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How Do We Program Paint Jobs?

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How Do We Program Paint Jobs? 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.
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