Painting Projects in PennDOT District 11

2014 National Bridge Preservation Partnership Conference Orlando, Florida April 23, 2014 Louis J. Ruzzi, P.E. Engineering District 11-0

• Allegheny(Pittsburgh area),Beaver and Lawrence Counties • State Bridges over 1800,federal oversight on over 500 local bridges • Over 500 sign structures, currently inventoring retaining walls(hundreds) and light poles (over 5000) Talking Points

• History of Programming/Funding Paint Projects • Choosing Paint Candidates including PennDOT Design Manual 4(Structures)-Paint Flow Charts • Paint Colors • Contracts • Maintenance Painting – Carboline – Termarust – Bulletin 15 – In-House Painting = Sewickley Bridge

Talking Points Continued

• Performance Issues – Amine Blush – Fort Duquesne/ 31st Street/ SR 28 SB over SR 8 – Rust (bleed through) on rehabbed bridges – Hulton – 1990 job – Rochester-Beaver • Costs per sf – $12/sf Full Paint – $18/sf Zone Paint Programming/Funding Paint Projects

• Prior to 2004 we did small group painting projects using Maintenance money generally in Allegheny County where have the money and when we did a major bridge rehab • The group painting projects were generally not coordinated with other roadway and bridge projects • In 2004,FHWA allowed the use of federal funds for bridge preservation work including painting- this really increased the amount of painting being done in our District bridges

Programming Funding/Paint Projects

• Painting bridges is now mainly included with other bridge and roadway projects as is part of an overall effort to improve bridges • Our budget for bridges in the Pittsburgh area went from $43 million to range from $79 million to $179 million between 2008 and 2012 • In late 2013, Pennsylvania legislature passed Act 89 will provide increased reliable transportation funding the next 10 years including for bridge projects

Choosing Paint Projects

• Bridge Preservation • Bridge Rehabs • New Bridges(Replacements) • Maintenance Painting Choosing Paint Projects

• Bridge Preservation-PennDOT’s policy uses federal money to fix beam ends, replacing leaking joints, deck overlays and painting(spot/zone and full) to name a few • Rehabs-include Deck/Superstructure replacements and full paint • New-Full paint in the shop except for knicks due to taking down the overhang jacks) or the top flanges which only get a primer(3-5 mils) after shear studs are placed. Choosing Paint Candidates Painting work is included in Bridge Rehabs and Preservations and roadway projects on the Interstate and Expressway, Betterments . Occasionally,we may do a stand alone paint job • For a stand-alone paint job, the paint condition is the primary way that we determine the scope-of work (SOW), but we also look at the condition of deck, superstructure and substructure, the load ratings and if a bridge is posted for other preservation work. • For roadway projects , the roadway condition and repair cycle will drives the priority, not the need for painting the bridge. Choosing Paint Candidates – Stand Alone Example

• The last stand-alone paint job that was the Ft Duquesne Bridge and its ramps (14 structures) in 2005. • This was at the request of the City of Pittsburgh because we built two new stadiums PNC park and Heinz Field in 2001 and city fathers wanted the entire area looking clean an well maintained. • This project cost $16 million job and included some expansion dam work, downspout repairs and some substructure repairs (basically for the money we had available at the time). Stand Alone Example – Ft. Duquesne Bridge Complex (14 structures)

• When more money became available for all bridge work in 2008, we let a $22 million job for the remainder of the work that was needed on these 14 structures.

• The money became available to the state due to a greater emphasis on bridges and thru bonding, the Federal Stimulus program and PennDot switched from doing capacity added roadway jobs to just fixing our existing roads Choosing Paint Projects

• When not getting the rare special request for painting, we have a procedure Design Manual 4 Structures discusses our Policy, Procedures and Life Cycles – Forexample-It is usually not worth painting bridges that are under 100ft – It also discussed Life cycle expectations- Spot/zone paint-10-18 years, full Paint-30-40 years, over coating (intermediate and finish coat over existing coats-which we don’t do

Choosing Paint Candidates Continued Choosing Paint Candidates – Bridge Preservation

Full paint Candidates: • Run queries on Bridge Inspection Paint Codes-GB 36 Paint Condition Rating and GB37 Extent of Paint Condition • Paint Condition Rating of 4-Paint system has broken down with major areas of peeling and high percentage of severely rusted areas • Paint Condition Rating of 8-Minor spots of deterioration or cracking with virtually all of the paint system intact, no peeling and a few minor rust spots • Extent Condition Rating of 4 or Less over 60% of the Bridge= Full Paint (Example –if we see rust on the bottom flange and rust pitting on the webs-full paint)

Choosing Paint Projects – Bridge Preservation

Spot/ Zone Candidates: • Condition Rating of 4 or Less just at the joints or beam ends and age of paint less than 30 years and the rest of the bridge Condition Rating of 8= spot and zone paint

• Extent Rating of 4-Blast cleaning needed for a zone which is 20-40% of the steel area Paint Colors – Pittsburgh Golden Triangle Paint Colors

• In the 1920s and 1930s,the architecture and the painting of bridges was controlled by the City of Pittsburgh Art Commission,which along with Allegheny County, built most of the bridges in the Pittsburgh area • After the Great Depression and WW2,PennDOT took over ownership of the bridges and for many years we used 4 basic colors:Green(Antique Bronze),Blue(Azure Blue),Gray,Gold(Aztec Gold) • Today,the colors are chosen by DE,ADE and myself. The DE likes to chose the colors for an Interstate Coridoors and major bridges Paint Colors

• The DE also wants to coordinate with other buildings in the area(Bridge Unit does some of this initial investigation • The DE will let me choose the colors on less visible areas.Besides using paint, we have also done metallizing and galvanizing Paint Colors - Fort Duquesne Bridge

(BMS#’s 02-0279-0008-0425, 02-0279-0009-2108)

AZTEC GOLD Paint Colors - 31st Street Bridge

(BMS# 02-2122-0010-0025)

31ST BLUE Paint Colors - SR 28 over SR 8

(BMS# 02-0028-0141-0000)

(AZURE BLUE) Paint Colors - Birmingham Bridge

(BMS# 02-2085-0010-0586)

ANTIQUE BRONZE Paint Colors - Bedford Ave over I-579

(BMS# 02-8078-0030-0018)

(PENNDOT ORANGE) Paint Colors - SR 4049 Nicholson Rd

(BMS# 02-4049-0060-0175)

NAUTILUS Polynox Example - SR 136 over SR 51

(BMS# 02-0136-0110-0092)

(COTTON WHITE) Homestead Grays Bridge

(BMS# 02-7301-3047-2392)

GRAY Smithfield Street Bridge

(BMS# 02-3027-0020-0000)

(MATCHED 1883 ORG COLOR SCHEME) Contract Items

– Length of Contract – Constructability – Blasting Painting Sequence – Blast/ Steel Repairs/ – Coating Types-Paint Types – Highlights From Pub 408 Construction Specs Contract Items – Length of Contract

• Generally the contract time on a project involving painting is based on the amount of structural work that needs be done in a given construction season. • This is not the case for a major bridge preservation job like the upcoming Birmingham Bridge project (estimated cost $33 million) – which includes full paint, concrete and steel repairs, rocker bearing replacements. While not a stand - alone paint painting job, the painting operation will control most of the schedule. Contract Items - Constructability

• Usually on these big projects we hire painting consultants like KTA Tator to work out the type of equipment to be used, the construction schedule based on traffic restrictions, where equipment can be placed during certain phases and conceptual containment ideas. • Example-rapid deployment on Birmingham Bridge over the Parkway East (I 376 East)-where we have limited night time work windows over Parkway to do the work. As a result, we will have 20 + overnight lane closures.

Contract Items – Blasting /Painting Sequence

• In addition, we insist in the first year of the project, that the painting contractor blast and prime the steel plus do steel repairs prior to doing the intermediate coat. • This is so we don’t have to redo the intermediate finish/ final coats of paint in the second year. All these things are taken into account when developing the final schedule

Contract Items – Coating Types

• Field Painting: organic zinc primer, epoxy intermediate coat, and urethane finish coat.

• Shop painting: Inorganic zinc rich primer, epoxy intermediate coat, and urethane finish coat.

• Maintenance Treatments – Polynox – SR 136/51 / Termrust – Elizabeth Bridge

Contracts – Highlights from Pub 408 (Construction Specs)

• Highlights from Pub 408 PennDOT's Construction Specs.- we have requirements for pollution controls, surface prep, weather conditions, paint mixture and types of painting(roller, spray, brush) .

• Specifically:

• Submittals and approvals for the paint itself • Pollution control

Contracts – Highlights from Pub 408 (Construction Specs)

• Surface prep • Conditions for painting:Moisture • Application Methods – Spray – Roller – Brush painting • Payment – lump sum

Contract Items – for Worker Health

• Exposure monitoring and Hygiene Facilities are required for toxic metals • Hygiene Facilities (showers, hand washing stations, etc.) are required when the Permissible Exposure Limits are exceeded for any of the identified toxic metals, i.e. lead, arsenic, cadmium.

Contract Items – Containment Examples

SR 376-B01 Contract Items – Containment Examples

Beaver-Rochester Contract Items – Containment Examples

Ambridge-Aliquippa Rapid Deployment – California Ave over SR 65 Rapid Deployment – California Ave over SR 65 Rapid Deployment – California Ave over SR 65 Maintenance Painting – Carboline SR136 over SR51

1. One coat of Carboline Rustbond (i.e. primer for bare steel and existing intact/tightly adhered paint)

2. One coat of Carbomastic 90 (mid coat)

3. One coat of Carbothane 134HS (finish coat and final color to match existing finish)

Maintenance Painting – Carboline SR136 over SR51 Surface prep and application consisted of the following: 1. Pressure wash the zones to remove all loose paint, rust and chlorides. 2. Remove the chlorides to the levels described in Section 1070.3(c)7. 3. Remove all loose mill scale, loose paint and loose rust in accordance with SSPC SP2 Hand Tool Cleaning and SP3 Power Tool Cleaning.

Maintenance Painting – Carboline SR136 over SR51

Surface prep and application consisted of the following continued: 4. Within your “zone” (for example 5’ zones at all joints) apply one coat of the penetrating epoxy pre-primer, followed by an epoxy mid- coat and a urethane • There was no warranty offered with this product. The only company who offered a warranty was polynox, but we aren't able to use their product due to Materials issues.

Maintenance Painting - Before and After with Carboline

Before Carboline 2011 After Carboline 2014 Termarust

• Test coat was applied March 2012 • Termarust provided 5 gallons as a free trial • Used Termarust Series 2000 High Ratio, Co-Polymerized, Calcium Sulfonate Coating System • Prior to application the area was tested for chlorides and washed with a Chlor*Rid product. • Coating was applied with a brush • Step by step: pressure wash, scrape existing rust, dry the area, chloride wash, dry, apply coating (2 hour process) • 2014 field view revealed that surface deterioration is coming through the Termarust.

Maintenance Painting: Termrust Example - Elizabeth Bridge

(BMS# 02-0051-0110-0000) Picture Descriptions

• 2012 – Picture 1 –view of the gusset before paint,Picture 2 &3– shows the amount of crevice corrosion that has accumulated – Picture 4 – Craig Ballinger (Termarust) scraping rust off the gusset – Picture 5 – heat drying – Picture 6 – Regis Doucette (Chlor*Rid) applying the chloride treatment – Picture 7 – same area as Picture 2 after removing pack rust – Picture 8 – Application of Termarust,Picture 9 – finished product • 2014 – Picture 9 – overall view of gusset plate,Picture 10 – Crevice corrosion area

2012 Pictures 2014 Pictures

9 10 Termarust/Carboline Products –Bulletin 15

• Bulletin 15 is an approved list of products for PennDOT • These types of products don’t fit your typical paint system. We are in the process of writing specs to fit a maintenance type painting application Maintenance Painting: Termrust Example - Elizabeth Bridge In-House Painting – Sewickley Bridge

• In District 11 we only do small areas like the (Sewickley Bridge) truss members, beam ends or as part of a repair on other bridges. We have never fully painted a bridge In-House. • When using Macropoxy 646 (a fast cure epoxy) or Acrolon 218 (acrylic polyurethane) brush or roll on application may require multiple coats to achieve maximum film thickness and uniformity of appearance. • In District 11 when cleaning bridges in preparation of applying either an epoxy or a polyurethane paint we use Power Tools, < 1000 SF • An example of this type of painting was used on the Sewickley Bridge, located at the upstream truss members where a break down of paint was evident ≈ 1 month+ • After 6.5 years the paint appears to still be performing well In-House Painting – Sewickley Bridge

4.2 Bare Metal, Corners, and Edges - Macropoxy 646 Epoxy shall be applied to bare metal, corners and edges at a dry film thickness of 3 to 6 dry mils per coat. 4.3 Tie Coat over existing paint - Macropoxy 646 Epoxy shall be applied uniformly to all surfaces to be coated, including over the primer in Section 4.2 and over the existing intact paint, at a dry film thickness of 3 to 6 mils. 4.4 Finish Coat – Acrolon 218 Polyurethane Finish Coat shall be applied uniformly to all surfaces to be coated at a dry film thickness of 2 to 4 mils. 4.5 Alternate primers, tie coats, and top coats may be allowed according to the substrate to be painted and the original coating system. Consult Sherwin-Williams.

Sewickley Bridge Paint Assessment 2007

Before Painting Typical random area of paint loss with light surface rust or rust staining (from Typical (random) area of paint loss with 0’-25’ above the bridge deck) – 100sf light surface rust or rust staining total (Conservative Estimate)

BMS #02-4025-0010-0097 Inspection Date 2/21/2007 Sewickley Bridge Paint 2011

BMS # 02-4025-0010-0097 After Painting Performance Issues

• New painting right out of the shop-25 years before you start seeing rust. Examples include Birmingham, Neville Island. (Both bridges were built in 1976) Perfomance Issues

• Girder Bridges - we are generally getting 15- 20 years out of a paint projects (example: I-79 over Thoms Run Road) exceptions SR 51 over Parkway West

• Bridges with Multiple ply's like old trusses with built up members with pack rust like eye-bars, gusset plates, lacing bars, rivets, etc… have rust bleeding thru within 5 years at the areas just mentioned. With the paint lasting 10-20 years on main members (examples: Hulton and Elizabeth Bridges)

Performances Issues – New Bridges to 1st Paint

Paint Pictures from the year 2000 Birmingham Bridge 02-2085-0010-0586 Performances Issues – New Bridges to 1st Paint

Birmingham Bridge – 1998 Paint Condition Performances Issues – New Bridges to 1st Paint

Birmingham Bridge - 2006 Paint Condition Performances Issues – New Bridges to 1st Paint

Birmingham Bridge 2014 Paint Condition Performance Issues – Old Trusses

Hulton Bridge 02-2082-0010-0148 Performance Issues – Old Trusses

Hulton Bridge 1992 Performance Issues – Old Trusses

Hulton Bridge 1994 Performance Issues – Old Trusses

Hulton Bridge 1994 Performance Issues – Old Trusses

Rochester- Bridgewater Bridge inspection photo from 2011; Rehab was done in 2010 Amine Blush

• Amine Blush occurs at epoxy intermediate coat, causing the finish coat to not adhere properly to the second coat.The finish coat then comes off in spots within a couple years . • We have traced this problem to a moisture build up on the intermediate coat before the curing occurs. This moisture build up contributes to creating a film(Amine Blush) on the intermediate coat and does not permit the proper cure. • Paint manufacturers had to adjust their mixing instructions to allow cooking/ sweating (15 -30 min) of this intermediate coat so that it can accept the finish coat.

Amine Blush Pictures

• Ft. Duquesne • 31st Street • 28 SB over 8 Amine Blush

SR 28 over SR 8 Bridge Painting Costs-Full vs Spot/Zone

SR 79 over Thoms Shippingport Bridge Run Rd, Chartiers Flood Channel Bridge Painting Costs

• Costs below are illustrative of industry averages of around $12-18/SF for Bridge Painting in PA.

Cost/SF of Project Paint Extent Notes Painted Area Crosstown Blvd 9 Bridges in Full Paint $11.52 – Phase 1 estimate Zone Painting- Crosstown Blvd Total removal and 10 Bridges in $16.81 – Phase 2 replacement with estimate blast cleaning SR79 over Bid/construction Thoms Run Rd, Spot Painting $20 price Chartiers Creek Possibly high Shippingport Full Paint $17.88 cost/SF due to Bridge truss spans