DMRB VOLUME 3 SECTION 2 PART 2 - BD 87/05 - · PDF fileBD 87/05 MAINTENANCE PAINTING OF...

May 2005

DESIGN MANUAL FOR ROADS AND BRIDGES

VOLUME 3 HIGHWAY STRUCTURES:INSPECTION ANDMAINTENANCE

SECTION 2 MAINTENANCE

PART 2

BD 87/05

MAINTENANCE PAINTING OFSTEELWORK

SUMMARY

This Document sets the Standard requirements for andgives advice on the Maintenance Painting of Steelwork.In addition, guidance is given on the appointment andduties of painting inspection firms. This Standardsupersedes BD 87/03.

INSTRUCTIONS FOR USE

1. Remove existing contents sheet for Volume 3 andinsert new contents sheet for Volume 3 datedMay 2005.

2. Remove BD 87/03 from Volume 3, Section 2,Part 2 and insert BD 87/05.

3. Please archive this sheet as appropriate.

Note: A quarterly index with a full set of VolumeContents Pages is available separately from TheStationery Office Ltd.

BD 87/05

Maintenance Painting ofSteelwork

Summary: This Document sets the Standard requirements for and gives advice on theMaintenance Painting of Steelwork. In addition, guidance is given on theappointment and duties of painting inspection firms. This Standardsupersedes BD 87/03.


THE HIGHWAYS AGENCY

SCOTTISH EXECUTIVE

WELSH ASSEMBLY GOVERNMENTLLYWODRAETH CYNULLIAD CYMRU

THE DEPARTMENT FOR REGIONAL DEVELOPMENTNORTHERN IRELAND

Volume 3 Section 2Part 2 BD 87/05

May 2005

REGISTRATION OF AMENDMENTS

Amend Page No Signature & Date of Amend Page No Signature & Date ofNo incorporation of No incorporation of

amendments amendments

Registration of Amendments

VOLUME 3 HIGHWAY STRUCTURES:INSPECTION ANDMAINTENANCE

SECTION 2 MAINTENANCE

PART 2

BD 87/05

MAINTENANCE PAINTING OFSTEELWORK

Contents

Chapter

1. Introduction

2. Basic Considerations

3. Painting Inspection Firms

4. References

5. Enquiries

Annex A Form HA/P4Purchaser’s Conditions of Order for Paint

Annex B Duties of Painting Inspectors

Annex C Form HA/P5Maintenance Painting Scheme SummarySheet


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Chapter 1Introduction

1. INTRODUCTION

Mandatory Sections

1.1 Sections of this document which form partof the Standards of the Overseeing Organisationsare highlighted by being contained in boxes. Theseare the sections with which the DesignOrganisations must comply, or must have agreed asuitable departure from standard with the relevantOverseeing Organisation. The remainder of thedocument contains advice and enlargement whichis commended to Design Organisations for theirconsideration.

General

1.2 This Standard supersedes BD 87/03.

1.3 The maintenance painting of steelwork willnormally be carried out under contractsincorporating the Overseeing Organisation’sSpecification for Highway Works, Manual ofContract Documents for Highway Works Volume 1Series 5000 (MCHW 1.5000). In such productsconforming to equivalent standards andspecification of other Members States (MS) of theEuropean Economic Area (EEA) and testsundertaken in other member states will beacceptable in accordance with the terms of Clauses104 and 105 (MCHW 1.100). Any contract notcontaining these Clauses must contain suitableclauses of mutual recognition having the sameeffect, regarding which advice should be sought.

Scope

1.4 This Standard provides details of the proceduresfor putting in hand a maintenance painting project forsteel in bridges and other highway structures.

1.5 In addition to providing information onprocedures, this Standard contains guidance on theminimum criteria for selection of painting inspection

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firms.

se in Northern Ireland

1.6 For use of this Standard in Northern Ireland,the Maintaining Agent must be considered to bethe appropriate Division of Roads Service.

mplementation

1.7 This Standard must be used forthwith for allschemes currently being prepared provided that, inthe opinion of the Overseeing Organisation, thiswould not result in significant additional expenseor delay progress. Maintaining Agents mustconfirm its application to particular schemes withthe Overseeing Organisation.

stablishing Need for Maintenance Painting

1.8 Generally, the need and timing for routinemaintenance painting must be established duringstructural inspection in accordance with theOverseeing Organisation’s requirements asdescribed in the Standards listed in Reference 1(see Chapter 4 for references). However, ifbetween structural inspections, instances ofdeterioration requiring urgent attention have beenobserved, then the remedying of these failuresmust not be delayed.

ealth & Safety, and Environmental Restrictions

1.9 Certain methods of surface preparation, thecontents of the existing protective system or theapplication of certain types of paint may give riseto health and safety hazards. The MaintainingAgent must carry out appropriate risk assessmentsfor the work to be undertaken and introducerelevant control procedures with respect of therisks to staff, members of the public and theenvironment that may be affected by the work.

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Chapter 1Introduction

1.10 Health and safety hazards and pollution areimportant factors which have to be taken intoaccount when selecting methods of surfacepreparation and the application and type of paintsystems. Surface preparation and the application ofprotective coatings can give rise to conditionswhich, unless precautions are taken, may beinjurious to operatives and others in the vicinity,including animal life. Damage to propertyincluding plants, crops and pollution of water mayalso be caused. The Maintaining Agent must assessthe risks to staff, members of the public and theenvironment that may be affected by the work, todetermine the need for personal protectiveequipment and any restrictions, protectiveequipment (breathing equipment), enclosures ormonitoring to protect staff, the public and theenvironment (in accordance with the currentrelevant legislation. See for example, Reference 8(Chapter 4)).

1.11 Consideration must be given to workrestrictions or special requirements for work tostructures built on or over internationally protectedsites (designated under European or UK laws) suchas those described in Environmental Assessment,Ecology and Nature Conservation (DMRB 11.3.4).

1.12 As part of the Maintaining Agent’s riskassessment, the views of the Environmental HealthOfficer, the Health and Safety Executive, the WaterAuthority and other interested parties, must beconsidered. Practical guidance is given in ‘TheControl of Substances Hazardous to HealthRegulations 2002. Approved codes of practice andguidance’. Additionally, the information given inSeries NG 5000 (MCHW 2.5000), must beconsidered when choosing a particular method ortype of system to use.

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Chapter 2Basic Consideration

2. BASIC CONSIDERATION

General

2.1 In order to achieve value for money inpresent and future maintenance it is essential that,before surface preparation and paint systemclauses are drawn up, certain basic considerationsare taken into account, viz.:

i. At the outset, required life and future use ofthe structure must be clarified with theOverseeing Organisation. For structures witha remaining life of less than 20 years, adviceon the selection of the most appropriatesystem must be sought.

ii. In particular the first overall maintenancerepaint of newer structures must be carriedout before the condition of the protectivesystems has deteriorated further than thatdescribed as Category II in paragraph 2.5 ofthis Standard.

iii. All structural maintenance work that mayaffect the protective system, including theremedying of deck leaks and repair ofleaking joints, must be carried out beforemaintenance painting is put in hand. Wherethis is not possible approval must be soughtfrom the Overseeing Organisation.

2.2 When a generally sound protective systemrequires overall maintenance it must be borne in mindthat if the work is delayed the engineering works cost ofrestoring the system to a satisfactory standard mayincrease rapidly. It is a question of regular inspectionand/or localised repair in time, so that a maintenancecycle can be programmed.

2.3 There is no valid estimated time for firstmaintenance of galvanizing or aluminium metal sprayplus sealer only systems.

2.4 In the case of steelwork protected by a paintsystem over zinc metal spray, a check must bemade as to the origin of any white deposits on thepaint surface; these may be the first signs ofbreakdown of the zinc. If remedial work is not

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carried out in the early stages, corrosion of the zincmay well become extensive, and blast cleaning toclean steel will become necessary. Aluminiummetal spray is less easily attacked, breakdownbeing usually because the aluminium has beenbadly applied in the Works, e.g. dry spray leadingto disintegration. Breakdown of paint overgalvanizing is often due to the lack of adhesionbetween the zinc and the paint system. If only afew patches are involved, remedial action can besuccessful. However, an overall check must bemade and if the lack of adhesion is widespread,painting must not be attempted until all the loosepaint has been removed to a firm edge.

ategories of Failure

2.5 When the need for maintenance painting hasbeen established, the category of failure of theexisting protective system must be determined asfollows:

Category Description

I Local failures only. Finishing coatotherwise sound, such that a repaint ofthe whole structure is not necessary.No corrosion of the steel substrateand/or no sign of deterioration of themetal coating.

II Normal weathering of finishing coat,e.g. chalking, surface affected bydeposits, with some areas of localfailure. Adhesion generally soundsuch that, after cleaning down, thesystem can accept local build up ofundercoats and overall coating of thewhole structure with an undercoat andfinish. No corrosion of the steelsubstrate and/or no sign ofdeterioration of the metal coating.

III General failure of the finishing coatat or before the expiry of its expectedlife. Some local failure of the finishingcoat and the undercoats but primersand/or metal coating appearing to bestill sound. Some corrosion (1 - 3% oftotal area) of the steel substrate.

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Category Description

IV General failure of system, with directexposure of the steel substrate.Widespread corrosion varying fromheavy rusting showing through thepaintwork to localised paintbreakdown. In some casesconsiderable areas of white corrosionproducts may be visible on thesurface, possibly due to extensivecorrosion of a metal coating or of azinc rich paint. Localised or generalcorrosion of the steel substrate(greater than 3%) with breakdown ofthe protective system.

Categories of Failure

2.6 The purpose of allocating one of the fourcategories of failure, is to standardize as far as possiblethe pre-contract procedure and to some extent the levelof maintenance, although the main criteria for the latterwill be the accessibility, environment, expected life ofthe structure and cost, including road user delay costsas outlined in the Economic Assessment of RoadMaintenance Section 1 The QUADRO Manual(DMRB 14) and rail access or train delay costs.

Pre-specification Overall Survey

2.7 For all categories of failure, unlessotherwise agreed with the OverseeingOrganisation, a comprehensive overall survey mustbe carried out, to establish the extent, intensity andmethods of surface preparation necessary to ensuresatisfactory performance of the maintenance paintsystem proposed by the Maintaining Agent.

2.8 In the case of a Category I or II failure, theMaintaining Agent must arrange for its own staffto carry out the survey providing they understandfully the methods of attaining satisfactorystandards of surface cleanliness and haveexperience in supervising maintenance painting. Ifnot, an independent surveyor with appropriateexperience must be appointed for the work.

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2.9 In the case of Category III and IV failures,an independent surveyor must be appointed tocarry out the survey, unless otherwise agreed withthe Overseeing Organisation. The surveyor musthave had proven experience of coatings inspectionof steel structures over a period of at least fiveyears and must be familiar with the maintenancepainting specification and the types of coatingsused in maintenance contracts. The surveyor musthave proven experience in examining samples ofexisting coatings for the purpose of establishingthe reason for failure and for identifying types andlevels of contaminants present.

2.10 The Maintaining Agent must instruct thesurveyor as to the manner in which he requires theareas to be recorded so that a bill of quantities canbe compiled. The surveyor must report on eachmain part of the structure separately and may berequested to give the percentage of each method ofsurface preparation required on each part or hemay be requested to state the actual areas.

2.11 Means of access such as hoists must beagreed with the Maintaining Agent.

2.12 On completion of his work the surveyormust submit a full report describing failures,including a draft surface preparation and paintsystem details on Appendix 50/1 Form HA/P1(Maintenance) Paint System Sheet, parts 1 to 9 inaccordance with NG 5008 (MCHW 2.5000) and beprepared to discuss his recommendations with theMaintaining Agent.

2.13 The Maintaining Agent must also inform thesurveyor as to the extent of the survey to be carriedout and any limitations and time constraints whichare likely to apply during the maintenance paintingcontract, e.g. restrictions on methods of surfacepreparation or access to the structure. In cases suchas bridges over motorways, gaining adequateaccess for surveys (except for safely accessibleareas that do not require traffic management) maywell be difficult and could cause excessivedisruption to traffic. In exceptional circumstances,the Maintaining Agent may decide therefore toinstruct the surveyor to estimate surfacepreparation for mid-span and this may well resultin more extensive surface preparation thannecessary. The Maintaining Agent will then have to

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balance the likely extra cost of the work against asaving in survey costs and avoidance of traffic userdelay costs. If several bridges are involved it maybe worthwhile surveying at least one representativebridge thoroughly.

2.14 The Maintaining Agent must refer to SeriesNG 5000 (MCHW 2.5000), for further advice onthe selection of method(s) of surface preparationand paints systems. If sufficient information is notprovided, the Maintaining Agent must seek furtheradvice from the Overseeing Organisation.

Feasibility Trials of Proposed Methods of SurfacePreparation and Proposed Paint System(s)

2.15 After completing an overall survey, orhaving otherwise determined the exact nature andextent of the work that is necessary, a completeprovisional specification must be drawn up forsurface preparation and paint system, usingAppendix 50/1 Form HA/P1 (Maintenance) PaintSystem Sheet, parts 1 to 9, before any feasibilitytrials are undertaken. (See Clause 5008 (MCHW1.5000) and NG 5008 (MCHW 2.5000)).Feasibility trials of the proposed method(s) ofsurface preparation and painting system must becarried out for all categories of failure in paragraph2.5 of this Standard except in the following cases:

i. Where the surface preparation has beenidentified as blast cleaning to clean steelover the whole surface area of the structure.

ii. For small section steelwork having readyaccess where the existing protective systemis a Category I, II or III failure.

2.16 At least two separate representative areasmust be selected for the trials. The proposedmethod(s) of surface preparation shall be carriedout in each of these representative areas followedby application of one manufacturer’s paint systemto each representative area. All paints for eachrepresentative area must have a current BritishBoard of Agrément HAPAS Roads and BridgesCertificates or equivalent. Copies of British Boardof Agrément HAPAS Road and BridgesCertificates for those paint products that havegained approval can be downloaded from the BBAwebsite: www.bbacerts.co.uk. Requirements for

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the certification of paints are given in BD 35(DMRB 2.4.1). The types of paints used are listedin the Manual of Paints for Structural Steelwork atAnnex A of BD 35 (DMRB 2.4.1).

7 Except in cases where the whole of the existingtective system is to be removed, it has been foundm experience that, in the majority of cases, it has notn possible to specify accurately the full extent ornsity of the surface preparation required, or, to a

ser extent, predict the behaviour of new paints whenlied over existing paints, without carrying outsibility trials. Changes in requirements shown to beessary during the trials not only prevent delaysing the contract but also avoid claims due toperable specification clauses. Feasibility trials alsovide an opportunity to assess the competence ofnt contractors.

8 Feasibility trials are not required in cases wheres proposed to remove the whole of the existingtective system over the entire surface area, where existing protective system consists of aluminiumtal spray and/or paint coats. The removal ofminium metal sprayed coatings by blast cleaning is well established and feasibility trials toonstrate this are unnecessary.

9 Zinc metal sprayed and galvanized coatings areerally more difficult to clean to an acceptable

ndard when atmospheric pollutants have reacted with zinc to form zinc salts. Where it is proposed toove entirely or in part a zinc metal coating,

sibility trials should be carried out to determine thet method of surface preparation and degree ofanliness which can be achieved.

0 For small section steelwork having ready access,h as some parapets and some steel lighting columns,ere failure of the existing protective system istegory I, II or III, the Maintaining Agent maypense with feasibility trials where the cost ofrying out such trials is proportionately high, sayater than 15% of the estimated works cost forintenance painting. In such cases the Maintainingent will need to be sure that the risks ofompatibility of the existing protective system with proposed system are minimal. Where doubts existut compatibility of systems, advice should be sought

m the Overseeing Organisation.

1 For Categories I and II steelwork other than thatntioned in paragraph 2.20, it is worthwhile carrying

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out feasibility trials to check the application propertiesof new paints and their compatibility with existingcoats. The trials may also show up hitherto unsuspectedfaults, such as an adhesion weakness in the existingsystem or underlying corrosion which has not beenapparent previously.

2.22 In the case of Categories III and IV, trials ofseveral methods of surface preparation are likely to benecessary; these include wet and/or dry blast cleaningas well as abrading and cleaning down. The paintsystem feasibility trials will necessarily be morecomprehensive than for Categories I and II as paint hasto be applied over several types of surface presented bythe different methods of preparation.

2.23 The work involved in feasibility trials forCategories I and II, i.e. abrading small areas,washing down and applying a paint system over anumber of days can be carried out economically bythe Maintaining Agent and this method should beadopted if possible. In the case of Categories III &IV, a specialist contractor must be appointed.

2.24 During the feasibility trials it will be necessary tocheck the adhesion of the existing system by testing toconfirm that any contamination or corrosion productsare being reduced to acceptable levels and that theproposed paints are tolerant of any existing residues. Itis particularly important to check compatibility ofproposed paints on older bridges which may have beenpainted with oil based paints, also that any effects offaulty paint technology in the original paint system canbe overcome.

Ordering Paint for Feasibility Trials

2.25 When the feasibility trials are carried out bythe Maintaining Agent, Form HA/P4 ‘Purchaser’sConditions of Order for Paint’ (see Annex A) mustbe used for ordering paint for the trials.

Colours of Finishing Paints

2.26 Unless the appearance of the structure is ofparticular importance, colours must be selectedfrom those in paragraph 2.27. When there is a needfor other colours, for example in the case of a largebridge or one which is in an environmentallysensitive area and visually dominant in its locality,

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or when it is proposed to change a colourpreviously submitted to the Commission forArchitecture and the Built Environment (CABE) inEngland or to equivalent bodies in Scotland, Walesand Northern Ireland, the matter must be referredto the Overseeing Organisation describing thestructure, its location and present colour, theproposed alternative BS 4800 colour and thereasons for selecting it.

.27 Where the use of paint formulations conformingo technical specifications of other member states of theuropean Community has been agreed, colours whichre a close match to those specified are acceptablenless there are particular objective reasons why anxact match is necessary.

. Gloss Finishes

From the following colours in BS 4800

Light Grey 00 A 05Medium Grey 18 B 21Dark Grey 18 B 25Green-yellow 12 B 21White 00 E 55

Black gloss paints are not usually required.

i. Semi-gloss Finishes

When a semi-gloss finish is preferred, or isspecifically required such as for sign gantrysteelwork, Item 169, or item 164 or item 121must be used. Because these paints contain acomparatively high percentage of dark greymicaceous iron oxide (MIO) pigment, colours arerestricted to the following in BS 4800:

Medium grey approximately 00 A 09Natural grey ” 00 A 13Dark blue ” 18 C 39Dark green ” 14 C 39

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Chapter 3Painting Inspection Firms

FIRMS
3. PAINTING INSPECTION
Selection of Painting Inspection Firms

3.1 Before appointing a painting inspectionfirm, the Maintaining Agent must verify that thefirm has the technical competence and resources toundertake inspection. Inspectors must hold theInstitute of Corrosion - Painting Inspector Level 1qualification, as a minimum, or an equivalentqualification. Senior Supervisory Inspectors musthold the Institute of Corrosion - Painting InspectorLevel 2 or an equivalent qualification. TheMaintaining Agent must obtain full details of thequalifications and experience of the Inspectors tobe employed in the Works before the appointment.

Briefing of Painting Inspection Firms

3.2 Following the appointment of the inspectionfirm, the Maintaining Agent must specify the roleand responsibilities of the inspector in the contractand fully brief the firm on the particular duties theInspector is required to perform. For this purposethe firm must be furnished with copies of allrelevant Drawings, the Specification for thecontract and any other information which mayaffect the work.

3.3 The Maintaining Agent must establish at thetime of the briefing working arrangements andlines of communication with the inspection firm.

3.4 The Maintaining Agent must agree thenumber of Inspectors to be employed in the Worksand the frequency of supervisory visits by theSenior Supervisory Inspector. The MaintainingAgent must continuously review with theinspection firm the general level of resourcesrequired during the period of the Works.

3.5 The Maintaining Agent must establish withthe inspection firm the frequency of reporting andrequirements for the keeping and forwarding ofspecific records in the contract.

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3.6 The Maintaining Agent must obtain from theinspection firm a quality plan for inspection workin the contract. The quality plan must include themethod of working on site and the role of theinspection firm’s support services and personnel inthe Contract.

Health and Safety

3.7 The Maintaining Agent must provide eachInspector with a copy of the assessment carried outin accordance with paragraph 1.9 and drawattention to the practical guidance given in ‘TheControl of Substances Hazardous to HealthRegulations 2002. Approved codes of practice andguidance’.

Duties of Painting Inspectors

3.8 Duties suitable for incorporation in terms ofappointment are given in Annex B of this Standard. Theduties associated with testing of contract paint samplesrelate to the standard testing arrangements. They are notwholly applicable in cases where alternative testingarrangements are used.

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Chapter 4References

4. REFERENCES

1 Trunk Road Maintenance Manual:

Volume 1. Highways Maintenance Code (for use inEngland)

2 Design Manual for Roads and Bridges

Volume 2: Section 4 Paints and Other ProtectiveCoatings

BD 35 Quality Assurance Scheme for Paints andSimilar Protective Coatings(DMRB 2.4.1)

Volume 3: Section 1 Inspection

BD 63 Inspection of Highway Structures(DMRB 3.1.4)

BA 63 Inspection of Highway Structures(DMRB 3.1.5)

Volume 3: Section 2 Maintenance

BD 62 As Built, Operational and MaintenanceRecords for Highway Structures(DMRB 3.2.1)

3. Manual of Contract Documents for HighwayWorks

Volume 1: Specification for Highway Works(MCHW 1)

Volume 2: Notes for Guidance on the Specificationfor Highway Works (MCHW 2)

Volume 4: Method of Measurement for HighwayWorks (MCHW 4)

4. British and Other Standards

BS 2015: Glossary of paint and related terms

BS EN ISO 1513, BS 3900-A2: Paints and varnishes.Examination and preparation of samples for testing

BS 4800: Schedule of paint colours for buildingpurposes

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S EN ISO 8503-1, BS 7079-C1: Preparation of steelubstrates before application of paints and relatedroducts. Surface roughness characteristics of blast-leaned steel substrates. Specifications and definitionsor ISO surface profile comparators for the assessmentf abrasive blast

S EN 971-1: Paints and varnishes. Terms andefinitions for coating materials. General terms

S EN 22063: Metallic and other inorganic coatings.hermal spraying. Zinc, aluminium and their alloys

S EN ISO 12944-1: Paints and varnishes. Corrosionrotection of steel structures by protective paintystems. General introduction

S EN ISO 12944-7: Paints and varnishes. Corrosionrotection of steel structures by protective paintystems. Execution and supervision of paintwork

. Regulations

ontrol of Substances Hazardous to Health Regulation002

ontrol of Substances Hazardous to Health RegulationsNorthern Ireland) 2003

he Control of Lead at Work Regulations 2002

. Acts

he Control of Lead at Work Regulations 2002

. Miscellaneous

he Control of Substances Hazardous to Healthegulations 2002. Approved codes of practice anduidance. Fourth Edition - HSE

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5. ENQUIRIES

All technical enquiries or comments on this Standard should be sent in writing as appropriate to:

Chief Highway EngineerThe Highways Agency123 Buckingham Palace RoadLondon G CLARKESW1W 9HA Chief Highway Engineer

Chief Road EngineerScottish ExecutiveVictoria QuayEdinburgh J HOWISONEH6 6QQ Chief Road Engineer

Chief Highway EngineerTransport WalesWelsh Assembly GovernmentCathays Parks M J A PARKERCardiff Chief Highway EngineerCF10 3NQ Transport Wales

Director of EngineeringThe Department for Regional DevelopmentRoads ServiceClarence Court10-18 Adelaide Street G W ALLISTERBelfast BT2 8GB Director of Engineering

Chapter 5Enquiries


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ANNEX A FORM HA/P4

Form HA/P4

PURCHASER’S CONDITIONS OF ORDER FOR PAINT

A.1. The paint(s) described below, subject to our Order No .......…....... dated ............... must comply with ............(paint manufacturer’s name) a current BBA HAPAS Road and Bridges Certificates or equivalent and must have theproperties stated in Form HA/P2 Paint Data Sheet completed by...............(paint manufacturer’s name) or havingbeen agreed in accordance to Departure……….. (ID number). (Purchaser to complete under each heading of list.)

Item No. Registered Desc. Method of Application Value of X% (see A2.iic)

A.2. In addition the following requirements must apply:

i. Keeping properties:

When stored in its original sealed container at a temperature between 5oC and 27oC,the paint must retain theoriginal properties for 12 months from date of despatch. During this time the paint must not show hardsettling, skinning or tendency to gel when tested in accordance with ‘BS EN ISO 1513, BS 3900-A2’.

ii. Application properties:

a. Except for two-pack chemically cured and moisture cured paints, paint(s) must be capable of beingapplied satisfactorily on suitably prepared surfaces at steel and ambient temperatures above 5oC.Two-pack chemically cured and moisture cured paint(s) must be capable of being applied satisfactorilyon suitable prepared surfaces at steel and ambient temperatures advised by the paint’s manufacturer.Paints must be overcoatable within the time stated in Form HA/P2 referred to in paragraph 1.

b. The paint(s) must be supplied ready for use at a viscosity entirely suitable for the method ofapplication.

c. Sag resistance.

There must be no sagging of paints when applied at 130% of the specified maximum wet filmthickness.

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Annex AForm HA/P4


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iii. Dry film properties:

The paint(s) must be capable of being applied by a competent operator, in accordance with the Data Sheet(s),such that:

a. Each coat must be generally free from surface defects, particularly cratering, pinholing, rivelling,sagging, bittiness, dry spray or excessive brush marks and cissing, as defined in BS 2015 andBS EN 971-1.

b. Each coat must have a uniform and even appearance and have satisfactory adhesion, checked inaccordance with ‘BS EN ISO 4624, BS 3900-E10’, ASTM D4541-02 or BS EN 22063 Annex Amethod 1, before overcoating with the next coat in the system.

c. Unless otherwise agreed, each coat of paint when applied at the minimum dry film thickness of therange stipulated in the Form HA/P2 must visually obliterate the substrate or the previous coat in acontrasting colour.

d. Colour and gloss of the finish

The finish coat of paint applied to the structure shall must match a coated reference panel provided bythe paint manufacturer. The panel must be tinplate 150mm x 100mm.

A.3. Containers

i. Paint must be supplied in tins up to 25 litre capacity with completely removable lids.

ii. The tins must be marked on the side. The marking must include the following:

Name of manufacturerRegistered description of the material (inc purpose, e.g. whether primer, undercoat or finish and also thecolour)Item NoPaint manufacturer’s reference NoBatch NoDate of manufacture (as such or in coded form which must be communicated to the purchaser).

for (purchasing authority)

Signature:

Date:

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Annex AForm HA/P4


NTING INSPECTORS

Annex BDuties of Painting Inspectors

ANNEX B DUTIES OF PAI

B.1. Health and Safety

B.1.1 The Inspection Firm must ensure that theInspector is aware of the firm’s duties as Employer inrespect of health and safety of employees and otherpersons at the workplace. The Inspector must also beaware of the duties imposed on him as employee bystatutory instruments and regulations concerning healthand safety.

B.1.2 The Maintaining Agent must provide theInspector with a copy of all Health and Safetyassessments carried out in accordance with regulation 6of the Control of Substances Hazardous to HealthRegulations 2002 or regulation 6 of the Control ofSubstances Hazardous to Health Regulations (NorthernIreland) 2003, as appropriate to the OverseeingOrganisation.

B.2. Definitions in the List of Duties

B.2.1 Where the word ‘verify’ has been used in the listof duties, the function of the Inspector is to ascertain byenquiry.

B.2.2 Where the word ‘check’ has been used in the listof duties, the function of the Inspector is to watch andreport.

B.2.3 Duties which require the Inspector to performsome other task, e.g. testing or measuring specificgravity, are explicitly described.

B.3. General Requirements and Duties

B.3.1 Painting Inspectors must be familiar withdocuments referred to in the Contract including thisStandard, British harmonised standards, Internationaland European harmonised Standards relevant to thework to be inspected.

B.3.2 Specific duties of the Inspector are given insections 4 to 9 of this Annex. The duties are set out tocorrespond with stages of a typical maintenancepainting contract carried out in accordance with thisStandard.

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B.3.3 During the procedure trials, the Inspector mustcarry out the duties in sections 6 to 8 which arenecessary to establish the Contractor’s ability toachieve the standards of surface preparation andprotection required in the main work.

B.4. Preliminaries at Start of the Contract

B.4.1 Verify that the Inspector and the Contractor haveidentical copies of the Specification.

B.4.2 Verify that the Contractor has submitted a qualityplan for the work in the Contract, and that this has beenagreed with the Maintaining Agent.

B.4.3 Verify with the Maintaining Agent anyrequirement of the Contractor to liaise with or notifythe Health and Safety Executive, Environmental HealthOfficer, Water Authority or any other interested party,of any relevant stage of the Contract at the start orduring the work.

B.4.4 Verify with the Maintaining Agent that theprogramme of work and method of working proposedby the Contractor have been accepted and that theContractor is aware of any limitations e.g. times ofaccess to carriageways.

B.4.5 Verify with the Maintaining Agent that theContractor’s proposed access arrangements have beenagreed as being suitable for the method of working andinspection.

B.4.6 Verify with the Maintaining Agent that theContractor is fully aware of the limitations in theContract regarding the effect of unfavourable weatherconditions on progress of the work, e.g. plannedcarriageway closures and access.

B.4.7 Verify with the Maintaining Agent that theContractor is aware of requirements for the enclosure,collection and disposal of spent abrasive, paint, debrisand dust.

B.4.8 Verify with the Maintaining Agent that the FormHA/P1 (Maintenance) Paint System Sheet has beenaccepted and that the Inspector and Contractor haveidentical copies of Forms HA/P2 Paint Data Sheets andhealth and safety data sheets for each of the paints to beused in the contract.

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B.4.9 Verify that the Contractor is aware of the timeneeded for testing ‘A’ samples and that paint is orderedsufficiently early to allow testing and reporting of paintsamples before paint from a particular batch is applied(other than painting in the procedure trial).

B.4.10 Verify that the Contractor is aware of hisresponsibility for the packaging and prompt despatch ofpaint samples for testing. Check that the Contractor hasprovided an adequate number of tins and lids for ‘B’samples and lid clips for ‘A’ and ‘B’ sample tins.

B.4.11 Verify with the Contractor the quantity ofpaint to be used for each coat in the system.

B.5. Procedure Trials

B.5.1 Verify with the Maintaining Agent the locationand steelwork area where the procedure trials are to becarried out.

B.5.2 Record names of personnel and details ofequipment used in the trials and check that surfacepreparation and painting equipment proposed aresuitable for the method of working and standardsrequired in the specification.

B.5.3 Check the efficiency of the equipment used in thetrials, including any enclosures or monitoring, and thatthe standards of surface preparation and paintingrequired in the main work are achieved. Check thatadequate lighting, heating, ventilation and accessequipment are used.

B.5.4 Where hand power tools are used for abrading,check that the Contractor is using the correct techniqueand that surfaces are not left with a burnishedappearance caused by the polishing in of old paint, rustor dirt.

B.5.5 Check that the Contractor is capable of detectingand removing unsound coatings and that featherededges of coatings have satisfactory adhesion.

B.5.6 Check that the Contractor is able to identifychemical and visible surface contaminants and that he isable to remove these as required in the specification.Test surfaces for freedom from chemical contaminants.

B.5.7 Check that the Contractor is capable of applyingthe protective coatings in accordance with thespecification, including film thickness and that eachcoat is free from surface defects including cratering,pinholing, rivelling, sagging, bittiness, cissing and dryspray, and that the finished system has an even and

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uniform appearance. Check that wet and dry paint filmthicknesses measured by the Contractor as paintingprogresses, are comparable with measurements taken bythe Inspector.

B.5.8 Where required by the Maintaining Agent, checkthat the Contractor applies all the paints (includingstripe coats) stepped back, including the finish coat ofpaint, to a 150 x 100 mm tinplate panel, to ensure thatthe coats are applied in the correct order and to be usedas a reference for shade and gloss of the finish coat laterin the work.

B.5.9 Notify and seek approval from the MaintainingAgent any adjustment required to tins of paint.

Note: Any adjustment to paint should be made at thepaint manufacturer’s works and the Inspector shouldverify that the Contractor has confirmed with theMaintaining Agent that revised formulations areregistered with the Overseeing Organisation beforepaints are offered for use in the Works.

B.5.10 Check that any unsatisfactory application isrectified before the start of the main painting.

B.6. Surface Preparation

B.6.1 Check that the type and grade of abrasive is thesame as that used in the procedure trial and that theabrasive is clean, dry, free from oversize particles andcontaminants detrimental to the surface to be prepared.

B.6.2 Verify that any chemical cleaning to be used hasbeen agreed by the Maintaining Agent.

B.6.3 Check that surfaces contaminated by oil or greasehave been cleaned with a suitable cleaning materialbefore being finally rinsed with clean water.

B.6.4 Before blast cleaning, check surfaces ofsteelwork for severe corrosion and/or contamination,e.g. prolonged damage caused to coating system from aleaking deck joint, and note these areas for closeexamination after blast cleaning. Record the position ofthese areas in the structure for future reference.

B.6.5 Check that only clean water is used in wet blastcleaning, wet cleaning down and for rinsing.

B.6.6 Check that surface defects revealed as surfacepreparation proceeds are remedied by the Contractor.Areas of surface defects, e.g. hackles, internaldiscontinuities, etc, which have been remedied shouldbe recorded and notified to the Maintaining Agent

May 2005



before overcoating. Some defects may be remediedafter primer application, with mechanical preparationbeing allowed through the blast primer and the primerre-applied locally by brush.

B.6.7 Check for the presence of sharp edges, burrs,weld spatter, etc and record and report these areas to theMaintaining Agent if these have not been removed byfettling or grinding and any final blast cleaning whichmay be necessary.

B.6.8 Check that any loose particles of embeddedabrasive in the cleaned surface are removed beforeovercoating.

B.6.9 Where wet/abrasive blast cleaning methods areused, check that prepared surfaces have been dry blastcleaned to remove any subsequent light rusting inaccordance with the specified standard of surfacepreparation. Check that finally prepared steel and metalcoated surfaces are overcoated within the specified timeand in accordance with clause 7.2.

B.6.10 Check that excessive burnishing of thesubstrate through prolonged or faulty application ofrotary power abrading tools, particularly rotary wirebrushes, is avoided and that any visible peaks andridges produced by mechanical cleaning tools areremoved before overcoating.

B.6.11 In areas where existing coats have beenfeathered back, check that all edges are firmly adhering.

B.6.12 Record any areas of unnecessary damage tosound existing metal coatings which are not required tobe removed during surface preparation.

B.6.13 Check that sealants which have been raked orcleaned out between plies and gaps are replaced with atype agreed by the Maintaining Agent.

B.6.14 Check finally that the specified standard ofsurface preparation has been achieved for each of theareas to be overcoated.

B.6.15 Check at the start of every shift that the anysheeting used for enclosure is effective in preventingdust, etc escaping into the atmosphere. Also ensure thatany damage to the enclosure is repaired immediately.

B.7

B.7

(i)

(ii)

(iii

(iv

(v)

B.7

(i)

(ii)

(iii

(iv

May 2005

. Paints

.1 General

Before paints are delivered to site, verify that theContractor has available a suitable site lock-upstore where paints can be kept at between 5°Cand 27°C until required for use.

Check that all paints delivered to site are insealed containers and are clearly marked with thename of the manufacturer, registered description,item number, batch number, manufacturer’sreference number and date of manufacture.

) Check that the first delivery of each paint to siteconsists of at least 10 tins from the same batch,where samples are required to be despatched tothe testing authority for checking.

) Verify that the Contractor has confirmed with thepaint manufacturer that the paint data sheets,including health and safety data sheets, cover theconditions under which the paints are to beapplied, e.g. temperature, humidity, use inconfined spaces, etc.

Verify that the Contractor’s paint applicationprogramme allows for overcoating within theminimum and maximum timescale rangerecommended by the paint’s manufacturer.

.2 Application of paints

Check that all painting is carried out usingequally qualified and experienced personnel andequipment used in the procedure trial.

Check that paints are used in strict rotation ofmanufacture and are used within the declaredshelf life.

) Check that no addition of solvent to the paint iscarried out on site.

) Check that 2-pack paints are mixed thoroughly(in the correct ratio) in accordance with the paintmanufacturer’s data sheet and that paints with alimited ‘pot life’ are not used after the expirationof the pot life. Check that other tins of paint withmore than 10% ullage are discarded at the end ofthe working day and not returned to the paintstore.

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(v) Check that adjacent surfaces which are not to bepainted are masked or protected from oversprayor paint splashes.

(vi) Check that painting, other than in the proceduretrial, is not started until results of satisfactorytesting of the first ‘A’ samples have been reportedto the Contractor by the Maintaining Agent.

(vii) Check that paint is not applied under thefollowing conditions:

(a) When the ambient temperature falls below5°C or the relative humidity rises above90% or, for types of paints in Series 5000(MCHW 1.5000) sub-Clause 5012.13,outside the temperatures and humiditiesrecommended by the paint manufacturer.

(b) During rain, snow, fog, mist or in a dust-laden atmosphere.

(c) When the amount of moisture likely to bedeposited on the surface by condensationor rain before or after painting, may have aharmful effect on the paint.

(d) When wind borne dust may have a harmfuleffect on the paint.

(e) When the steel temperature is less than 3ºCabove dew point.

(viii) Check immediately before the application of eachcoat of paint, that surfaces to be overcoated stillcomply with the specified standard(s) of surfacepreparation.

(ix) Check that stripe coats of paint in contrastingcolour to the previous overall coat are applied inthe correct sequence in accordance with thespecification and that the colours of the sameItem number are applied in the agreed order.

(x) Check that the dry film thickness of each coat ofpaint, and of the applied system, is in accordancewith the specification. Verify that the Contractoris aware of any reduction in dry film thickness ofcoatings and the overall system resulting fromcuring/drying, particularly for paints with slowevaporating solvents.

(xi) Check that each coat of paint is free from surfacedefects including cratering, pinholing, rivelling,sagging, bittiness, cissing holidays and dry spray,and that the finished system has an even anduniform appearance.

(x

B

(i

(i

(i

(i

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ii) Where applicable, check that the shade and glossof the finish coat is the same as applied to thereference panel in the procedure trial.

.7.3 Paint Testing

) Immediately on delivery of paint and anyreconstituted paint to site, verify that it is for theuse specified and carry out the following tests:

(a) Specific gravity. Samples which fail tocomply with the following tolerances mustbe rejected and not sent to the testingauthority:

• paints with a specific gravity lessthan or equal to 1.4: + or - 3 %

• paints with a specific gravity greaterthan 1.4: + or - 4 %

(b) Wet to dry film thickness ratio (volumesolids).

(c) Sag resistance to ASTM D4400-99.

(d) Opacity.

(e) Drying time.

i) Following satisfactory site testing by theInspector, and where required by theSpecification, select the first set of ‘A’ samples ofunopened tins of each type of paint and hand tothe Contractor for packing, addressing anddespatch to the testing authority.

ii) Immediately after the ‘A’ samples are despatchedby the Contractor, record the despatch date in thecompleted Form HA/P3, Paint Sample DespatchList and send one copy to the testing authorityand, together with Form HA/P1 (Maintenance)Paint System Sheet, one copy to HighwaysAgency, Paint Specialist, Safety Standards andResearch (SSR), City Tower, Piccadilly Plaza,Manchester, M1 4BE or the relevant OverseeingOrganisation. The Inspector must retain one copyof each Form HA/P3 as inspection records.

v) Ensure that subsequent sets of ‘A’ samples aredespatched for testing by the Contractor inaccordance with the Specification in sufficienttime to allow for testing and reporting of samplesbefore the paints are used in the Works.

May 2005



(v) Take ‘B’ control paint samples before use atintervals as instructed by the Maintaining Agentfrom painters’ kettles or from airless spray gunnozzles, with a minimum of one batch in threebeing sampled. Check the specific gravity of ‘B’samples immediately samples are taken. If thespecific gravity is found to be incorrect, theInspector must record areas painted with thatpaint and report immediately to the MaintainingAgent.

(vi) Following satisfactory checks on ‘B’ samples,clip down tin lids and mark tins B1, B2, etc andhand to the Contractor for packing, addressingand despatch to the testing authority inaccordance with the Maintaining Agent’sinstructions, given on From HA/P3.

(vii) Immediately after the ‘B’ samples are despatchedby the Contractor, record the despatch date in thecompleted Form HA/P3 and send one copy to thetesting authority, one copy to Highways Agency,Paint Specialist, Safety Standards and Research(SSR), City Tower, Piccadilly Plaza, Manchester,M1 4BE and retain one copy for the Inspector’srecords.

B.8 Records and Reporting to the MaintainingAgent

B.8.1 Record and report progress and compliance withthe programme at intervals agreed with the MaintainingAgent.

B.8.2 Record and report immediately to theMaintaining Agent non-compliance with the approvedmethod of working, statutory requirements regardinghealth and safety and environmental protection, or otherhealth and safety hazards or infringements which mayaffect the Contractor’s workforce or third parties.

B.8.3 Keep and submit records of the work as required.

B.8.4 Record and report immediately sub-standardwork.

B.8.5 Keep records of all tests required for the contractand submit reports of all tests and inspections asrequired.

B.8.6 Record details of equipment and materials usedin the procedure trials and in the main work. Check andretain material consumable certificates and certificatesof conformity issued by the Contractor. Record type ofscaffolding or other access and details of screening andworking conditions throughout the work.

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B.8.7 Record steel temperature, air temperature,relative humidity and paint temperature, prior to use, ateach area to be painted before and at intervals duringpainting using suitable calibrated instruments.

B.8.8 Record date of blast cleaning of each area andnote if any re-blasting was required and the reason.Record action taken to remedy surface defects.

B.8.9 Record date and time of application of each paintcoat, atmospheric conditions and area covered by eachbatch of paint.

B.8.10 Keep record copies of all Forms HA/P1 andHA/P3 sheets. Also retain copies of Paint SampleAnalyses Reports if so required by the MaintainingAgent.

B.8.11 Where authorised to issue certificates ofcompletion in respect of any part of the Works, forwardcopies immediately to the Maintaining Agent and retaincopies for the Inspector’s records.

B.8.12 On completion of the Works, forward onecopy of the completed Form HA/P5, MaintenancePainting Scheme Summary Sheet, together withForm(s) HA/P1 to Highways Agency, Safety Standardsand Research (SSR), City Tower, Piccadilly Plaza,Manchester, M1 4BE or the relevant OverseeingOrganisation and, where required, one copy to theMaintaining Agent.

B.8.13 On completion of the Works check that allrecords have been forwarded.

B.9. Record Sheets, Tables and Equipment

B.9.1 The inspection firm must provide the Inspectorwith all necessary record sheets and tables, includingthe following:

i. Inspector’s daily record sheets.

ii. Inspection firm’s instructions and data sheets forcarrying out checks for contaminants.

iii. Tables or disk calculator for calculating relativehumidity or suitable digital instrument.

iv. Tables for calculating specific gravity afteradding solvent.

B.9.2 The inspection firm must provide the Inspectorwith all suitably calibrated equipment necessary for theInspector to carry out his duties.

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Inspection equipment must be calibrated at intervalsrecommended by the equipment manufacturer inaccordance with the manufacturer’s requirements orother national, international or European standards.Calibration records and certificates must be retained bythe inspection firm and, where required, copiesprovided to the Maintaining Agent.

The inspection firm must provide the Inspector with thefollowing minimum inspection equipment:

i. Steel and air temperature thermometers orprobes.

ii. Surface profile gauge conforming to ISO 8503Part 1.

iii. Wet film thickness gauges.

iv. Dry film thickness gauge to BS 3900-C5, method6A and 7.

v. Pull-off adhesion tester.

vi. Metal spray adhesion tester.

vii. Telescopic mirror.

viii. Equipment to measure relative humidity.

ix. Equipment to measure specific gravity.

x. Equipment to detect and measure surfacechemical contaminants.

xi. X10 illuminated magnifying glass or pocketmicroscope.

xii. Wet sponge holiday detector or spark tester asappropriate.

May 2005B/6


May 2005

ANNEX C FORM HA/P5

FORM HA/P5 MAINTENANCE PAINTING SCHEME SUMMARY SHEET

[On completion of the Works, Inspector to forward one copy of completed Form HA/P5 with Forms HA/P1 to:Highways Agency, Paint Specialist, Safety Standards and Research (HA SSR), City Tower, Piccadilly Plaza,Manchester, M1 4BE or the relevant Overseeing Organisation]

Contract Title…………………………………………………………………………………….

Structure No/Name…………………………………………….…………………………………

1. Date of original construction, where known……………………………………………................……

2. Date of last major repaint, where known…………………………………………………................….

3. Category of failure of previous I II III IVCoating system (see definitions BD 87)……………………..please tick

4. Details of previous protective system, where known:

Description Item No.

Metal coat:…………………………………..……………. …………………..………

1st Paint coat:……………………………..……………… …………………..………

2nd Paint coat:…………………………………………….. ………………………….

3rd Paint coat:……………………………………………… …………………………..

4th Paint coat:…………………….………………………. …………………………..

5th Paint coat:…………………..………………………… …………………..………

6th Paint coat:…………………………………………….. …………………………..

Total minimum dft of paint system microns

No. of stripe coats…………………………………

5. Protective system for this Contract Type…………………

6. Date of paint survey, where known…………………………………………………………………..

7. Date of feasibility trial, where known………………………………………………………..............

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Annex CForm HA/P5


May 2005

Yes No

8. Have ‘A’ or ‘B’ paint samples beensent for testing for this contract? …….. please tick

9. Has maintenance painting been major,i.e. affecting greater than 10% of thesurface area of the steelwork? …….. please tick

10. If yes, has minor maintenance paintingbeen undertaken since the last majorrepaint or, where this is the first majorrepaint since completion ofconstruction? …….. please tick

11 Has work in the maintenance paintingcontract been carried out as part of ahybrid maintenance scheme, i.e. inconjunction with other highway orstructure maintenance? …….. please tick

If yes, please give a brief descriptionof the other work.……..

12. Have carriageway/lane restrictionsbeen specially required to carry outwork in the maintenance paintingcontract? …….. please tick

13. Has work in the maintenance paintingcontract been carried out at night? …….. please tick

14. If you have any constructive comments to make regarding the maintenance painting specification,either general or in relation to work in this contract, please include them on a separate sheet andforward to the Highways Agency’s Safety Standards and Research (HA SSR) with this form.

Inspecting Firm……………………………………………………………………………………..

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Annex CForm HA/P5

DMRB VOLUME 3 SECTION 2 PART 2 - BD 87/05 - · PDF fileBD 87/05 MAINTENANCE PAINTING OF...

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