properly labeled, that proper certifications

have been obtained, and that samples are retained for testing

by the owners laboratory, an independent laboratory, or for

future reference. Any exceptions or replacements should be

noted. Pre-sampling, testing, and approval prior to shipment

can help assure that approved material arrives on the job. This

can help prevent job delays.

A.18 Quality Assurance/Quality Control: Quality

Assurance (QA) and Quality Control (QC) are important

parts of any maintenance program. The purpose of the

QA/QC program is to ensure that the processes and work

products are in conformance with the specified criteria. The

CSI specification format includes QC under Part 3. Execution.

The CSI approach requires the contractor to execute the QC

program. The contractor is responsible for quality control. The

processes need to be verified, which requires the contractor to

perform various inspection functions related to the QC effort.

The owner is responsible for quality assurance and should

be functioning to provide this assurance role. In other words,

the owner should assure that the contractor is providing the

necessary quality control. (This concept is often misinterpreted

as meaning the QC program will be executed by the owner,

utilizing in-house personnel or independent third party inspec-

tors, with the contractor providing no quality control effort.)

Qualified personnel are essential to the execution of the QC

as well as the QA program. Qualified inspector quali

fication

programs, such as NACE Internationals CIP4 or equivalent

for individual inspectors, or SSPC-QP 5 for coating and lining

inspection companies, are excellent tools for obtaining qualified

inspectors. The inspectors can be utilized in either a quality

control role or a quality assurance role. The content of the QC

program as described in the specification is also important.

The QC program must include appropriate methods and tools

with suitable references. Inspection frequency, distribution, and

data analysis methods must also be described. The correct

amount of inspection is important. Inadequate inspection may

not identify serious deficiencies. There are numerous guides,

such as Inspection of Coatings and Linings: A Handbook of

Basic Practice for Inspectors, Owners, and Specifiers, andASTM D 3276, which may be used to develop project-specific

coating inspection plans. Over-inspection may increase the

cost of the coating project while returning little or no additional

benefits.


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