Specification for Road

Works Series 1900 -

Protection of Steelwork
Against Corrosion

CC-SPW-01900
June 2014

Construction &
CC Commissioning Standards
 TRANSPORT INFRASTRUCTURE IRELAND (TII) PUBLICATIONS

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TII Publication Title Specification for Road Works Series 1900 - Protection of Steelwork
Against Corrosion
TII Publication
CC-SPW-01900
Number

Activity Construction & Standards

Document Set
Commissioning (CC)
Stream Specification for Works Publication Date June 2014
(SPW)
Document 01900 Historical Series 1900
Number Reference

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Volume 1 Series 1900
Specification for Roadworks Protection of Steelwork Against Corrosion

PROTECTION OF STEELWORK AGAINST

CORROSION
Contents
Clause Title Page

1901 Introduction ............................................................................................................................3

1902 Surface Preparation – General Requirements.........................................................................3

1903 Surface Preparation – Materials and Methods........................................................................4

1904 Workmanship Standards for the Surface Preparation of Steel by Blast cleaning,
abrading, grinding and cleaning .............................................................................................7

1905 Workmanship Standards for the Surface Preparation of Coated Steelwork by Blast
Cleaning, Abrading, Grinding and Cleaning ..........................................................................8

1906 Procedures for Treatment at Joints .......................................................................................10

1907 Procedures for Treatment at Areas of Mechanical Damage or Other Surface Defects ........13

1908 Procedures for Treatment of Local Failure in Protective Coatings ......................................14

1909 Metal Coatings .....................................................................................................................15

1910 Testing of Thermally Sprayed Aluminium Metal Coatings .................................................16

1911 Paint and Similar Protective Coatings ..................................................................................17

1912 Testing of Paints ...................................................................................................................35

1913 Storage Requirements and Keeping Periods for Paints ........................................................37

1914 Application of Paint..............................................................................................................37

1915 Procedure Trials ...................................................................................................................40

1916 Storage and Transport of Steel and Fabricated Steelwork ...................................................41

1917 Surfaces in Contact with Concrete .......................................................................................41

1918 Form BE/P1 (New Works) Paint System Sheet (Appendix 19/1) Form BE/P2 Paint Data
Sheet (Appendix 19/3)..........................................................................................................42

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1919 Access and Lighting .............................................................................................................42

1920 Additional Requirements for the Protection of Steel in Bridge Bearings ............................42

1921 Additional Requirements for the Protection of CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms ...................................................................................42

1970 Maintenance Provision Introduction ....................................................................................44

1971 Maintenance Provision - Surface Preparation - General Requirements ...............................44

1972 Maintenance Provision - Surface Preparation - Materials and Methods ..............................45

1973 Maintenance Provision - Surface Preparation - Workmanship Standards ...........................48

1974 Maintenance Provision - Metal Coatings .............................................................................50

1975 Maintenance Provision - Testing of Metal Spray Coatings ..................................................51

1976 Maintenance Provision - Paint and Similar Protective Coatings ..........................................52

1977 Maintenance Provision - Surface Preparation and Protective Systems ................................52

1978 Maintenance Provision - Testing of Paints...........................................................................59

1979 Maintenance Provision - Storage Requirements and Keeping Periods for Paints ................61

1980 Maintenance Provision - Procedure Trials ...........................................................................61

1981 Maintenance Provision - Application of Paint .....................................................................62

1982 Maintenance Provision - Form BE/P1 (Maintenance) Paint System Sheet (Appendix
19/6) Form BE/P2 Paint Data Sheet (Appendix 19/3) .........................................................66

1983 Maintenance Provision - Access, Containment and Lighting ..............................................66

1984 Maintenance Provision - Additional Requirements for the Protection of CCTV Masts,
Cantilever Masts, Steel Lighting Columns and Bracket Arms .............................................66

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Specification for Roadworks Protection of Steelwork Against Corrosion

PROTECTION OF STEELWORK AGAINST

CORROSION
1901 Introduction
1 Whilst this Series is particularly relevant to the subject in its title it must be read in conjunction
with the general requirements in Series 000 and 100 and with all other Series relevant to the
specification for the particular Works to be undertaken. Clauses 1901 to 1921 shall be used for
surface preparation and protection of steelwork for new construction. Clauses 1970 to 1984 shall
be used for surface preparation and protection of steelwork for maintenance of existing structures.

2 Surface preparation and protection against corrosion of steelwork shall be carried out in
compliance with Clauses 1901 to 1921and where applicable Series 1800, Clause 1810 (Surface
Treatment), using systems appropriate to the information given in Appendix 19/1, Form BE/P1
(New Works) Paint System Sheet (parts 3, 4 and 5) and Appendix 19/2 if applicable, as
appropriate to the design and method of fabrication of the components.

3 The Manual of Paints for Structural Steelwork, which is included in NRA BD 35, provides data
on paints and similar materials. The Manual contains item numbers and a summary is also given
in Table 19/1.

4 Subject and without prejudice to the Conditions of Contract, the Contractor shall comply with any
measures to contain people, plant, materials, dust and debris described in Appendix 19/5.

5 Compliance with sub-Clause 4 of this Clause does not confer immunity from relevant legal
requirements.

1902 Surface Preparation – General Requirements

Workmanship and Site Work

1 Before blast cleaning or abrading steel surfaces or before overcoating painted or hot dip
galvanized surfaces, any contamination including by oil or grease shall be removed. Solvents
shall not be used.

2 Clean water which does not leave harmful residues on the surface shall be used for wet cleaning
and rinsing.

3 Only cleaning agents which are not harmful to the surface being cleaned and which do not leave
harmful residues on the surface after final rinsing shall be used for cleaning.

4 Surface preparation shall be continued until the required standard has been achieved.

5 Weld spatter shall be removed, in accordance with Series 1800, sub-clause 1807.5.17 if
applicable.

6 After dry surface preparation of internal surfaces and before any wet cleaning, all dust and debris
shall be removed from accessible areas by sweeping and vacuum cleaning.

7 Immediately before application of each coat of paint, the Contractor shall ensure that the surfaces:

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Specification for Roadworks Protection of Steelwork Against Corrosion

i) meet the required standard of preparation;

ii) are free from harmful residues and detrimental contamination, including water moisture
condensation, oil, grease, mortar, concrete, dust, grit paint degradation products,
chlorides and sulphides (See sub-clause 1904.7).

8 Joints, plies and fasteners shall be sealed in compliance with sub-Clauses 1906.27 and 28.

9 Coats of paint shall be free from embedded metallic or other foreign particles including metallic
dust. Deposits of adherent matter on metallic coatings or painted surfaces shall be cleaned off
immediately they occur. Coatings damaged in the process shall be restored.

10 The final workshop coats on external surfaces shall be wet cleaned on site.

1903 Surface Preparation – Materials and Methods

Dry Blast cleaning in the workshop

1 Metallic blast cleaning abrasives complying with IS EN 11124 or non-metallic blast cleaning
abrasives complying with IS EN ISO 11126 shall be used.

Grades for metallic abrasives shall comply with the following:

Profile (see sub-clause 1904.1) Grade

Fine G050 or S060
Medium G070 or S100
Coarse G100 or S120

2 The particle size of metallic abrasive in plant or equipment shall not exceed the maximum for the
relevant grade as specified above.

3 Before the start of blast cleaning and during blast cleaning the Contractor shall ensure that the
abrasive is free from matter which could leave detrimental contamination, as defined in sub-
Clause 1904.7, on the surfaces to be coated.

Abrading in the workshop or on Site

4 Any encrusted foreign matter or paint which may be difficult to remove by abrading alone shall
be dislodged by scraping, aided by hand or power wire-brushing. This work shall be completed
before abrading the areas so affected.

5 Abrading shall be carried out using abrasive paper or other material or a flexible abrasive disc
mounted on a power driven flexible pad, or a power driven arbor or spindle-mounted flexible
abrasive flap wheel. Abrading tools may be used to remove weld spatter. Wet abrading may be
employed for the preparation of finishes over sound undercoats, over unsound systems over hot
dip galvanizing, or hot dip galvanizing. Wet abrading shall not be allowed to come into contact
with exposed thermally sprayed metal coatings.

6 All equipment including tools, abrasive sheets, abrasive discs and abrasive wheels shall be of a
type, capacity and in a condition appropriate for the work. The use of hard grinding wheels for
abrading shall not be permitted.

7 A polished appearance caused by polishing in of paint, rust or dirt shall not be acceptable.

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8 Areas of previously corroded steel or unsound metal coatings, except hot dip galvanizing, which
have been prepared by abrading down to bright steel or bright metal coating, and blast cleaned
where appropriate, shall be protected by the primer and next coat of paint before any cleaning
down or preparation of adjacent surfaces.

Wet cleaning in the workshop or on Site

9 Wet cleaning shall be carried out by scrubbing with a stiff-bristled brush using water and a
cleaning agent or a pressure washer. Immediately after cleaning, the surfaces shall be thoroughly
rinsed.

Dry cleaning in the workshop or on Site

10 Surfaces shall be cleaned by scrubbing with a dry stiff-bristled brush.

Dry Blast cleaning on Site Using Dry air/ abrasive System

11 Metallic abrasives shall comply with sub-Clauses 1, 2 and 3 of this Clause. Metallic grit or
aluminium oxide abrasive shall be used for dry blast cleaning of relatively small areas on site
which are to be thermally sprayed aluminium metal coating, such as at site welds, at areas
prepared to clean steel or areas where a thermally sprayed aluminium metal coating is to be
restored, as indicated in sub-Clause 1905.3(i). The Contractor shall ensure that the grade and
particle shape of non-metallic abrasives are adequate for the purpose intended. Excepting for
aluminium oxide, non-metallic abrasives shall not be recycled.

Wet Blast cleaning Using low Pressure air/ water/abrasive System on Site

12 Unless otherwise specified in Appendix 19/5 a low-pressure air/water/abrasive system shall be

used. The air/water pressure at the nozzle shall not exceed 7.0 kgf/cm² and shall be fully
adjustable below this level. The system shall incorporate a mechanical metering device remote
controlled by the operator from the nozzle to enable him to regulate from zero to maximum the
quantity of non-metallic abrasive being fed into the air/water mixture. During abrasive cleaning,
the air, water and abrasive shall be thoroughly mixed and this mixture shall be projected on to the
surface to be cleaned through a single bore nozzle or tube. The use of an inhibitor during wet
blast cleaning or washing shall not be permitted.

Wet Blast cleaning using High Pressure water/abrasive System or Ultra High Pressure water
System on Site

13 Unless otherwise specified in Appendix 19/5, the water pressure shall not exceed 562 kgf/cm2 for
high pressure or between 1750 and 2860 kgf/cm2 for ultra-high pressure. The system shall
incorporate a mechanical metering device controlled by the operator at the nozzle, to regulate
from zero to maximum the quantity of non-metallic abrasive being fed into the water.

14 Within 60 minutes of wet blast cleaning, the whole of the cleaned surface shall be thoroughly
washed using the blast cleaning equipment with air and water. Any further deposits of abrasive on
already rinsed surfaces shall be removed in a similar manner also within 60 minutes of being
deposited. All accumulated deposits of abrasive and debris on other parts of the structure shall be
removed by the same method before the end of the working day. After washing, the surfaces shall
be free from all detrimental contamination. Tests for freedom from detrimental contamination
shall be made after the washing.

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Combined wet/Dry Blast cleaning on Site

15 Wet blast cleaning using the low pressure air/water/abrasive system (in compliance with sub-
Clauses 12 and 14 of this Clause) shall be followed, after a minimal interval, by dry blast cleaning
in compliance with sub-Clause 11 of this Clause, of all the previously wet blast cleaned areas.

16 The specified standard of surface preparation shall have been achieved in full, initially by wet
blast cleaning and washing, before any later dry blast cleaning of the same areas to remove flash
rusting or to restore the required standard of surface preparation.

Other Requirements

17 When surface preparation is to be carried out by dry blast cleaning and, on adjacent surfaces, by
wet cleaning and or abrading, then unless otherwise necessary, the wet cleaning and any abrading
shall be carried out first.

When combined wet/dry blast cleaning has been specified instead of dry blast cleaning only, the
above sequence may be reversed. On completion of the wet blast cleaning part of the process, the
areas to be abraded shall be cleaned in compliance with sub-Clause 9 of this Clause except that
for rinsing, the wet blast cleaning equipment may be used. The dry blast cleaning part of the
process, and dry abrading shall be carried out after any wet abrading required and final rinsing.
Any prepared dry metal surface shall be protected from the effects of any further wet method of
surface preparation by the application of a minimum 75 microns dry film thickness of paint.

Grinding after Surface Preparation in the workshop or on Site

18 Grinding wheels and discs shall be of the size, shape and grade of coarseness appropriate to the
particular operation. The speed of revolution shall be appropriate for the work.

19 Grinding shall be carried out after surface preparation by other methods, including cleaning
down, has been completed, except where it is necessary to achieve a blast profile and this would
necessitate blast cleaning after grinding.

20 Surfaces prepared by grinding to bright steel shall be protected by the application of the primer
and the next coat of paint, including any stripe coats, before cleaning down or other preparation
of adjacent surfaces specified in Appendix 19/5 is undertaken.

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1904 Workmanship Standards for the Surface Preparation of Steel by Blast

cleaning, abrading, grinding and cleaning
1 The surface profile to be achieved by blast cleaning, either ‘Fine’ ‘Medium’ or ‘Coarse’ as
appropriate, shall be within the limits set by the Surface Profile Comparator for the Assessment of
Abrasive Blast Cleaned Surfaces, conforming to IS EN ISO 8503-1.

2 Blast cleaned surfaces shall be virtually free from sharp spikes of parent metal defined as ‘rogue
peaks’ formed by the impact of abrasive particles and which project above the blast cleaning
profile. Any ‘rogue peaks’ which would be detrimental to the protective system shall be removed.

3 ‘Hackles’ and inclusions caused by the rolling process, visible after blast cleaning, which would
be detrimental to the protective system, shall be removed. Affected surfaces shall be prepared by
grinding or abrading to bright steel in compliance with sub-Clause 1907.1. Sharp edges shall be
rounded to a radius of not less than 3mm, in accordance with Series 1800, 1810.2 if applicable. If
thermally sprayed aluminium metal coating is to be applied the surfaces shall then be blast
cleaned.

4 Steel surfaces to be prepared by any of the methods described in the Contract shall be such that
after surface preparation the surfaces are free from detrimental contamination.

5 Surface preparation by blast cleaning shall be to one or more of the following standards of visual
cleanliness:

i) Sa3 to IS EN ISO 8501-1

ii) Sa2½ to ‘IS EN ISO 8501-1

6 Additionally, after surface preparation by blast cleaning to Sa3 or Sa2½ quality the surface profile
shall be virtually free from embedded abrasive particles when viewed through a 10X illuminated
magnifying glass. Surfaces assessed as unsatisfactory in this respect shall be blast cleaned again
with fresh abrasive. Another abrasive complying with the Specification may be used if necessary.

7 Harmful residues’ or ‘detrimental contamination’:

Surfaces shall be deemed to be free from ‘harmful residues’ or ‘detrimental contamination’ after
surface preparation when any such remaining matter will not be detrimental to the application,
adhesion, curing or reduce the required durability of the specified protective system.

8 Bright steel’:

Surfaces free from defects or prepared to this standard by grinding or abrading shall have an
overall bright appearance.

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1905 Workmanship Standards for the Surface Preparation of Coated

Steelwork by Blast Cleaning, Abrading, Grinding and Cleaning
1 Before overcoating, surfaces shall be free from:

i) any visible gloss;

ii) any unsound paint down to sound paint;

iii) any unsound paint down to Sa3 or Sa2½ quality steel;

iv) any unsound paint down to bright steel;

v) any unsound paint down to sound metal coating;

vi) any unsound paint down to bright metal coating;

vii) any unsound metal coating down to sound metal coating;

viii) any unsound metal coating down to bright metal coating;

ix) any unsound metal coating down to Sa3 or Sa2½ quality steel;

x) any unsound metal coating down to bright steel;

xi) detrimental contamination.

2 Definitions of terms used in describing the above standards of workmanship are as follows:

i) Sa3 or Sa2½ quality, as in sub-Clause 1904.5;

ii) ‘bright steel’, as in sub-Clause 1904.8;

iii) ‘free from detrimental contamination’, as in sub-Clause 1904.7;

iv) ‘bright metal coating’ resulting from abrading, a metal coating whose surfaces are free
from all corrosion products and of bright appearance overall;

v) ‘unsound metal coating’, a metal coating showing signs of disruption, inadequate

adhesion or penetration by rust or other corrosion products;

vi) ‘sound metal coating’, a metal coating which complies with sub-Clause 1909.2
including such a metal coating which has been blast cleaned but which has a reduced
thickness in accordance with sub-Clause 1908.1;

vii) ‘unsound paint’, paint showing signs of disruption, rusting through, having inadequate
adhesion or covering rust scale, loose rust, loose mill scale or other detrimental
products;

viii) ‘sound paint’, paint which is sound down to a metal substrate.

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3 Definitions of terms used in Clauses 1906, 1907 and 1908 are as follows:

i) ‘restored’ coatings. Unless otherwise described in Appendix 19/5, when paint or similar
coatings or thermally sprayed aluminium metal coatings are to be restored, the standard
of surface preparation and coating material shall comply with the original standard.
Damaged or failed paint systems over thermally sprayed aluminium metal coating shall
be restored using dry blast cleaning. The thickness of any underlying thermally sprayed
aluminium metal coating or paint coating which may have been reduced in thickness
during surface preparation shall be brought up to specification;

ii) ‘restored’ surface preparation. Unless otherwise described in Appendix 19/5, the
original standard shall be obtained. When further thermally sprayed aluminium metal
coating is to be applied, the surface of the existing thermally sprayed aluminium metal
coating shall be restored by dry blast cleaning with metallic grit abrasive or aluminium
oxide to metal coating;

iii) ‘local failure’. An isolated breakdown of a protective coating or system due to

extraneous causes excluding mechanical damage.

4 Permitted residual thermally sprayed aluminium.

When clean steel is exposed through a metal coating during remedial surface preparation,
remnants of sound thermally sprayed aluminium metal coating, which cannot be picked away
with a knife blade, may be retained within the blast clean profile.

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1906 Procedures for Treatment at Joints

Fasteners, Joint Material and Parent Material in Joints, Before Assembly or Welding, in the
Workshop or on Site

Fasteners, Including Bolts, Nuts and Washers

1 Surfaces of uncoated fasteners shall be free from all but traces of oil or grease before assembly.

2 Unless otherwise described in Appendix 19/5, threaded fasteners at joints in hot dip galvanized
steelwork or in hot dip galvanized steelwork which is to be painted, shall be hot dip galvanized.
Hot dip galvanized fasteners which are to be painted shall be treated with an adhesion promoter
as described in Table 19/2B.

3 Metal coatings on surfaces of fasteners which are to be painted shall be:

i) free from all traces of oil or grease and then treated with an adhesion promoter where
specified; or

ii) treated at the same time as the parent material where fasteners are already assembled in
compliance with sub-Clause 24 of this Clause.

Fasteners excluding those in (ii) above shall be pressure-rinsed with water and
allowed to dry before assembly or packing for delivery at least one hour and not
more than four hours after satisfactory application of adhesion promoter Item 155.

4 Fasteners which have become difficult to tighten because of corrosion shall be replaced.

Joint Material and Parent Material in Joints

5 The standard of initial blast cleaning of joint material and parent material in joints shall be at least
equal to that for the parent material. The standard of preparation and treatment of the friction
surfaces of joint material and parent material in slip resistant connections shall be as described in
Series 1800, 1810.1(5). Before a slip resistant connection is made, friction surfaces shall meet the
standard of preparation and treatment described in Series 1800, 1810.1(5).

At Preloaded Connections

6 In steelwork painted only overall:

The blast primer applied to the parent material shall be taken 10 mm to 15 mm inside the
perimeter of the joints. The outer surfaces and edges of site joint material may, at the option of
the Contractor, also be given a coat of the blast primer.

7 In steelwork with thermally sprayed aluminium metal coating at joints only, and painted overall:

The thermally sprayed aluminium metal coating shall be applied to the contact surfaces of the
joints and to the outer surfaces and edges of joint material. The thermally sprayed aluminium
metal coating on the contact surfaces of the parent material shall be taken 10 mm to 15 mm
outside the perimeter of the joints. The blast primer applied to the parent material shall be taken
10 mm to 15 mm inside the perimeter of the joints. The thermally sprayed aluminium metal
coating on the outer surfaces and edges of site joint material shall be given a coat of aluminium
epoxy sealer (Item 159).

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8 In steelwork with thermally sprayed aluminium metal coating overall and sealed only or painted
overall:

The thermally sprayed aluminium metal coating shall be applied to the contact surfaces of the
joints and to the outer surfaces and edges of joint material. The sealer applied to the parent
material shall be taken 10 mm to 15 mm inside the perimeter of the joints. The thermally sprayed
aluminium metal coating on outer surfaces and edges of site joint material shall also be given a
coat of aluminium epoxy (Item 159) sealer.

9 In steelwork hot dip galvanized only or hot dip galvanized and painted overall:

All material at joints shall be hot dip galvanized. When an adhesion promoter and a first
undercoat are applied before a joint is made they shall be taken 10 mm to 15 mm inside the
perimeter of the joint; these coats shall also be applied to edges and outer surfaces of the joint
material.

10 The thickness of a protective paint coat applied to the outer surfaces of joint material prior to
assembly of any preloaded shall not exceed 50 microns dry film thickness.

At Non Preloaded Connections

11 At workshop joints in all steelwork other than in hot dip galvanized steelwork the blast primer
alone or thermally sprayed aluminium metal coating plus sealer shall be applied initially to parent
and joint material.

Immediately before assembly of a joint which is to be painted the first undercoat shall be applied
to the contact surfaces and the joint made while the paint is wet.

12 At site joints in all steelwork other than in hot dip galvanized steelwork unless otherwise
described in Appendix 19/2, all surfaces except those of fasteners, shall receive in the workshop
the workshop protective system which is applied to the parent material.

13 At all joints in hot dip galvanized steelwork, an adhesion promoter and workshop coats may be
applied to the joint material before or after workshop joints are made. When hot dip galvanized
steelwork is painted on site an adhesion promoter and paint shall be applied to joint material after
the joint has been made.

At Welded Joints

14 At workshop and site joints in all steelwork, surfaces to be welded shall be restored to Sa2½
quality or to bright steel and shall be free of any protective or other coating immediately prior to
welding.

Parent Material, Workshop Treatment Adjacent to Joints Which are to be Assembled or Welded
Later on Site

At Preloaded Connections

15 The paint coats, with the exception of the primer or first coat of paint, shall be stepped back at 30
mm intervals commencing 10 mm from the perimeter of the joints.

At Non Preloaded Connections

16 Unless otherwise described in Appendix 19/5, workshop paint coats are not required to be stepped
back.

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At Welded Joints

17 Thermally sprayed aluminium metal coating shall be kept clear of the weld by a distance of at
least 15 times the thickness of the steel in the area to be welded, with a minimum of 150mm and
maximum of 300 mm from the joint. The restricted area shall be masked during metal spraying.
Hot dip galvanizing shall be removed a minimum of 5 mm back from the edges of weld areas.
Paint coats shall be stepped back at 30 mm intervals commencing at least 150 mm from the joint,
or from the edge of the thermally sprayed aluminium metal coating, starting with the 2nd coat of
paint.

At Completed Joints

18 Within 14 days of a joint being completed, exposed surfaces of parent and joint material shall be
prepared in compliance with sub-Clauses 19 to 23 of this Clause and fasteners in compliance with
sub-Clauses 24 to 26 of this Clause.

At Bolted Joints

19 In steelwork painted only overall, blast cleaned only or primed surfaces shall be prepared by dry
blast cleaning to restore or provide the required standard of surface preparation, for workshop or
site work as appropriate.

20 In steelwork with thermally sprayed aluminium metal coating at joints only, and painted overall,
primed or sealed thermally sprayed metal coatings shall be prepared by dry blast cleaning to
restore the surfaces to the required standard.

21 In steelwork with thermally sprayed metal coating overall, and sealed only or painted overall,
thermally sprayed metal coatings shall be prepared as described in sub-Clause 20 of this Clause.

22 In steelwork hot dip galvanized only or hot dip galvanized and painted overall the surfaces shall
be free from detrimental contamination by wet cleaning.

At Welded Joints

23 In all steelwork, welds shall be prepared by the methods and to the standards described in sub-
Clause 1911.6 (ii), 1911.7, 1911.9 or Appendix 19/2 for workshop or site work as appropriate.
Surfaces of areas adjacent to the weld shall be similarly prepared. For site welds in hot dip
galvanized steelwork, surfaces shall be treated in accordance with sub-Clause 1907.8.

Surfaces of Fasteners

24 Uncoated and temporarily coated fasteners shall be free from all but traces of oil and grease and
blast cleaned to Sa2½ quality, medium profile, before painting.

25 Fasteners, including those which have been treated with an adhesion promoter shall be dry
cleaned after final surface preparation of the joint and then painted.

26 Fasteners which are to receive thermally sprayed aluminium metal coating after assembly shall be
blast cleaned to Sa3 quality, medium profile, with chilled iron grit, cast steel grit or aluminium
oxide.

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Sealing at Joints or Plies

27 Bolted joints or built-up sections shall be free from any water which has penetrated the plies.

When drying out has been completed or when surfaces are dry after surface preparation, fine gaps
around the perimeter of joints or along plies shall be sealed by successive application of
undercoat paint. All wider gaps shall be sealed with a proprietary sealant compatible with the
paint system.

Sealing of Gaps at Nibs of Load Indicating Fasteners or Washers

28 Gaps shall be sealed by brush application of primer and successive undercoats, of the types used
on adjacent areas.

1907 Procedures for Treatment at Areas of Mechanical Damage or Other

Surface Defects
1 Score marks, other surface defects and indentations in the surface of a steel substrate or of a metal
coating shall be treated by abrading or grinding to bright steel or bright metal coating, to produce
a surface without sharp edges or abrupt change in contour. Damage to unprepared surfaces shall
be treated before blast cleaning. A blast cleaning profile shall be restored on areas to be thermally
aluminium metal sprayed but not necessarily areas to be painted only. Other surface defects in the
steel substrate, including fissures caused by the removal of ‘hackles’ or inclusions described in
sub-Clause 1904.3, shall be similarly treated.

2 In the case of damage to paint coatings only, surface preparation shall be by blast cleaning or
abrading. The paint coatings shall then be restored.

3 When a two-pack Epoxy paint system is restored over a steel substrate prepared by abrading, the
adhesion of the first paint coat to the substrate shall be checked in accordance with ASTM D4541
(type III) before overcoating with the next coat in the system. The first coat over abraded surfaces
shall be an aluminium epoxy (two-pack) primer (Item 115).

4 When an area of a thermally sprayed aluminium metal coating is to be restored after surface
preparation by abrading or grinding, any affected thermally sprayed aluminium metal coating or
exposed steel substrate shall be dry blast cleaned immediately before further application of
thermally sprayed aluminium metal coating.

5 In the workshop, a damaged thermally sprayed aluminium metal coating, together with any
damaged sealer or paint coats, shall be restored.

6 On site, with the exception of the small areas, relative to the size of the component, permitted
under sub-Clause 7 of this Clause, a damaged thermally sprayed aluminium metal coating,
together with any damaged sealer or paint coats shall be restored but with a minimum thickness
of 150 microns of thermally sprayed aluminium metal coating.

7 On site, small areas of isolated damage in a thermally sprayed aluminium metal coating plus paint
system, need not be restored; after surface preparation in compliance with sub-Clause 1 of this
Clause, the thermally sprayed aluminium metal coating shall be replaced by 100 microns of the
first undercoats, omitting the sealer. Adjacent paint coats, excluding the sealer shall then be
restored over the repaired area.

8 In the workshop, in the case of hot dip galvanizing only, small isolated areas of up to 40 mm2,
and not exceeding 0.5% of the total surface area of the component, whichever is the lesser, may

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after surface preparation, be repaired with low melting point zinc alloy, providing that the total
area of any damage on a component does not exceed 0.5% of the total surface area of the
component. Components with damaged areas greater than the above limits shall be re-galvanized.

Isolated areas of damage larger than 40 mm² in hot dip galvanizing which is to be painted later or
which has already been painted may be repaired with low melting point zinc alloy after surface
preparation. Alternatively the whole of the affected area including exposed steel substrate shall,
after surface preparation, be overcoated with two coats of Zinc Rich Epoxy Blast Primer (Item
109), minimum dry film thickness of 50 microns each.

9 On site, surfaces of hot dip galvanized components found to have minor damage shall be prepared
in accordance with sub-Clause 8 of this Clause and coated with two coats of Zinc Rich Epoxy
Blast Primer (Item 109), minimum dry film thickness of 50 microns each. Alternatively, the
components shall be re-galvanized.

10 In all cases where paint coats only are to be restored, or thermally sprayed aluminium metal
coatings replaced or restored, or hot dip galvanizing is to be replaced by paint, the edges of paint
coatings or metal coating adjacent to the affected area shall be bevelled back into sound paint or
metal coating. This work shall be carried out before any final blast cleaning described in sub-
Clause 4 of this Clause.

11 In the workshop exposure and overcoating times shall not exceed those specified in Clause 1914.
On site overcoating shall be started immediately after surface preparation of the affected area and
before any deterioration in the standard of the prepared surface occurs, and continued as soon as
each coat is dry enough for overcoating.

1908 Procedures for Treatment of Local Failure in Protective Coatings

1 In the workshop, failed paint coatings and failed thermally sprayed aluminium metal coating shall
be restored. Abrading down to sound paint only is permissible. If a thermally sprayed aluminium
metal coating is damaged or reduced to less than 80% of the specified minimum thickness during
abrading, it shall be restored.

2 On site, failed paint coatings and thermally sprayed aluminium metal coatings shall be restored
except that:

i) abrading down to sound paint or to bright steel; or

ii) blast cleaning to Sa2½ quality

are permissible methods of surface preparation when restoring paint systems over a steel
substrate.

3 In the workshop and on site, hot dip galvanized components showing signs of failure, e.g. blisters
and rust, of the coating shall be re-galvanized.

4 In the workshop and on site, failed paint coatings over hot dip galvanizing shall be restored.
Surface preparation of affected areas shall be by abrading. Areas of sound hot dip galvanizing
exposed through a paint system shall be abraded only as necessary to ensure satisfactory
application of an adhesion promoter and paint. If the hot dip galvanizing is damaged or reduced to
less than 80% of the specified minimum thickness during abrading, the component shall be re-
galvanized.

5 Sub-Clauses 1907.3, 4, 10 and 11 shall be complied with.

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1909 Metal Coatings

Hot Dip Galvanized Coatings

1 Hot dip galvanized coatings shall, unless otherwise described in Appendix 19/5, comply with IS
EN ISO 1461 and with the following:

i) Inhibited hydrochloric acid with a strength not exceeding 18% and within a temperature
range of 15ºC to 25ºC or inhibited sulphuric acid with a strength not exceeding 18% and
within a temperature range of 60ºC to 80ºC shall be used for pickling.

ii) Components shall not be immersed in the pickling acid longer than is necessary for
cleaning the surfaces prior to hot dip galvanizing. Components shall receive a fresh
water rinse between pickling and the galvanising bath.

iii) The surfaces of components to be hot dip galvanized shall be dried before immersion in
the molten zinc.

iv) When an aqueous flux is to be used, all traces of acid shall be washed off immediately
after pickling.

v) Hot dip galvanized coatings shall be relatively smooth, continuous and free from flux
staining.

vi) Detrimental contamination of hot dip galvanized coatings which are to be painted shall
be removed by wet cleaning in compliance with sub-Clause 1903.9. Surfaces to be
painted shall not receive chromate passivation treatment.

vii) Vent holes drilled in hollow sections prior to hot dip galvanizing shall be plugged after
hot dip galvanizing and before any painting in accordance with Series 1800, 1810.5 if
applicable.

viii) The contractor shall take measures to minimise the potential for liquid metal assisted
cracking occurring during the galvanizing process and to identify any cracks that may
have occurred in galvanized steelwork.

Thermally Sprayed Aluminium Metal Coatings

2 Thermally sprayed zinc metal coatings are not advised for road structures and are prohibited as a
protective system. Thermally sprayed aluminium metal coatings shall comply with IS EN ISO
2063 and with the following:

i) Aluminium coating shall have a composition complying with IS EN ISO 14949-3.1.

ii) The thickness of the coating shall be not less than 100 microns.

iii) The strength of adhesion of thermally sprayed aluminium metal coatings shall not be
less than the following:

Aluminium 50 kgf/cm²

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iv) Thermally sprayed aluminium metal coatings shall be applied continuously over each
0.5 m² per gun or the area of the component whichever is the lesser until the specified
thickness has been achieved.

v) The application of thermally sprayed aluminium metal in separate layers shall not be
permitted.

vi) All surfaces to be thermally metal sprayed, including that of the reference panel having
equivalent hardness to that of the parent material, shall be blast cleaned with chilled iron
grit or high carbon cast-steel grit with a hardness value greater than 650 HV, or
aluminium oxide with a hardness value greater than 9 Mohs, and the standard shall be
Sa3 quality, medium profile.

vii) Thermally sprayed aluminium metal coatings shall be de-nibbed.

Other Requirements

3 When a metal coating is required on only part of a component it shall be applied before the rest of
the component receives paint.

1910 Testing of Thermally Sprayed Aluminium Metal Coatings

1 At the start of the Works, and subsequently at intervals scheduled in Appendix 1/5 (with the
exception of coatings on steel in bearings, curved surfaces, repairs to mechanical damage, local
failure of thermally sprayed aluminium metal coating at site joints or areas restored on site), the
Contractor shall demonstrate by means of a pull-off adhesion test in accordance with ‘ASTM
D4541-Type III’, that the minimum adhesion requirement is being attained as detailed in sub-
Clause 1909.2 (iii).

In the excepted areas, the Contractor shall demonstrate that the adhesion is satisfactory by means
of grid tests in accordance with IS EN ISO 2063. Areas affected by the tests shall be restored in
accordance with Clause 1907.

2 The pull-off adhesion tests shall be carried out initially on flat panels 150 mm x 150 mm x 6 mm
which are of the same grade of steel as the parent material and which before blast cleaning had
the same surface condition. The panels shall be blast cleaned and thermally aluminium metal
sprayed together with the parent material to the same standard and using the same technique.

3 The Contractor shall ensure that adhesion tests have been carried out satisfactorily before any
further work continues.

4 If the adhesion requirement on any test panel is not met, the Contractor shall carry out a further
test on the parent material adjacent to the panel position. In the case of adhesion failure on the
steelwork itself by either method of test, unsound thermally sprayed aluminium metal coating
shall be restored and the tests repeated.

5 If more than two local areas of faulty adhesion occur on any one component, the whole of the
thermally sprayed aluminium metal coating on the component shall be considered as having
failed, and it shall be restored. Sub-Clause 1905.4 is not applicable in the case of adhesion failure.

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1911 Paint and Similar Protective Coatings

General

1 The term paint shall be deemed to refer to protective coatings in general.

2 The paints permitted for use in the Works are listed in the Manual of Paints for Structural
Steelwork which is included in the NRA BD 35 and which also contains details of the quality
assurance scheme for paints and similar protective coatings. All paints shall have a NSAI
Agrément Certificate, BBA HAPAS Roads and Bridges Certificate or equivalent appropriate to
the use of the paint in the proposed system in accordance with NRA BD 35.

3 All paints shall be supplied in sealed containers of a capacity suitable for the volume and method
of application. For sitework, all paints shall be supplied in sealed containers of not more than 25
litre capacity. The capacity of the containers to be used shall be confirmed as being suitable as
part of the Procedure Trials described in Clause 1915. All containers shall be used in order of date
of manufacture and batch number, the oldest being used first. Each container shall have a
completely removable lid and be clearly marked on the side to show the name of the
manufacturer, registered description of the material (including purpose, e.g. whether primer,
undercoat or finish), colour, Item No, paint manufacturer’s reference number, batch number and
date of manufacture. Where date of manufacture is coded, the Contractor shall provide the code
key. In addition paints shall be supplied in sealed containers of no greater than 5 litre capacity for
testing purposes in accordance with Clause 1912, for ‘A’ samples.

4 The Contractor shall ensure that the properties of the paints he has selected are suitable for the
atmospheric conditions in the workshops and on site, including temperature and humidity, and
that he is able to apply the paints satisfactorily to all parts of the structure in these conditions.

5 Unless otherwise described in Appendix 19/5, all paints forming any one protective system or
overlapping systems shall be obtained from the same manufacturer, as named by the Contractor in
Appendix 19/1 Form BE/P1 (New Works) Paint System Sheet.

Surface Preparation and Protective Systems for Steelwork (except Bearings, CCTV Masts,
Cantilever Masts and Steel Lighting Columns and Bracket Arms)

6 Protective systems

Note: mdft = minimum dry film thickness

B = apply by brush

AS = apply by airless spray

HB = High Build (dft: above 75 µm per coat)

NB = Normal Build (dft: between 50 and 75 µm per coat)

LB = Low Build (dft: below 50 µm per coat)

i) Item numbers in the Protective Systems are listed in the Manual of Paints for Structural
Steelwork at Annex A of NRABD 35 and a summary is shown in Table 19/1.

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ii) Details of Surface Preparation and Protective Systems for Steelwork Except Bearings,
CCTV Masts, Cantilever Masts and Steel Lighting Columns and Bracket Arms are
given in Table 19/2A and 19/2B.

Surface Preparation and Protective Systems for Steel in Bridge Bearings (and Metal Coated
Fasteners)

7 Details of surface preparation are given in Table 19/3A and the protective system Type V is given
in Table 19/3B.

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TABLE 19/1: NRA BD 35 Quality Assurance Scheme for Paints and Similar Protective Coatings
Annex A Manual of Paints for Structural Steelwork
Current Paint Item Numbers
Item Description Coat Type Build Applied by
109 Zinc Rich Epoxy Blast Primer (two pack) Blast Primer LB or NB B or AS
(B to small areas only)
110 Zinc Phosphate Epoxy (two-pack) Blast Primer/Sealer LB B or AS
(B to small areas only)
111 Zinc Phosphate High Build Quick Drying Blast Primer HB AS
Epoxy (two-pack) (B to small areas only)
112 MIO High Build Quick Drying Epoxy Undercoat/Finish HB AS
(two-pack)
113 Water based epoxy primer for blast cleaned Primer HB B or AS
internal surfaces (two-pack)
114 Water based epoxy undercoat/sheen finish Undercoat/Sheen Finish HB B or AS
for internal use (two-pack)
115 High Build Aluminium Epoxy (two-pack) Surface tolerant HB B or AS
maintenance (e.g. for
abraded surfaces)
116 High Build Epoxy (2-pack) Surface tolerant HB B or AS
maintenance undercoat
121 Extended Cure Epoxy MIO (two-pack) Primer, Undercoat and/or HB AS (B to small areas
Finish only)

123 High Build Glass Flake Epoxy (two-pack) Undercoat for blast cleaned HB AS (stripe coats and
steel new construction small repairs only by
brush)
155 ‘T’ Wash Adhesion promoter for hot HB B
dip galvanised steel
157 Adhesion promoting (single-component) To promote substrate LB B or AS
adhesion properties of
coating systems for hot dip
galvanised steel, aluminium
and stainless steel surfaces
159 Aluminium Epoxy (two-pack) Sealer/Primer LB B or AS
160 Red Oxide Moisture Cured Polyurethane Primer/Blast Primer for LB B or AS
(single-component) maintenance or new works
162 MIO Moisture Cured Polyurethane Undercoat/Finish NB or HB B or AS
164 Moisture Cured Polyurethane (single- Semi-gloss Finish LB B
component) NB AS
167 Epoxy Acrylic Finish (two-pack) Gloss of Semi-gloss Finish NB B (small areas by brush)

168 Polyurethane (two-pack) Gloss Finish LB B

NB AS
169 Polyurethane (two-pack) Semi-gloss Finish NB B (small areas by brush)
HB AS
185 Organic Modified Polysiloxane (two-pack) Gloss Finish for new works NB B
or maintenance HB AS

200 Grease Paint Primer B

(AS for difficult access
areas)
201 Grease Paint Undercoat/Finish HB B or AS

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Notes:
1 Colour reference shall be as per the manufacturer’s declared colour given with reference to BS 4800 and/or BS 381C
where appropriate.
2 Dry Film Thickness (dft) range shall be as per the manufacturer’s data sheet. The minimum dry film thickness of the
paint coats and paint system shall be as per the protective systems detailed in Tables 19/2 to 19/4 where given.
3 All materials to be handled and applied in accordance with the manufacturers Product and Health & Safety Data Sheets.

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Table 19/2A Requirements for Bridges, Parapets and Other Road Structures (except Bearings,
CCTV Masts, Cantilever Masts and Steel Lighting Columns and Bracket Arms)

Surface Preparation and Protective Systems

Surface Preparation Protective systems

(given in Table 19/2B)
(i) Bridge steelwork, fabrication stage
Area Description Method Surface Standard Type
Area A Blast clean Sa3, Medium profile I for Inland Ready Access
Exterior main surfaces, II for Inland Difficult Access,
including shop welds Marine Ready or Difficult Access
Area B Blast clean Sa2½, Medium III
Interior of box girder surfaces, profile
except area C, but including
shop welds
Area C As described in Series 1800, As described in As described in Series 1800, 1810.1
Friction surfaces of parent 1810.1 (5) Series 1800, 1810.1 (5)
material at slip resistant (5)
connections
Area D Friction surfaces: As Friction surfaces: As Friction surfaces: As described in
Friction and outer surfaces of described in Series 1800, described in Series Series 1800, 1810.1 (5)
joint material at slip resistant 1810.1 (5) 1800, 1810.1 (5)
connections.
Outer surfaces: Blast clean Outer surfaces: Sa3, Outer surfaces: I for Ready Access
Medium profile II for Inland Difficult Access,
Marine Ready or Difficult Access
(ii) Bridge steelwork, erection stage
Area E Remove slag, wire brush, Sa3, Medium profile I for Ready Access
Exterior surfaces of site welds wet clean and blast clean as II for Inland Difficult Access,
and weld affected areas Area A Marine Ready or Difficult Access
Area F
Interior surfaces of site welds Remove slag, wire brush Sa2½, Medium III with additional coat of primer
and weld affected areas and wet clean profile
(iii) Parapets.
Area G
All surfaces, subject to Pickling for hot dip In accordance with IV
accessibility galvanizing Clause 1909

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Table 19/2B Requirements for Bridges, Parapets and Other Road Structures (except Bearings,
CCTV Masts, Cantilever Masts and Steel Lighting Columns and Bracket Arms

Protective Systems

Type Metal 1st 2nd 3rd 4th Coat Minimum total dry
Coating Coat Coat Coat film thickness of the
paint system
(microns)
I Item No 109 112 167, 275 (325 if Item 185
168, 169 finish is specified)
or 185
Min dry film thickness 50 125 50 or
per coat (µm) 100*
Item No 111 112 167, 300 (350 if Item 185
168, 169 finish is specified)
or 185
Min dry film thickness 75 125 50 or
per coat (µm) 100*
II Item No 109 112 112 167, 400 (450 if Item 185
168, 169 finish is specified)
or 185
Min dry film thickness 50 125 125 50 or
per coat (µm) 100*
Item No 110 123 167, 525 (575 if Item 185
168, 169 finish is specified)
or 185
Min dry film thickness 25 400 50 or
(µm) 100*
Item No 111 112 112 167, 425 (475 if Item 185
168, 169 finish is specified)
or 185
Min dry film thickness 75 125 125 50 or
(µm) 100*
III Item No 109 112 200
Min dry film thickness 50 125
per coat (µm)
Item No 111 112 225
Min dry film thickness 75 125
per coat (µm)
Item No 113 114 225
Min dry film thickness 100 100
per coat (µm)
IV Item No Hot dip 155 or 110, 112 or 167, 168 2nd Coat Item 110: 225
galvanize sweep 112 or 121 169 or (275 if Item 185 finish
blast 121 185 is specified)
Min dry film thickness 25 (Item 125 50 or
per coat (µm) 110) or 100* 2nd Coat Items 112 or
125 121: 350 (400 if Item
(Items 185 finish is specified)
112 or
121)

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Notes

Finish Coats
(i) *Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100µm
(ii) Type I, Type II and Type IV: A finish coat may need to be applied in the workshop to comply with the maximum coating
times for the preceding epoxy MIO undercoat (Item 112 or Item 121). In such circumstances an additional finish coat shall
be applied on site to meet the requirements of sub-Clause 1914.9. Prior to applying the additional finish coat on site any
damage to the paint system shall be restored in accordance with the requirements of Clause 1907 and the surface of the
workshop applied finish coat shall be prepared by light abrading and wet cleaning. The finish coats in Type I and II
protective systems above are either gloss coats (Item 168) or semi-gloss coats (Item 164). When a low sheen finish is
required, e.g. fascia of a sign gantry, the semi-gloss or gloss finish shall be replaced by Item 169.
(iii) Type I shall only be used when agreed in writing with the National Roads Authority.

Area D. Type II
(i) A type II system incorporating a metal coating of thermally sprayed aluminium metal, 1st coat Item 159 (12-20m2/litre), 2nd
coat Item 111 (mdft 75µm), 3rd coat Item 112 (mdft 112µm), 4th coat Item 167, 168, 169 (mdft 50µm) or 185 (mdft
100µm), with a total minimum dft of the paint system of 350µm (Items 167, 168 or 169) or 400µm (Item 185) may be used
for Area D outer surfaced only, where aluminium metal spray is identified as the required treatment of Area D friction
surfaces in Series 1800, 1810.5(5). Type II incorporating Item 123. The completed system shall be tested for pinholes
using a spark test over the whole of the coating area. The test current selected shall be in accordance with the coatings
dielectric strength and/or the coating thickness in accordance with ASTM G 62-87

(i) Parapets Type IV: For parapets to be erected in a Marine environment, 1st, 2nd and 3rd coats shall be applied in the
workshop; the 4th coat may be applied in the workshop or if within the intermediate coat overcoating time, on site. For
parapets in an Inland environment, all coats of paint may be applied in the workshop or on site.
(ii) Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance with IS EN ISO
12944-4 to surface roughness ‘fine’ in accordance with IS EN ISO 8503-2.

Fasteners
(i) Unless otherwise specified in Appendix 19/2, fasteners in steelwork shall be supplied with an anti-corrosive protective
coating comprising hot dip galvanizing in accordance with IS EN ISO 10684, or a similar alternative surface protection
treatment which has a current NSAI Agrément Certificate, BBA HAPAS Roads and Bridges Certificate or equivalent, as
an anti-corrosion protective coating for use on steel fixings intended for use on steel road structures. For such similar
alternative surface protection treatments, prior to commencement of the Works, the Contractor shall provide to the
Employers Representative a copy of the NSAI Agrément Certificate, BBA HAPAS Roads and Bridges Certificate or
equivalent, and the fasteners shall be installed and prepared prior to application of paint in accordance with the
requirements of the Certificate. Certification equivalence must be demonstrated to the satisfaction of the Employers
Representative and must be approved in writing.
(ii) Hot dipped galvanised fasteners in steelwork that is to be painted shall have surfaces that are to be painted treated with an
adhesion promoter (Item 155) before installation, or alternatively after installation, shall be cleaned with a solvent wipe to
remove all traces of oil and grease and be abraded with (coarse grade) abrasive paper to sufficiently roughen then exposed
galvanized surface in order to provide a suitable ‘adhesion key’ and be painted with a coat of either Item 110, Item 157 or
Item 160 as an adhesion promoter.
(iii) After the joints are made and fasteners have been treated with an adhesion promoter, fasteners shall be protected as
specified for the joint material.

Paint suppliers
Paints for any one system shall be obtained from the same manufacturer.

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TABLE 19/3A: Requirements for Steel in Bridge Bearings (and Metal Coated Fasteners)

Surface Preparation

Area Description Method: Surface Standard:

Area A
Exterior surfaces, excepting wearing surfaces Blast clean Sa3, Medium profile
but including a 25 mm minimum return on
areas of top bearing plates or base plates in
contact with grout or mortar

Area B
Central area of top bearing plates in contact Blast clean Sa2½, Medium profile
with grout or mortar

Area C
Areas of top bearing plates or base plates in Blast clean Sa3, Medium profile
contact with structural steel components

Area D
Exposed workshop fasteners in components Blast clean Sa3, Medium profile
to be coated after assembly

Area E No requirement
Concealed workshop fasteners No requirement

Area F
Site fasteners for fixing bearings to piers or Restore metal coating as Restore metal coating as necessary to
abutments and for fixing bridge components necessary to specified standard of specified standard of cleanliness
to bearings cleanliness

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TABLE 19/3B: Requirements for Steel in Bridge Bearings (and Metal Coated Fasteners)

Protective System Type V

Applied Metal Coating 1st Coat 2nd 3rd 4th Minimum total dry
over Coat Coat Coat film thickness of the
paint system (microns)
Area A Item No Aluminium metal 110 or 111 112 167, 275 (325 if Item 185
and D spray 159 168, finish is specified)
169 or
185
Min dry film 150 12-20 75 125 50 or
thickness per m2/litre 100
coat (µm)
Area B Item No 112 150
Min dry film 150
thickness per
coat (µm)
Area C Item No Aluminium metal 159
spray
Min dry film 150 12-20
thickness per m2/litre
coat (µm)
Area F Item No Hot dip Adhesion 110 121 or 167, 275 (325 if Item 185
galvanising promoter 121 168, finish is specified)
(see 169 or
Notes) 185
Min dry film 25 125 50 or
thickness per 100*
coat (µm)

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Notes
Finish Coats
*Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. 100µm.

Area A and D
(i) 4th coat for bearings for steel bridge beams, brush applied on site; colour to match finish on main steelwork
(ii) Aluminium metal spray plus Items 110 or 159 are required on interfaces of machined surfaces of spreader plates and of
bearing.

Areas A, B, C and D.
(i) Aluminium metal spray, Items 110 or 159, 111 and 112 shall be applied at the bearing manufacturer’s works. Item 167,
168, 169 or 185 shall be applied on site.
(ii) Items 110 or 159 shall not be over-applied and shall not be included in the overall thickness of the protective paint
system.

Area F
(i) Adhesion promoter: tem 155 shall be applied on site, either before or after erection, to surfaces to be painted. Item 155
coming into contact with adjacent paint coats shall be removed immediately. Alternatively after installation, surfaces to
be painted shall be cleaned with a solvent wipe to remove all traces of oil and grease and be abraded with (coarse grade)
abrasive paper to sufficiently roughen the exposed surface in order to provide a suitable ‘adhesion key’ and be painted
with a coat of either Item 110, Item 157 or Item 160 as an adhesion promoter. The remaining site coats shall be applied
to exposed surfaces after erection.

Stripe coats for bearings only:

(i) Area F: Stripe coats are not required for bearing site fasteners.
(ii) Area A and D: A single stripe coat in Item 112 paint shall be applied over Item 111 at the bearing manufacturer’s
works. A second stripe coat in Item 112 shall be applied on site. Item 112 coats shall be in contrasting shades, e.g.,
medium grey, natural grey.

Site Coats
(i) Site coats shall be applied by the Contractor.

Paint suppliers
(i) The requirements of Clause 1920 shall be noted.

Appendix 19/1
When completing Appendix 19/1, the appropriate finish paints shall be selected from the protective system. The letter
references, A, B, C etc. shall be varied as appropriate, and the application instructions arranged to suit.

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Surface Preparation and Protective Systems for CCTV Masts, Cantilever Masts, Steel Lighting
Columns and Bracket Arms

8 General

i) Details of protective systems A1, G1, A2a and G2a, A2b and G2b are given in Tables
19/4A, B & C.

ii) In the case of protective systems A2a and G2a, A2b and G2b the Contractor may opt to
apply the finishes in the workshop or, if within the intermediate coat overcoating time,
at site, unless otherwise specified.

iii) When a white or pale tint finish is specified, an additional finish coat may be required to
ensure full opacity us achieved, completely obliterating the Item 112 undercoat.

iv) Type A1, A2a and A2b protective systems are based on aluminium metal spray.

v) Type G1, G2a and G2b protective systems are based on hot dip galvanizing.

vi) Unless otherwise stated in Appendix 19/5 the nominal ground level adjacent to a mast
or column shall be assumed to be at a distance of 600 mm below the door opening. The
‘ground section’ of planted masts and columns shall extend from the bottom of the mast
or column to 250mm above the nominal ground level. The ‘ground section’ of flange
mounted masts and columns applies where the flange is below ground level or is built
over and shall extend from the bottom of the mast or column to 250mm above the
nominal ground level. The ‘upper section’ of a mast or column with a ground section is
the remainder of the mast or column above the ground section.

9 Protective system

TABLE 19/4A: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms Systems

System Environment Access

A1 Inland Ready
A2a and A2b Inland Difficult

Marine Ready or Difficult

G1 Inland Ready
G2a and G2b Inland Difficult

Marine Ready or Difficult

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TABLE 19/4B: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms Surface Preparation

System A1, A2a and A2b

Location Method Surface Standard
External surface:
Flange mounted and planted masts and Blast clean Sa3, Medium profile
columns, overall treatment.
Internal surfaces:
Flange mounted masts and columns, flange Blast clean where access allows Sa2½, Medium profile
to door area. or or
Planted masts and columns, ground section Hand tool preparation Bright Steel
to door area
System G1, G2a and G2b
Location Method Surface Standard
External and internal surfaces:
Flange mounted and planted masts and In accordance with Clause 1909 In accordance with
columns, overall treatment Clause 1909

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems

Type Metal 1st Coat 2nd Minimum total dry

Coating Coat film thickness of the
paint system
(microns)

A1 (i) External surfaces

Flange mounted and Item No Thermally 159 112* 125

planted masts and sprayed
columns, overall aluminium
protection plus 2nd coat metal
for ground section (See
1911.8(vi)) Application rate/ 125
Min dry film 12-20
thickness per coat m2/litre
(µm)

(ii) Internal surfaces

Flange mounted and Item No 110 112* 175

planted masts and
columns, protection Min dry film 25 125
applied from the bottom thickness (µm)
to 300mm above the door
opening

Notes
*Item 112 finish coat colour to be agreed with the NRA
Blast cleaning, thermally sprayed aluminium metal and all workshop paint coats on external surfaces shall be
returned on to edges at ends, at door and other openings and under base flange.
All paint coats shall be applied in the workshop.
Item 159 shall be overcoated within 96 hours.

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems (continued)

Type Metal 1st Coat 2nd Coat 3rd Coat Minimum total
Coating dry film
thickness of the
paint system
(microns)

A2a (i) External surfaces

Flange mounted and Item No Thermally 110 or 112 167, 168, 200 (250 if Item
upper section (See 1911.8 sprayed 159 169 or 185 finish is
(vi)) of masts columns, aluminium 185 specified)
overall protection metal

Application 125
rate / Min
dry film 12 – 20 50 or
thickness m2 / litre 100*
per coat
(µm)

Overall protection for Item No Thermally 110 or 112 112** 275

ground section (See sprayed 159
1911.8 (vi)) aluminium
metal

Application 125
rate / Min
dry film 12 – 20
125
thickness m2 / litre
per coat
(µm)

(ii) Internal surfaces

Flange mounted and Item No 110 112** 175

planted masts and
columns, protection Min dry 25 125
applied from the bottom film
Hot dipped
to 300mm above the door thickness
galvanised
opening. per coat
(µm)

Notes
* Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm.
**Item 112 finish coat colour to be agreed with the NRA
Blast cleaning, thermally sprayed aluminium metal and all workshop paint coats on external surfaces and site paint
coats where access permits shall be returned on to edges at ends, at door and other openings and under base flange.
All paint coats except finish coats shall be applied in the workshop. Finish coats may be applied in the workshop or,
if within the intermediate coat overcoating time, on site.
Item 110 or 159 applied over thermally sprayed aluminium metal shall be overcoated within 96 hours.
For external surfaces, the upper section finish coat shall overlap the ground section finish coat by 25mm.

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems (continued)

Type Metal 1st Coat 2nd 3rd Coat Minimum total

Coating Coat dry film
thickness of the
paint system
(microns)

A2b (i) External surfaces

Flange mounted Item No Thermally 110 or 159 111 112 225

and planted masts sprayed
and columns, aluminium
overall protection metal

Application rate / 12-20 75 125

Min dry film m2/litre
thickness per coat
(µm)

(ii) Internal surfaces

Flange mounted Item No 111 112 225

and planted masts
and columns, Min dry film 75 125
protection applied thickness per coat
from the bottom to (µm)
300mm above the
door opening.

Notes
Blast cleaning, thermally sprayed aluminium metal, and all workshop paint coats on external surfaces, and site paint
coats where access permits, shall be returned on to edges and 25mm inside at ends, at door and other openings and
under base flange.
Item 110 or 159 shall be overcoated within 96 hours.
The ground section (See 1911.8 (vi)) of masts and columns shall have an additional sacrificial steel section thickness
of a minimum 1.0mm, above that needed in the design. The additional thickness shall be recorded in which ever is
appropriate of the following: Part A of Appendix 13/2 – Typical Lighting Column and Bracket Data Sheet; Part A of
Appendix 13/5 – Typical CCTV Mast Data Sheet; Part A of Appendix 13/8 – Typical Cantilever Data Sheet.

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems (continued)

Metal 1st Coat 2nd 3rd Coat Minimum total

Type
Coating Coat dry film thickness
of the paint
system (microns)
(i) External surfaces
G1
Flange mounted Item No Hot dip 155 or 11 112 or 225 (at ground
and planted masts galvanize sweep 121** section)
and columns, blast
overall protection Min dry film 75 125
plus adhesion thickness (µm)
promotion and 2nd
and 3rd coats
protection for
ground section
(See 1911.8 (vi))
(ii) Internal surfaces

Flange mounted Item No Hot dip

and planted masts galvanize
and columns,
overall protection Min dry film
thickness (µm)

Notes

**Items 112 or 121 finish coat colour to be agreed with the NRA

The requirements of sub-Clause 1914.21 relating to the application of the first coat of paint need not apply for CCTV
masts, cantilever masts and steel lighting columns and bracket arms which remain in a workshop environment after
hot dip galvanizing.

All workshop paint coats on external surfaces shall be returned on to edges and 25mm inside at ends, at door and
other openings and under the base flange.

All paint coats shall be applied in the workshop.

Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance with IS EN ISO
12944-4 to surface roughness ‘fine’ in accordance with IS EN ISO 8503-2.

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems (continued)

Type Metal 1st 2nd 3rd 4th Minimum total dry

Coating Coat Coat Coat Coat film thickness of
the paint system
(microns)

G2a (i) External surfaces

Flange mounted Item No Hot dip 155 or 112 or 112 or 167, 275 (325 if Item
and upper section galvanize sweep 121 121 168, 169 185 finish is
(See 1911.8 (vi)) blast or 185 specified)
of masts and
columns, overall Min dry film 100 100 50 or
protection. thickness per 100*
coat (µm)

Overall protection Item No Hot dip 155 or 112 or 112 or 112 or 350
for ground section galvanize sweep 121 121 121**
(See 1911.8 (vi)). blast

Min dry film 100 100 100

thickness per
coat (µm)

(ii) Internal surfaces

Overall treatment Item No Hot dip

galvanize

Min dry film

thickness per
coat (µm)

Notes
*Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm
**Items 112 or 121 finish coat colour to be agreed with the NRA
The requirement of sub-Clause 1914.21relating to the application of the first coat of paint need not apply for CCTV
masts, cantilever masts and steel lighting columns and bracket arms which remain in a workshop environment after
hot dip galvanizing.
All workshop paint coats on external surfaces and site paint coats where access permits shall be returned on to edges
and 25mm inside at ends, at door and other openings and under base flange.
All paint coats except finish coats shall be applied in the workshop. Finish coats may be applied in the workshop or,
if within the intermediate coat overcoating time, on site.
Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance with IS EN ISO
12944-4 to surface roughness ‘fine’ in accordance with IS EN ISO 8503-2.
For external surfaces, the upper section finish coat shall overlap the ground section finish coat by 25mm.

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TABLE 19/4C: Requirements for CCTV Masts, Cantilever Masts, Steel Lighting Columns and
Bracket Arms

Protective Systems (continued)

Type Metal 1st 2nd 3rd 4th Minimum total

Coating Coat Coat Coat Coat dry film
thickness of
the paint
system
(microns)

G2b (i) External

surfaces

Flange mounted Item No Hot dip 155 or 110 112 or 167, 200 (250 if Item
and upper section galvanize sweep 121 168, 168 185 finish is
(See 1911.8 (vi)) blast or 185 specified)
of masts and
columns, overall Min dry film 25 100 50 or
protection thickness per 100*
coat (µm)

Overall protection Item No Hot dip 155 or 110 112 or 112 or 250
for ground section galvanize sweep 121 121**
(See 1911.8 (vi)). blast

Min dry film 30 100 50

thickness per
coat (µm)

(ii) Internal
surfaces

Overall treatment Item No Hot dip

galvanize

Min dry film

thickness (Nm)

Notes
*Items 167, 168 or 169 finish coats min. dft 50µm. Item 185 finish coat min. dft 100 µm
**Items 112 or 121 finish coat colour to be agreed with the NRA
The requirements of sub-Clause 1914.21 relating to the application of the first coat of paint need not apply for CCTV
masts, cantilever masts and steel lighting columns and bracket arms which remain in a workshop environment after
hot dip galvanizing.
All workshop paint coats on external surfaces, and site paint coats where access permits, shall be returned on to
edges and 25mm inside at ends, at door and other openings and under base flange.
Where sweep blast is the chosen method of adhesion promotion, it shall be undertaken in accordance with IS EN ISO
12944-4 to surface roughness ‘fine’ in accordance with IS EN ISO 8503-2.
For external surfaces, the upper section finish coat shall overlap the ground section finish coat by 25mm.
The ground section (See 1911.8 (vi)) of masts and columns shall have an additional sacrificial steel section thickness
of a minimum 1.0mm, above that needed in the design, from the bottom of the column to at least 250mm above the
ground level. The additional thickness shall be recorded in which ever is appropriate of the following: Part A of
Appendix 13/2 – Typical Lighting Column and Bracket Data Sheet; Part A of Appendix 13/5 – Typical CCTV Mast
Data Sheet; Part A of Appendix 13/8 – Typical Cantilever Mast Data Sheet.

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1912 Testing of Paints

Testing Authority

1 Paint testing shall be undertaken by the appointed independent testing authority which shall be
CREST (Centre for Research in Engineering Surface Technology), FOCAS Institute, DIT Kevin
St, Dublin 8, or an equivalent testing authority in any member state of the European Community
as agreed with the National Roads Authority.

Independent Painting Inspection Firms

2 An independent inspection firm shall be employed by the Contractor to inspect and test the
corrosion protection system for all elements of National Roads Authority Schemes. All aspects of
the works shall be inspected throughout all of the stages associated with the application of the
surface treatments for durability and appearance.

3 All inspection personnel shall be certified Painting Inspectors to either the Institute of Corrosion
and qualified to hold a current minimum Level 2 ICorr Certificate, or certified to NACE
International and hold a current CIP Level 2 certificate with bridge speciality. The names and
Curriculum Vitae of the proposed inspector(s) shall be submitted to the Employer’s
Representative for acceptance prior to the independent painting inspection firm commencing
work. The independent painting inspection firm shall have recourse to all of the equipment
required for testing and measuring the specific parameters in accordance with the requirements of
the Contract.

4 All independent inspection at the fabrication location and on site shall be carried out by the same
independent painting inspection firm and by the same inspector(s), unless otherwise accepted in
writing by the Employer’s Representative.

5 The independent painting inspection firm shall produce a report on the progress of the application
of the corrosion protection within five days of each inspection and submit two copies of each
report to the Employer’s Representative. Any significant problems shall be reported to the
Employer’s Representative immediately after identification.

Provision of Samples

6 The Contractor shall provide unopened samples, known as ‘A’ samples, for quality assurance
purposes, for each type of paint to be used for the Works in accordance with this Clause. In
addition the Contractor shall supply at least 500 ml samples, known as ‘B’ samples, for
application control purposes.

7 ‘A’ and ‘B’ samples are tested for paint composition and/or properties against the values obtained
during the approval testing of the original formulation and issued by the paint manufacturer to the
certifying body.

‘A’ Samples

8 ‘A’ samples are required in all cases where more than 500 litres of any one coat of paint is to be
used in the Works. ‘A’ samples are not required for paints to be applied to bearings, CCTV masts
cantilever masts, steel lighting columns and bracket arms. For two-pack systems separate samples
of the base and activator shall be despatched by the Contractor to the testing authority.

9 The first ‘A’ samples shall be taken from the first representative batch of each type of paint
delivered to the fabricator’s workshop or to site.

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10 Additional ‘A’ samples of the paints subject to testing under sub-Clause 4 of this Clause shall be
provided by the Contractor at a rate of one set of samples for each 500 litres (or part thereof) of
each type of paint used in the works.

The Contractor shall also provide an ‘A’ sample:

i) of any replacement batch of paint subject to testing under sub-Clause 4 of this Clause;

ii) returned paint described in sub-Clause 1913.4;

iii) when the paint is showing unsatisfactory application characteristics under Clause 1914.

11 The ‘A’ samples shall be selected at random to be fully representative of each 500 litres (or part
thereof) of paint to be used in the works.

12 Immediately after selection, the ‘A’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form BE/P3.

13 Paint shall be supplied in sufficient time to allow for sampling and testing before the start of
application.

14 Except for procedure trails, paint shall not be applied until the ‘A’ sample from the paint to be
applied has been tested and confirmed as being satisfactory for use.

‘B’ Samples

15 ‘B’ Samples are required in all cases including for paints to be applied to bearings, CCTV masts,
cantilever masts, steel lighting columns and bracket arms. ‘B’ samples shall be taken as spot
checks, with a minimum of every batch of paint being sampled. The Contractor shall take ‘B’
samples for two-pack materials as separate unmixed samples of the base and activator (cure)
components. The ‘B’ samples shall be taken following homogenization of the individual
components and immediately prior to mixing the two components for use in the Works. The
samples shall be decanted directly into clean, new 500ml tins which shall be filled and
immediately sealed prior to despatch to the testing authority.

16 Immediately after selection, the ‘B’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form BE/P3.

Provision of 500 ml Tins, Packing and Transport of ‘A’ and ‘B’ Samples

17 The Contractor shall provide 500 ml tins with lids and lid clips, for ‘B’ samples at the start of
painting or before any procedure trials required by Clause 1915. The quantity supplied shall be
sufficient to avoid any delay in taking ‘B’ samples throughout the work.

18 The Contractor shall ensure that the lids of all tins of sample paint are securely clipped down
when they are despatched for testing.

19 The Contractor shall be responsible for handling, packing as necessary, prompt despatch and
transit of ‘A’ and ‘B’ samples, including collection of samples from the testing authority for use
or disposal as appropriate, following satisfactory testing and reporting.

20 Employers Representative shall report back to Supervising Firm, as stated on Appendix 19/4
Form BE/P3, all results of the testing, who shall then notify the Contractor of the results.

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1913 Storage Requirements and Keeping Periods for Paints

1 On delivery to the workshop or site, paint shall be unloaded directly into one or more secure paint
stores which shall be located approximately within 100 metres of the painting area. Insulation and
means of heating and ventilating shall be provided as necessary to maintain the temperature of
paint stores between 10ºC and 27ºC.

If at any time or place paint in tins, painters’ kettles or airless spray containers is allowed to reach
temperatures outside the 10ºC and 27ºC limits or the paint manufacturer’s recommended storage
temperature, the paint shall be discarded and not used in the Works. Two pack products which
produce an exothermic reaction when mixed, may be allowed to exceed the specified higher
temperature limit. The Contractor shall also implement any additional storage requirements
recommended by the paint manufacturer.

2 Unless excepted in accordance with sub-Clause 4 of this Clause, paint which has not been used
within the shelf life recommended by the manufacturer or within 18 months of the date of
manufacture, whichever is the lesser, shall be discarded or returned to the manufacturer and not
used in the Works.

3 Chemically or moisture cured paints shall not be used after the expiry of the pot life stipulated by
the paint manufacturer. They shall be discarded on expiry of the pot life or at the end of each
working day/night whichever is the less. All other paints in opened tins or open containers
including painters’ kettles shall be returned to store and kept in sealed containers with not more
than 10% ullage.

4 Exceptionally, components of two-pack epoxy paints may have their keeping period extended to
24 months provided that the Contractor returns the paints to the paint manufacturer and ascertains
that the manufacturer examines the contents of each tin and reconstitutes the paints as necessary
so that such paints are equal in all respects to the paints described in the Contract. The Contractor
shall provide a Certificate of Conformity confirming that such paints have been inspected and
where necessary reconstituted and conform in all respects to the Contract.

5 Each tin of reconstituted paint returned to the workshop or site by the manufacturer shall have an
additional label affixed stating ‘Extended Shelf Life to (date)’. The previous date marking shall
remain and not be obscured. A set of ‘A’ samples shall be taken and be submitted for testing in
accordance with Clause 1912 from all batches of paint that have their shelf life extended.

1914 Application of Paint

1 Paint shall be supplied from the Contractor’s paint store to the painters ready for application, the
only adjustment of formulation permitted being as described in sub-Clause 1915.4. In exceptional
circumstances any addition of solvent necessary to improve application shall in accordance with
the paint manufacturer’s instructions and be carried out by the paint manufacturer, preferably in
the paint process plant with adequate equipment and controlled measurements.

2 Paint shall be applied only to surfaces that have been prepared and cleaned as described in this
Series.

3 Unless otherwise described in Appendix 19/2 a coat of paint in a system shall be applied by one
of the following methods:

i) brush (B);

ii) airless spray (AS);

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iii) air assisted spray.

Application of paint by roller is not permitted.

4 Paint shall not be applied when the following conditions will apply during paint application and
/or curing:

i) when the temperature of the surfaces to be coated is less than 3oC above the Dew Point,
and/or when the ambient temperature is at or falls below 5ºC or the relative humidity is
above 75% in an enclosed workshop or 80% on site; or, outside the temperatures and
humidities recommended by the paint manufacturer’s data sheet;

ii) during rain, snow, fog, mist or in a dust laden atmosphere;

iii) when moisture is likely to be deposited on the surface by condensation or rain;

iv) when wind-borne dust may have a harmful effect on the paint.

5 All workshop painting of steelwork shall be carried out in a fully enclosed weatherproof
workshop.

6 Before starting the procedure trials described in Clause 1915, the Contractor shall make available
details of the overall wet film thickness for each coat he proposes to apply. He shall also make
available information as to the total amount of paint that he expects to use for each coat of each
system for which procedure trials are required. The calculation of the amount of paint to be used
shall be based on the volume solids plus an allowance for waste.

7 The following requirements on paint film thicknesses shall apply:

i) Wet film thickness gauges shall be used where practicable to check that the wet film
thickness is not less than:

minimum dry film thickness (mdft) x 100 volume solids %

ii) During the application of a paint system the Contractor shall ensure that the progressive
total thickness of the applied coats shall allow the specified minimum total dft of the
system to be attained without exceeding, overall, the proposed wet film thicknesses
referred to in sub-Clause 6 of this Clause by more than 20%.

iii) In no case shall the total dry film thickness of a paint system or the mdft of the last
undercoat and finish be less than that specified in Appendix 19/1 Form BE/P1 (New
Works) Paint System Sheet.

iv) The local dry film thickness for any primer shall not exceed the specified mdft by more
than 30% and for other paints by more than 75%.

8 Each coat of paint of a specified system shall have satisfactory adhesion which shall be
determined by testing to ASTM D4541 Type III. A minimum value of 52kgf/cm2 (750psi) shall
be achieved before any paint film detachment occurs. The testing shall be restored in accordance
with Clause 1907.

9 Each applied specified paint coat shall be free from defects, including bloom, cratering, pin-
holing, blistering, rivelling, sagging, bittiness, dry spray and cissing etc. The presence of these
defects shall be determined by unaided visual assessment supplemented by other appropriate test
methods. The presence of pin holing or porosity in the completed paint system, except at corners,

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bolted joints or welds, shall be determined by low or high-voltage detectors in accordance with
ASTM G62-07. The finished system shall have an even and uniform appearance with no defects
and the finishing paint in visually sensitive areas shall be from the same batch.

10 The gloss level of the finishing coat shall be established before the procedure trials. A painted tin
plate reference panel, 150 mm x 100 mm, shall be provided by the Contractor for this purpose.

11 All successive coats in a system including the stripe coats shall be contrasting colours to aid
identification.

12 Before starting the procedure trials described in Clause 1915, the Contractor shall provide a
reference panel, coated with the stepped-back paint system to indicate the contrast between each
coat of paint.

Stripe Coats

13 Stripe coats shall be applied to all welds and all fasteners including washers and to all external
corners except those of RHS. The first stripe coat, using second undercoat paint, shall be applied
over the primer, sealer or adhesion promoter. When a second stripe coat is specified in Appendix
19/5, it shall be separated from the first stripe coat by an undercoat. All stripe coats shall be
applied by brush.

A solvent shall be used to remove final traces of oil and grease from fasteners before treatment
with an adhesion promoter.

The Contractor shall enter the details of the stripe coats he has selected in Appendix 19/1 Form
BE/P1 (New Works) Paint System Sheet giving the Item No., colour and method of application.

14 Square solid infill bars shall, after the second undercoat has been applied, be given an extra coat
of first undercoat in lieu of stripe coats.

Exposure Times for Prepared Steel Surfaces and for Metal Coatings.

Exposure Times and Treatment of Item 155 and Overcoating Times for Paints

15 Clean steel prepared by dry blast cleaning or bright steel prepared by abrading or by grinding
shall be primed within 4 hours.

16 Clean steel prepared by wet blast cleaning only, shall be primed within 4 hours of being dry
enough for painting.

17 Clean steel prepared by combined wet/dry blast cleaning shall be primed within 4 hours of dry
blast cleaning.

18 Steel or steelwork blast primed at the mills or in the workshop shall be overcoated within 8
weeks. The primed surfaces shall only be exposed outside for a maximum of 2 weeks of the 8
week period. Prepared surfaces affected by detrimental contamination or corrosion shall be
restored before overcoating.

19 Workshop steelwork which has been thermally metal sprayed shall be primed and sealed within 4
hours. The next coat shall be applied within 72 hours.

20 Workshop prepared steel surfaces, unsealed thermally sprayed aluminium metal coating and
undercoats, except final workshop undercoat, shall not be exposed outside.

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21 All surfaces treated with Item 155, except those of fasteners which have been treated in
compliance with sub-Clause 1906.3, shall, after initial drying, be wet cleaned in compliance with
sub-Clause 1903.9, taking care not to remove adhering Item 155, and allowed to dry before
overcoating. The first coat of paint shall be applied within 48 hours of the surfaces treated with
Item 155 being first dry enough for painting over.

22 When hot dip galvanized steel is to be protected by a paint system, the adhesion promoter shall be
applied not later than 14 days after delivery to site.

23 When hot dip galvanized steelwork is to be erected in a Marine environment and is to be

protected by a paint system, the adhesion promoter and the workshop coats shall be applied
within 7 days after hot dip galvanizing.

24 A first workshop undercoat shall be overcoated within 72 hours. Further shop coats shall be
applied within 72 hour intervals per coat.

25 The application of sealant in gaps, in compliance with sub-Clause 1906.27, may be carried out
either before or after application, as appropriate, of the first coat of paint to be applied to the
completed joints or assembled plies.

26 Prepared steel surfaces and thermally sprayed aluminium metal coatings which have been
restored, also paint coats and hot dip galvanizing which have been prepared after surface damage
or deterioration shall be overcoated with the sealer primer or first undercoat as appropriate before
the surfaces have been affected by moisture and in any case within 4 hours.

27 On site, steel surfaces and thermally sprayed aluminium metal coating shall be primed or sealed
within 4 hours and shall have the following coat applied within 72 hours. The next coat shall be
applied within a further 72 hours. Finish coats shall be applied within 7 days if application of the
preceding undercoat.

1915 Procedure Trials

1 The Contractor is required to procure an independent paint inspector for all painting jobs. The
paint inspector shall be suitably qualified as an NACE coating inspector, ICATS registered or
similar. Equivalent qualifications shall be submitted to the Employer’s Representative and must
be approved in writing.

2 The Contractor shall carry out workshop and site procedure trials of the protective system when
more than 50 litres of any coat of paint are to be applied to ‘Difficult Access’ road-bridge,
footbridge and gantry steelwork.

Procedure trials are not required for systems applied to joints or for hot dip galvanizing only. The
procedure trials shall be completed at least ten days before the start of application of the systems
on the main steelwork. The trials shall be carried out with the labour and equipment to be used for
the work.

3 The Contractor shall provide for the workshop trials, samples of steel from 2 m² to 10 m²
representing the main steelwork, hot dip galvanized when necessary. The Contractor shall
demonstrate his ability to carry out surface preparation by blast cleaning and by using power
assisted tools, to apply thermally sprayed aluminium metal coating and the paints he has selected.
The Contractor shall provide sufficient paint for the trials in containers of the size to be used for
the works.

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4 Thermally sprayed aluminium metal coating application and painting of the main steelwork shall
not be started in the workshop or on site until procedure trials have been completed satisfactorily.

5 Any adjustment to the registered paint formulations shown to be required by the trials, other than
an adjustment to the solvent shall be agreed with the National Roads Authority and made at the
paint manufacturer’s works.

6 The Contractor shall carry out further procedure trials whenever he employs replacement skilled
labour or proposes to use equipment of a different type.

1916 Storage and Transport of Steel and Fabricated Steelwork

1 Steel awaiting fabrication for the Works and uncoated steelwork shall be adequately protected
from contaminants liable to cause heavy rusting and possibly pitting of the surfaces.

2 Steelwork shall not be loaded for transport until the paint system is sufficiently hard for handling.

3 During storage, steelwork shall be kept clear of the ground and shall be laid out or stacked so as
to prevent water or dirt accumulating on or against any of the surfaces. Suitable packings shall be
placed between layers of stacked steelwork. When cover is provided it shall be ventilated
sufficiently to keep condensation to a minimum.

4 Components weighing less than one tonne shall be kept in a storage area away from their erection
point in order to minimise damage to protective coatings.

5 Lengths of parapet and individual steel lighting columns and masts shall be supported on timber,
and precautions taken to prevent damage to their protective coatings and ingress of water. They
shall only be positioned adjacent to their erection point immediately before erection. If the
planned erection time is delayed by more than 72 hours the components shall be returned to the
storage area.

6 Hot dip galvanized components shall be transported and stored under dry and well ventilated
conditions, to avoid wet storage staining. If stored outdoors, close contact of surfaces of
components shall be avoided, and suitable packing shall be placed between components, and to
keep the components clear of the ground. Components shall be stored wherever possible at a
slight angle to allow water run-off. When cover is provided it shall be ventilated sufficiently to
keep condensation to a minimum.

7 If damage to coatings is excessive, or may be difficult to deal with satisfactorily after erection, the
Contractor shall restore the coatings before erection.

1917 Surfaces in Contact with Concrete

1 Unless otherwise described in Appendix 19/5 or in Series 1800, 1810.7 if applicable, thermally
sprayed aluminium metal coating and all workshop paint coats shall be returned a minimum of 50
mm into the concrete/steelwork contact area.

2 Where aluminium metal spray, which has been sealed only, is returned into the contact area, it
shall be given a coat of Item 110 of 30 microns mdft, not later than 48 hours before concreting.
Application of the paint outside the contact area shall be prevented, by masking if necessary.

3 Hot dip galvanized coatings shall be applied overall. Unless otherwise described in Appendix
19/5 or in Series 1800, 1810.7 if applicable, concrete may come into direct contact with the hot
dip galvanized surfaces.

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1918 Form BE/P1 (New Works) Paint System Sheet (Appendix 19/1) Form
BE/P2 Paint Data Sheet (Appendix 19/3)
1 As soon as the Contract has been awarded the Contractor shall prepare and make available a copy
of Form BE/P1 (New Works) Paint System Sheet (Appendix 19/1), of which he shall have
completed Parts 6 to 10 together with relevant copies of Form BE/P2 Paint Data Sheet (Appendix
19/3).

2 Following any relevant approvals in accordance with the Contract and recorded in Part 11 of
Form BE/P1 (New Works) Pain System Sheet (Appendix 19/1), Forms BE/P1 (New Works) Paint
System Sheet (Appendix 19/1) shall be adopted for the Works.

1919 Access and Lighting

1 Without prejudice to the Conditions of Contract, access for inspection shall be provided and
erected by the Contractor. The access shall be adequate in all respects for inspection purposes.

2 Manual surface preparation and coating application work shall not be carried out when light
intensity at the workface is less than 500 lux. When the natural light intensity falls below this
level the Contractor shall install and maintain temporary lighting which shall provide a minimum
light intensity of 500 lux over at least 1.0 m² at the workface during the work and also for
inspection when required.

1920 Additional Requirements for the Protection of Steel in Bridge Bearings

Applicable Clauses

1 Unless otherwise described in Appendix 19/5, the work described in this Clause shall be carried
out in compliance with Appendix 19/1 and with Clauses 1901 to 1919 and the following:

Supply of Coatings

2 Information, including the name of the paint manufacturer, required for completing Form BE/P1
(New Works) Paint System Sheet (Appendix 19/1), for the bearings, shall be obtained by the
Contractor from the bearing manufacturer.

3 Item 155 and Epoxy MIO paints when required for application on site shall be obtained from the
manufacturer of the workshop applied coats. Paint applied to the bearings on site to match the
bridge steelwork paint system shall be obtained from the manufacturer of that system.

1921 Additional Requirements for the Protection of CCTV Masts, Cantilever

Masts, Steel Lighting Columns and Bracket Arms
Applicable Clauses

1 Unless otherwise described in Appendix 19/5, the work described in this Clause shall be carried
out in compliance with Appendix 19/1 and with Clauses 1901 to 1919 and the following:

Surface Preparation

2 In the workshop, any CCTV mast, steel lighting column or component material, the surfaces of
which show rust pitting when viewed by normal vision after surface preparation, shall be
discarded and not used for the Works.

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3 On site, any CCTV mast, cantilever masts, steel lighting column and bracket arms or component
material, the internal surfaces of which show rust pitting when viewed by normal vision after
surface preparation, shall be discarded and not used for the Works.

Stripe Coats

4 For CCTV Masts, cantilever masts and steel lighting columns and bracket arms, only one stripe
coat in undercoat paint is required. For protective system Types A2 and G2, the stripe coat shall
be applied before the last undercoat of the total protective system, in the workshop or on site as
appropriate. All stripe coats shall be applied by brush.

Adhesion Strength of Aluminium Metal Spray

5 For aluminium metal sprayed CCTV masts, cantilever masts and steel lighting columns and
bracket arms, the strength of adhesion of thermally sprayed aluminium metal coating to the steel
shall not be less than 35 kgf/cm² when tested by means of a tensile test in accordance with IS EN
ISO 2063.

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1970 Maintenance Provision Introduction

1 Surface preparation and the maintenance painting of steelwork shall be carried out in compliance
with Clauses 1970 to 1984, using systems appropriate to the information given in Appendix 19/6,
Form BE/P1 (Maintenance) Paint System Sheet (parts 3 to 9) and Appendix 19/7 if applicable, as
appropriate to the design, accessibility and condition of the components.

2 The Manual of Paints for Structural Steelwork, which is included in NRA BD 35, provides data
on paints and similar materials for use in the National Road Authority’s contracts. The Manual
contains item numbers and a summary is also given in Table 19/6.

3 Subject and without prejudice to the Conditions of Contract, the Contractor shall comply with any
measures to contain people, plant, materials, dust and debris described in Appendix 19/8.

4 Compliance with sub-Clause 3 of this Clause does not confer immunity from relevant legal
requirements.

5 The appropriate level of surface preparation and the suitable protective system shall depend on
reported results from the assessment of the existing protective system, which is determined as
described in Clause 2.5 of NRA BD 87.

6 NRA standard requirements on the maintenance painting of steelwork is defined within NRA BD
87.

1971 Maintenance Provision - Surface Preparation - General Requirements

1 The general requirements are specified in sub-Clauses 1971.2 to 1971.11. The various materials
and methods are specified in Clause 1972. The standards to be achieved are specified in Clause
1973. Definitions of terms used are given in Clause 1973. The particular requirements for surface
preparation for the structure(s) included in the Contract are specified in Appendix 19/6.

2 Any areas of contamination, including by oil or grease, shall be removed. Solvents shall not be
used.

3 Clean water, which does not leave any harmful residues on the surface shall be used for cleaning
and rinsing.

4 Only cleaning agents which are not harmful to the surface being cleaned and which do not leave
harmful residues on the surface after final rinsing shall be used for cleaning.

5 Surface preparation shall be continued until the required standard has been achieved.

6 After dry surface preparation of internal surfaces and before any wet cleaning, all dust and debris
shall be removed from accessible areas by sweeping and vacuum cleaning.

7 Immediately before application of each coat of paint, the Contractor shall ensure that the surfaces
to be painted:

i) meet the required standard of preparation;

ii) are free from harmful residues and detrimental contamination, including water,
moisture, condensation, oil, grease, mortar, concrete, dust, grit and paint degradation
products, chlorides and sulphides (See sub-clause 1973.1 (vii))

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8 The edges of existing coatings adjacent to abraded or blast cleaned areas shall be bevelled back
where practicable into sound and firmly adhering material.

9 Unless otherwise specified in Appendix 19/8, fasteners shall be prepared and painted to the same
standard as adjacent main surfaces.

10 After surface preparation by methods using water or when the steelwork has been exposed to the
weather after surface preparation by other methods or when there are deck leaks, areas containing
riveted or bolted joints or built up sections shall be freed of any standing water which may be
present in the nominal joint gaps; compressed air or other approved methods shall be used. When
drying out has been completed or when surfaces are dry after surface preparation, line gaps
around the perimeter of joint or along plies shall be sealed effectively by successive applications
of undercoat paint. All wider gaps shall be sealed with a sealant compatible with the primer.

11 The use of an inhibitor during wet blast cleaning or cleaning shall not be permitted.

1972 Maintenance Provision - Surface Preparation - Materials and Methods

Abrading

1 Any encrusted rust, foreign matter or paint which may be difficult to remove by abrading alone
shall be dislodged by scraping, aided by hand or power wire brushing. This work shall be
completed before abrading of the areas so affected.

2 Abrading shall be carried out using abrasive paper or other material or a flexible abrasive disc
mounted on a power drive flexible pad, or a power driven arbor or spindle-mounted flexible
abrasive flap wheel. Abrading tools may be used to remove weld spatter. Wet abrading may be
employed for the preparation of finishes over sound undercoats, over unsound systems over hot
dip galvanizing, or hot dip galvanizing. Wet abrading shall not be allowed to come into contact
with exposed thermally sprayed metal coatings unless the metal coating is to be entirely removed.

3 All equipment including tools, abrasive sheets, abrasive discs and abrasive wheels shall be of a
type, capacity and in a condition appropriate for the work. The use of hard grinding wheels for
abrading shall not be permitted.

4 A polished surface appearance caused by the polishing in of paint, rust or dirt shall not be
acceptable.

5 Areas of corroded steel or unsound metal coatings, which have been prepared by abrading down
to bright steel or bright metal coating, and blast cleaned where appropriate, shall be protected by
the primer and next coat of paint before any cleaning down or other preparation of adjacent
surfaces specified in Appendix 19/6 is undertaken.

6 Areas of unsound hot dip galvanizing which have been prepared down to bright steel by abrading
shall be protected by the application of the primer and next coat of paint before cleaning down or
other preparation of adjacent surfaces specified in Appendix 19/6 is undertaken.

7 After surface preparation by wet abrading of hot dip galvanizing, but prior to any cleaning down
of adjacent painted or hot dip galvanised surfaces specified in Appendix 19/6, any exposed areas
of steel shall be dry abraded down to bright steel and protected by the primer and the next coat of
paint, including the stripe coat, before cleaning down or other preparation of adjacent surfaces
specified in Appendix 19/6 is undertaken.

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Dry or wet cleaning

8 Wet cleaning shall be carried out by scrubbing with a stiff bristle brush using water and a
cleaning agent or a pressure washer. Immediately after cleaning down, the surfaces shall be
thoroughly rinsed using clean cold water.

9 Dry cleaning shall be carried out by scrubbing with a dry stiff bristled brush.

10 Where the existing surfaces are affected by embedded metallic grit or other abrasive particles,
they shall be scraped to dislodge looser particles and then dusted off. This work shall be carried
out after any final rinsing and when the surface is dry.

Dry Blast cleaning using Dry air/abrasive System

11 Unless otherwise specified in Appendix 19/8, metallic blast cleaning abrasives complying with IS
EN ISO 11124 or non-metallic blast cleaning abrasives complying with IS EN ISO 11126 shall be
used.

Grades for metallic abrasives shall comply with the following:

Profile (see Sub-clause 1973.3) Grade

Fine G050 or S060
Medium G070 or S100
Coarse G100 or S120

12 The particle size of metallic abrasive in plant or equipment shall not exceed the maximum for the
relevant grade as specified above.

13 Before the start of blast cleaning and during blast cleaning the Contractor shall ensure that the
abrasive is free from matter which could leave detrimental contamination, as defined in sub-
Clause 1973.1 (vii), on the surfaces to be coated.

14 Metallic grit or aluminium oxide abrasive shall be used for dry blast cleaning of relatively small
areas on site which are to be thermally sprayed aluminium metal coated, such as at areas prepared
to clean steel. The Contractor shall ensure that the grade and particle shape of non-metallic
abrasives are adequate for the purpose intended. Excepting for aluminium oxide non-metallic
abrasives shall not be recycled.

Wet Blast cleaning using low pressure air/water/ abrasive System

15 Unless otherwise specified in Appendix 19/8, a low-pressure air/water/abrasive system shall be

2
used. The air/water pressure at the nozzle shall not exceed 7.0 kgf/cm and shall be fully
adjustable below this level. The system shall incorporate a mechanical metering device, remote
controlled by the operator from the nozzle, to enable him to regulate from zero to maximum the
quantity of non-metallic abrasive being fed into the air/water mixture. During abrasive blast
cleaning the air/water/abrasive shall be thoroughly mixed and the mixture shall be projected onto
the surface to be cleaned through a single bore nozzle/tube. The use of an inhibitor during wet
blast cleaning or washing shall not be permitted.

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Wet Blast cleaning using High pressure water / abrasive System or Ultra High pressure water
System
2
16 Unless otherwise specified in Appendix 19/8, the water pressure shall not exceed 562 kgf/cm for
2
high pressure or between 1750 and 2860 kgf/cm for ultra-high pressure. The system shall
incorporate a mechanical metering device controlled by the operator at the nozzle, to regulate
from zero to maximum the quantity of non-metallic abrasive being fed into the water.

17 Within 60 minutes of wet blast cleaning, the whole of the cleaned surface shall be thoroughly
washed using the blast cleaning equipment with air and water. Any further deposits of abrasive on
already rinsed surfaces shall be removed in a similar manner also within 60 minutes of being
deposited. All accumulated deposits of abrasive and debris on other parts of the structure shall be
removed by the same method before the end of the working day. After washing, the surfaces shall
be free from all contamination. Tests for freedom from detrimental contamination shall be made
after the washing.

Combined wet/Dry Blast cleaning

18 Wet blast cleaning using the low pressure air/water/abrasive system in accordance with sub-
Clause 1972.15 and 17 shall be followed, at a minimal interval, by dry blast cleaning in
accordance with sub-Clauses 1972.11 to 14 of all the previously wet blast cleaned areas.

19 The specified standard of surface preparation shall have been achieved in full, initially by wet
blast cleaning and washing to achieve the required cleanliness, before any later dry blast cleaning
of the same areas to remove flash rusting or to restore the required surface profile.

Other Requirements

20 When surface preparation is to be carried out by dry blast cleaning and, on adjacent surfaces by
wet cleaning down and/or abrading, then unless otherwise necessary, the wet cleaning down and
any wet abrading shall be carried out first.

21 When combined wet/dry blast cleaning has been specified instead of dry blast cleaning only, the
sequence given in sub-clause 20 of this clause can be reversed. On completion of the wet blast
cleaning part of the process, the areas to be abraded shall be cleaned in accordance with sub-
clause 8 of this clause except that for rinsing, the wet blast cleaning equipment shall be used. The
dry blast cleaning part of the process, and dry abrading shall be carried out after any wet abrading
required and final rinsing.

22 Any prepared dry metal surfaces shall be protected from the effects of any further wet method of
surface preparation by the application of a minimum 75 microns dry film thickness of paint.

Grinding

23 Grinding wheels and discs shall be of the size, shape and grade of coarseness appropriate to the
particular operation. The speed of revolution shall be appropriate for the work.

24 Grinding shall be carried out after surface preparation by other methods, including cleaning
down, has been completed, except where it is necessary to achieve a blast profile and this would
necessitate blast cleaning after grinding.

25 Surfaces prepared by grinding to bright steel shall be protected by the application of the primer
and the next coat of paint, including any stripe coats, before cleaning down or other preparation
of adjacent surfaces specified in Appendix 19/6 is undertaken.

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1973 Maintenance Provision - Surface Preparation - Workmanship

Standards
1 Definitions of terms in sub-Clause 1973.2 describing coatings, the extent of surface preparation
and chemical cleanliness of surfaces are given below:

i) ‘unsound paint’. Paint showing signs of disruption, rusting through, having inadequate
adhesion or covering, rust scale, loose rust, loose mill scale or other detrimental
products;

ii) ‘sound paint’. Paint which is sound down to a metal substrate;

iii) ‘unsound metal coating’. A metal coating showing signs of disruption, inadequate
adhesion or penetration by rust or other corrosion products;

iv) ‘sound metal coating’. A metal coating which complies with Clause 1974 or a metal
coating restored to these requirements by blast cleaning, but with a reduced thickness;

v) Visual cleanliness of a steel substrate prepared to:

a) ‘clean steel’ by blast cleaning

Appearance:

There shall be a blast cleaning pattern overall. The surface profile shall be free
from mill scale, rust and foreign matter when viewed by normal vision;

b) ‘bright steel’ by abrading

Appearance:

The surface shall be free from all surface rust, mill scale and defects, and shall
have an overall bright appearance;

c) St3 to IS EN ISO 8501-1 and IS EN ISO 8501-2 by abrading

Appearance:

The surface shall be free from all rust scale, loose rust and loose mill scale;

d) ‘Bright steel’ by grinding

Appearance:

The surface shall be free of weld spatter, shelling, internal discontinuities and
other surface defects, leaving an overall bright appearance. Rounding of sharp
edges shall be to a radius of not less than 3mm, in accordance with Series
1800, 1810.2 if applicable;

vi) visual cleanliness of a metal coating restored or prepared to:

a) ‘sound metal coating’ by blast cleaning

Appearance:

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The surface shall be free from corrosion products and embedded abrasive
particles and shall have a bright appearance overall;

b) ‘bright metal coating’ by abrading

Appearance:

The surface shall be free from surface corrosion and corrosion products and
shall have a bright appearance overall;

vii) ‘freedom from ‘harmful residues’ or contamination’: Surfaces shall only be deemed to
be free from ‘harmful residues’ or ‘contamination’ after surface preparation when any
such remaining matter will not be detrimental to the application, adhesion, curing or
reduce the required durability of the specified protective system.

2 The following standards of surface preparation shall be achieved:

i) areas containing existing sound finishing paint shall be freed of:

a) any visible gloss which may prevent adequate adhesion of the next coat; and

b) detrimental contamination;

ii) areas of existing unsound paint coating(s) over a steel substrate shall be freed of:

a) any unsound paint down to sound paint;

b) any unsound paint down to clean steel;

c) any unsound paint down to Sa2½ or St3 quality steel;

d) any unsound paint down to bright steel;

e) all paint down to Sa2½ or St3 quality steel;

f) all paint down to clean steel; and

g) detrimental contamination;

iii) areas of existing unsound paint coating(s) over a metal coated steel substrate shall be
freed of:

a) any unsound paint down to sound paint or to sound metal coating;

b) any unsound metal coating down to bright metal coating;

c) any unsound metal coating down to clean steel;

d) any unsound metal coating down to bright steel;

e) all paint and unsound metal coating down to sound metal coating or to clean
steel;

f) all paint and metal coating down to clean steel; and

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g) detrimental contamination;

iv) areas of sound hot dip galvanizing exposed through a paint system during surface
preparation shall be abraded to an extent necessary to ensure effectiveness of adhesion
promoter and/or adhesion of the primer;

v) areas of unsound metal coating over a steel substrate shall be freed of:

a) any unsound metal coating down to bright metal coating;

b) any unsound metal coating down to sound metal coating;

c) any unsound metal coating down to clean steel;

d) any unsound metal coating down to bright steel;

e) all metal coating down to clean steel; and

f) detrimental contamination.

vi) when either ‘clean steel’, ‘Sa2½ or St3 quality steel’ or ‘bright steel’ is exposed through
a metal coating during surface preparation, the standard shall be as defined in sub-
Clause 1973.1 as appropriate, except for the profile of previously blast cleaned steel
surfaces. In the case of aluminium and zinc metal spray, remnants of soundly adhering
and clean aluminium or zinc may be retained. Any sound metal spray which is
contaminated by lead shall be completely removed.

3 The surface profile to be achieved by blast cleaning, either ‘Fine’ ‘Medium’ or ‘Coarse’ as
appropriate, shall be within the limits set by the Surface Profile Comparator for the Assessment of
Abrasive Blast Cleaned Surfaces, conforming to IS EN ISO 8503-1.

1974 Maintenance Provision - Metal Coatings

Hot Dip Galvanised Coatings

1 Unless otherwise specified in Appendix 19/8, structural members which were originally hot
dipped galvanised and display signs of deterioration shall be replaced by newly hot dipped
galvanised members or alternatively the surface shall be cleaned to bright metal and protected by
the application of coatings.

Thermally Sprayed Aluminium Metal Coatings

2 Thermally sprayed aluminium metal coatings shall, unless otherwise described in the Contract,
comply with IS EN 2063 and with the following:

i) aluminium coating shall have a composition complying with IS EN ISO 14919-3.1;

ii) the thickness of the coating shall be not less than 100 microns;

iii) The strength of adhesion of thermally sprayed aluminium metal coatings shall not be
2
less than 50 kgf/cm

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iv) thermally sprayed aluminium metal coatings shall be applied continuously over each
0.5m2 per gun, or the area of the component whichever is the lesser until the specified
thickness has been achieved;

v) the application of thermally sprayed aluminium metal in separate layers shall not be
permitted;

vi) all surfaces to be thermally aluminium metal sprayed shall be blast cleaned with iron
grit or high carbon cast-steel grit with a hardness value greater than 650 HV, or
aluminium oxide with a hardness value greater than 9 Mohs. The standard shall be Sa3
quality to IS EN ISO 8501-1, medium profile;

vii) thermally sprayed aluminium metal coatings shall be de-nibbed.

Other Requirements

3 When a metal coating is required on only part of a component it shall be applied before the rest of
the component receives paint.

1975 Maintenance Provision - Testing of Metal Spray Coatings

1 At the start of the Works, and subsequently at intervals scheduled in the Contract (with the
exception of coatings on steel in bearings, curved surfaces, repairs to mechanical damage, local
failure of thermally sprayed metal coatings at site joints or areas restored on site), the Contractor
shall demonstrate by means of a pull off adhesion test in accordance with ‘ASTM D4541-Type
III’, that the minimum adhesion requirement is being attained as detailed in sub-Clause 1974.2
(iii). In the excepted areas, the Contractor shall demonstrate that the adhesion is satisfactory by
means of grid tests in accordance with IS EN ISO 2063. Areas affected by the tests shall be
restored in accordance with Clause 1907.

2 The tensile tests shall be carried out initially on flat panels 150 mm x 150 mm x 6 mm which are
of the same grade of steel as the parent material and which before blast cleaning had the same
surface condition. The panels shall be blast cleaned and thermally metal sprayed together with the
parent material to the same standard and using the same technique.

3 The Contractor shall ensure that adhesion tests have been carried out satisfactorily before any
further work continues.

4 If the adhesion requirement on any test panel is not met, the Contractor shall carry out a further
test on the parent material adjacent to the test panel position. In the case of adhesion failure on the
steelwork itself by either method of test, unsound thermally sprayed aluminium metal coating
shall be restored and the tests repeated.

5 If more than two local areas of faulty adhesion occur on any one component, the whole of the
thermally sprayed aluminium metal coating on the component shall be considered as having
failed, and it shall be restored.

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1976 Maintenance Provision - Paint and Similar Protective Coatings

1 The term paint shall be deemed to refer to protective coatings in general.

2 The paints permitted for use in the Works are listed in the Manual of Paints for Structural
Steelwork which is included in NRA BD 35 and which also contains details of the quality
assurance scheme for paints and similar protective coatings. All paints shall have a current NSAI
Agrément Certificate, BBA HAPAS Roads and Bridges Certificate or equivalent appropriate to
the use of the paint in the proposed system in accordance with NRA BD 35.

3 All paints shall be supplied in sealed containers of a capacity suitable for the volume and method
of application. The capacity of the containers to be used shall be confirmed as being suitable as
part of the Procedure Trials described in Clause 1980. All containers shall be used in order of date
of manufacture and batch number, the oldest being used first.. Each container shall have a
completely removable lid and be clearly marked on the side to show the name of the
manufacturer, registered description of the material (including purpose, e.g. whether primer,
undercoat or finish), colour, Item No, paint manufacturer’s reference number, batch number and
date of manufacture. Where date of manufacture is coded, the Contractor shall provide the code
key. In addition paints shall be supplied in sealed containers of no greater than 5 litre capacity for
testing purposes in accordance with Clause 1978, for ‘A’ samples.

4 The Contractor shall ensure that the properties of the paints he has selected are compatible with
the existing system and suitable for the conditions on site, including temperature and humidity,
and that he is able to apply the paints satisfactorily to all parts of the structure in these conditions.

5 Unless otherwise described in Appendix 19/8, all paints forming any one protective system or
overlapping systems, shall be obtained from the same manufacturer as named by the Contractor in
Appendix 19/6 Form BE/P1 (Maintenance) Paint System Sheet.

1977 Maintenance Provision - Surface Preparation and Protective Systems

1 The particular methods of surface preparation are to be detailed in Appendix 19/6 Form BE/P1
(Maintenance) Paint System Sheet, parts 1 to 9.

2 Protective systems

Note: mdft = minimum dry film thickness

B = apply by brush

AS = apply by airless spray

HB = High Build (dft: above 75 µm)

NB = Normal Build (dft: between 50 and 75 µm)

LB = Low Build (dft: below 50 µm)

i) Item numbers in the Protective Systems are listed in the Manual of Paints for Structural
Steelwork which is included in NRA BD 35 and a summary is shown in Table 19/5.

ii) Details of Protective Systems for Steelwork are given in Table 19/6.

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TABLE 19/5 NRA BD 35: Quality Assurance Scheme for Paints and Similar Protective Coatings -
Annex A Manual of Paints for Structural Steelwork Current Paint Item Numbers

Description Coat Type Build Applied by

109 Zinc Rich Epoxy Blast Primer (two pack) Blast Primer LB or NB B or AS
(B to small areas only)
110 Zinc Phosphate Epoxy (two-pack) Blast Primer/Sealer NB B or AS
(B to small areas only)
111 Zinc Phosphate High Build Quick Drying Blast Primer HB AS
Epoxy (two-pack) (B to small areas only)
112 MIO High Build Quick Drying Epoxy Undercoat/Finish HB AS
(two-pack)
113 Water based epoxy primer for blast Primer HB B or AS
cleaned internal surfaces (two-pack)
114 Water based epoxy undercoat/sheen finish Undercoat/Sheen Finish HB B or AS
for internal use (two-pack)
115 High Build Aluminium Epoxy (two-pack) Surface tolerant HB B or AS
maintenance primer
(e.g. for abraded
surfaces)
116 High Build Epoxy (two-pack) Surface tolerant HB B or AS
maintenance undercoat
121 Extended Cure Epoxy MIO (two-pack) Primer, Undercoat, HB AS
and/or Finish (B to small areas only)
123 High Build Glass Flake Epoxy (two-pack) Undercoat for blast HB AS
cleaned steel new (stripe coats and small
construction repairs only by brush)
155 ‘T’ Wash Adhesion promoter for LB B
hot dip galvanized steel
157 Adhesion promoting (single-component) To promote substrate LB B or AS
adhesion properties of
coating systems for hot
dip galvanised steel,
aluminium and stainless
steel surfaces
159 Aluminium Epoxy (two-pack) Sealer/Primer LB B or AS
160 Red Oxide Moisture Cured Polyurethane Primer/Blast Primer for LB B or AS
(single-component) maintenance or new
works
162 MIO Moisture Cured Polyurethane Undercoat/Finish NB or HB B or AS
164 Moisture Cured Polyurethane (single- Semi-gloss Finish LB NB B AS
component)
167 Epoxy Acrylic Finish (two-pack) Gloss or Semi-gloss
NB B (small areas by brush) AS
finish
168 Polyurethane (two-pack) Gloss Finish LB NB B AS
169 Polyurethane (two-pack) Semi-gloss Finish NB HB B (small areas by brush) AS
185 Organic Modified Polysiloxane (two- Gloss Finish for new NB HB B AS
pack) works or maintenance
200 Grease Paint Primer B (AS for difficult access
areas)
201 Grease Paint Undercoat/Finish HB B or AS

Notes:
1 Colour reference shall be as per the manufacturer’s declared colour given with reference to BS 4800
and/or BS 381C where appropriate.

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2 Dry Film Thickness (dft) range shall be as per the manufacturer’s data sheet. The minimum dry film
thickness of the paint coats and paint system shall be as per the protective systems detailed in Table 19/6
where given.
3 All materials to be handled and applied in accordance with the manufacturers Product and Health &
Safety Data Sheets.

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TABLE 19/6: Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms and other Road Structures: Protective Systems

Minimum total
Surface 1st 2nd 3rd dry film thickness
Substrate Type
preparation Coat Coat Coat of the paint
system (microns)
I (M) – High Steel Clean, bright Item No. 115 116 168 300
Build Epoxy Sa2½ or St3 Min dry film
(two-pack) / quality steel 100 50
thickness (µm)
Polyurethane
(two-pack) 116 or
Item No. 115 168
finish Aluminium Bright or sound 112 300
metal spray metal coating Min dry film
100 50
thickness (µm)
Existing paint Sound finishing Item No. Nil Nil 168 50
coats coat or last Min dry film
undercoat - - 50
thickness (µm)
Other sound 116 or
Item No. Nil 168
coats 112 175
Min dry film
- 100 50
thickness (µm)
STRIPE COATS: Item 116 or 112. Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal
coating. Applied over 1st coat
PATCH COATS: NIL
NOTES: 1. When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 169 Polyurethane Finish,
may be used in lieu of Item 168 to provide a semi-gloss finish, alternatively Item 164 (Moisture Cure Polyurethane finish) can
provide a semi-gloss finish and is tolerant of surface moisture (but not running water) and low temperatures during application
and curing. 2. Types I (M) and II (M) can be combined to allow paint maintenance to proceed when temperature falls and
relative humidity increases and for night work.
HEALTH AND SAFETY: Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be
injurious to health if not used correctly. An assessment of the risks and controls for their safe use shall be carried out before
use.

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TABLE 19/6: Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms and other Road Structures: Protective Systems (continued)

Minimum
total dry film
Substrate Surface 1st 2nd 3rd 4th thickness of
Type preparation Coat Coat Coat Coat the paint
system
(microns)

II (M) – MC/ Steel Clean or 164

Item No. 160 162 162
Polyurethanes bright steel /169
275/325
Min dry film
40 70 40/50
thickness (µm)

Sa2½ or St3 Item No. N/A N/A N/A N/A

quality steel
Min dry film
- - - -
thickness (µm)

Aluminium Bright or Item No. 160 162 162 164

metal spray sound metal /169
coating
Min dry film
40 70 40/50
thickness (µm) 275/325

Existing Sound Item No. 164

- - -
paint coats finishing coat /169
or last
undercoat Min dry film
- - - 40/50
thickness (µm) 50/100

Other sound Item No. 162 162 164

-
coats /169

Min dry film 70 70 40/50

-
thickness (µm) 225/275

STRIPE COATS: Item 162: Brush or airless spray. Two stripe coats, the first applied over 1st coat, the second coat applied
over 2nd coat

PATCH COATS: NIL

NOTES: 1. Item 168, Polyurethane (two-pack) gloss finish may be used in lieu of Item 164 MC Polyurethane semi-gloss
finish (two-pack Polyurethane gloss finishes are less tolerant of moisture and low temperatures during application and curing
than MC Polyurethanes and shall therefore only be specified when conditions preclude the formation of moisture on surfaces
and when the ambient temperature is likely to remain above 5oC during application and the curing period). 2. Types I (M) and
II (M) can be combined to allow paint maintenance to proceed when temperature falls and relative humidity increases and for
night work.

HEALTH AND SAFETY: Moisture cured Polyurethane and Polyurethane (two-pack) paints contain isocyanate and can be
injurious to health if not used correctly. An assessment of the risks and controls for their safe use shall be carried out before
use.

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TABLE 19/6: Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms and other Road Structures: Protective Systems (continued)

Minimum total
dry film
Substrate Surface 2nd
1st Coat 3rd Coat thickness of the
Type preparation Coat
paint system
(microns)

III (M) – Hot dip Bright or Item No. 155 or 121 164, 168 175/250
Extended galvanizing sound metal other or 169
Cure Epoxy/ coating adhesion
Polyurethanes promoter

Min dry film

thickness 100 40/50/50
(µm)

Hot dip Bright or Item No. 121 164, 175

galvanizing sound metal 168 or
coating 169

Min dry film 100 50

thickness
(µm)

STRIPE COATS: Item 121: Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal coating.
Applied over 1st coat

PATCH COATS: NIL

NOTES: 1. Some Item 121 formulations have been developed for direct application to hot dipped galvanised surfaces with
excellent adhesion without the need for an adhesion promoter (to be checked with and guaranteed by paint manufacturer). 2.
When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 164, Moisture Cured Polyurethane
Finish, may be used in lieu of Item 168 to provide a semi-gloss finish tolerant of surface moisture (but not running water) and
low temperatures during application and curing.

HEALTH AND SAFETY: Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be
injurious to health if not used correctly. An assessment of the risks and controls for their safe use shall be carried out before
use.

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TABLE 19/6: Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms and other Road Structures: Protective Systems (continued)

Minimum total
Surface 1st 2nd 3rd dry film thickness
Substrate Type
preparation Coat Coat Coat of the paint
system (microns)
Steel Clean, bright or 116 or 164 or
IV (M) – Item No. 160
Sa2½ or St3 112 168
MC/Epoxy/ quality steel
Polyurethane Min dry film
50 50
thickness (µm) 250
STRIPE COATS: Item 112: Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal coating.
Applied over 1st coat
PATCH COATS: NIL
NOTE: 1. When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 164, Moisture Cured
Polyurethane Finish, may be used in lieu of Item 168 to provide a semi-gloss finish tolerant of surface moisture (but not
running water) and low temperatures during application and curing.
HEALTH AND SAFETY: Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be
injurious to health if not used correctly. An assessment of the risks and controls for their safe use shall be carried out before
use.

TABLE 19/6: Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel
Lighting Columns and Bracket Arms and other Road Structures: Protective Systems (continued)

Minimum total dry

Surface 1st 2nd 3rd film thickness of
Substrate Type
preparation Coat Coat Coat the paint system
(microns)

V (M) - Steel Clean, bright or Item No. 200 201 201

Grease Sa2½ or St3
Paints quality steel Min dry film
- 150 150
thickness (µm) 350

Aluminium metal Bright or sound Item No. Nil 201 201

spray, zinc metal metal coating
spray or hot dip Min dry film
150 150
galvanizing thickness (µm) - 350

Existing paint Sound finishing Item No. Nil Nil 201

coats coat or last
undercoat or
Min dry film
other sound - - 150
thickness (µm)
coats 150

STRIPE COATS: Item 201, 150 µm mdft. Brush One stripe coat in all areas over 2nd coat

PATCH COATS: Item 201, Brush, over 2nd coat The total dft of existing coats plus new coats including patch coats, shall
not be less than 400 µm. Number of patch coats to suit.

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1978 Maintenance Provision - Testing of Paints

Testing Authority

1 Paint testing shall be undertaken by the appointed independent testing authority which shall be
CREST (Centre for Research in Engineering Surface Technology), FOCAS Institute, DIT Kevin
St, Dublin 8, or an equivalent testing authority in any member state of the European Community
as agreed with the National Roads Authority.

Independent Painting Inspection Firms

2 An independent inspection firm shall inspect and test the corrosion protection system for all
elements of National Roads Authority Schemes. A total inspection approach shall be adopted
throughout all of the stages associated with the application of the surface treatments for durability
and appearance.

3 All inspection personnel shall be certified Painting Inspectors to either the Institute of Corrosion
and qualified to hold a current minimum Level 2 ICorr Certificate, or certified to NACE
International and hold a current CIP Level 2 certificate with bridge speciality. The names and
Curriculum Vitae of the proposed inspector(s) shall be submitted to the Employer’s
Representative for acceptance prior to the independent painting inspection firm commencing
work. The independent painting inspection firm shall have recourse to all of the equipment
required for testing and measuring the specific parameters in accordance with the requirements of
the Contract.

4 All independent inspection at the fabrication shop and on site shall be carried out by the same
independent painting inspection firm and by the same inspector(s), unless otherwise accepted in
writing by the Employer’s Representative.

5 The independent painting inspection firm shall produce a report on the progress of the application
of the corrosion protection within five days of each inspection and submit two copies of each
report to the Employer’s Representative. Any significant problems shall be reported immediately
to the Employer’s Representative after identification.

Provision of Samples

6 The Contractor shall provide unopened samples, known as ‘A’ samples, for quality assurance
purposes, for each type of paint to be used for the Works in accordance with this Clause. In
addition the Contractor shall supply at least 500 ml samples, known as ‘B’ samples, for
application control purposes.

7 ‘A’ and ‘B’ samples are tested for paint composition and/or properties against the original
formulation issued by the paint manufacturer to the certifying body.

‘A’ Samples

8 ‘A’ samples are required where more than 500 litres of paint for any one coat are supplied to a
single Contract. For two-pack systems separate samples of the base and activator shall be
despatched by the Contractor to the testing authority.

9 ‘A’ samples are not required for CCTV masts, cantilever masts, steel lighting columns and
bracket arms.

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10 The first ‘A’ samples shall be taken from the first representative batch of each type of paint
delivered to site.

11 If paint is to be supplied in tins of greater than 5 litre capacity then, for ‘A’ sampling, a minimum
of four 5 litre tins of paint taken from each batch to be sampled shall be provided by the paint
manufacturer. The ‘A’ samples shall be selected from these 5 litre tins.

12 Additional ‘A’ samples of paints subject to testing under sub-Clause 4 of this Clause shall be
provided by the Contractor at a rate of one set of samples for each 500 litres (or part thereof) of
each type of paint used in the works.

The Contractor shall also provide an ‘A’ sample:

i) of any replacement batch of paint subject to testing under sub-Clause 4 of this Clause;

ii) of any returned paint described in sub-Clause 1979.4;

iii) when the paint is showing unsatisfactory application characteristics under Clause 1981.

13 Immediately after selection, the ‘A’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form BE/P3.

14 Paint shall be supplied in sufficient time to allow for sampling, delivery to the testing authority
and testing before the start of application.

15 Except for procedure trails, paint shall not be applied until the ‘A’ sample from the paint to be
applied has been tested and confirmed as being satisfactory for use.

‘B’ Samples

16 ‘B’ samples are required in all cases including for paints to be applied to bearings, CCTV masts,
steel lighting columns and bracket arms. ‘B’ samples shall be taken as spot checks, with a
minimum if every batch of paint being sampled. The Contractor shall take ‘B’ samples for two-
pack systems as separate unmixed samples of the base and activator (cure) components. The ‘B’
samples shall be taken following the homogenization of the individual components and
immediately prior to mixing the two components for use in the Works. The samples shall be
decanted directly into clean, new and clearly labelled 500ml tins which shall be filled and
immediately sealed prior to despatch to the testing authority

17 Immediately after selection, the ‘B’ samples shall be despatched by the Contractor to the testing
authority, together with Appendix 19/4 Form BE/P3. For two-pack systems separate tins
containing the activator and the base shall be dispatched to the testing authority.

Provision of 500ml Tins, Packing and Transport of ‘A’ and ‘B’ Samples

18 The Contractor shall provide 500 ml tins with lids and lid clips for ‘B’ samples at the start of
painting or before any procedure trials required by Clause 1980. The quantity of tins supplied
shall be sufficient to avoid any delay in taking ‘B’ samples throughout the work.

19 The Contractor shall ensure that the lids of all tins of sample paint are securely clipped down
when they are despatched for testing.

20 The Contractor shall be responsible for handling, packing as necessary, prompt despatch and
transit of ‘A’ and ‘B’ samples, including collection of samples from the testing authority for use
or disposal as appropriate, following satisfactory testing and reporting.

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21 The Employers Representative shall report back to the Supervising Firm, as stated on Appendix
19/4 Form BE/P3, all results of the testing, who shall then notify the Contractor of the results.

1979 Maintenance Provision - Storage Requirements and Keeping Periods

for Paints
1 On delivery to site, paint shall be unloaded directly into one or more secure paint stores which
shall be located approximately within 100 metres of the painting area. Insulation and means of
heating and ventilation shall be provided as necessary to maintain the temperature of paint stores
between 10ºC and 27ºC.

If at any time or place, paint in tins, painters’ kettles or airless spray containers is allowed to
reach temperatures outside the 10ºC and 27ºC limits, or the paint manufacturer’s recommended
storage temperature, the paint shall be discarded and not used for the Works. Two pack products
which produce an exothermic reaction when mixed, may be allowed to exceed the specified
higher temperature limit. The Contractor shall also implement any additional storage restrictions
recommended by the paint manufacturer.

2 Unless excepted in sub-Clause 4 of this Clause, paint which has not been used within the shelf
life recommended by the manufacturer or within 18 months of the date of manufacture,
whichever is the lesser, shall be discarded or returned to the manufacturer and not used in the
Works.

3 Chemically or moisture cured paints shall not be used after the expiry of the pot life stipulated by
the paint manufacturer. They shall be discarded on expiry of the pot life or at the end of each
working day/night whichever is the less. All other paints in opened tins or open containers
including painters’ kettles shall be returned to store and kept in sealed containers with not more
than 10% ullage.

4 Exceptionally, components of two-pack epoxy paints may have their shelf life extended to 24
months provided that the Contractor returns the paints to the paint manufacturer and ascertains
that the manufacturer examines the contents of each tin and reconstitutes the paints as necessary
so that such paints are equal in all respects to the paints described in the Contract. The Contractor
shall provide a Certificate of Conformity confirming that such paints have been inspected and
where necessary reconstituted and conform in all respects to the Contract.

5 Each tin of reconstituted paint returned to site by the manufacturer shall have an additional label
affixed stating ‘Extended Shelf Life to (date)’. The previous date marking shall remain and not be
obscured. A set of ‘A’ samples shall be taken and be submitted for testing in accordance with
Clause 1978 from all batches of paint that have their shelf life extended.

1980 Maintenance Provision - Procedure Trials

1 At the start of the Works, the Contractor shall carry out procedure trials on areas totalling
2 2
between 2 m and 10 m , employing the labour and equipment to be used in the Works. The
Contractor shall demonstrate his ability to carry out the specified methods of surface preparation
to the standard required and to apply the paints he has selected in accordance with the
specification. The Contractor shall supply sufficient paint for the trials as required for the size of
the test area. The remaining surface preparation shall not be started until the first stage of the
procedure trials specified in sub-Clause 2 of this Clause are confirmed as satisfactory.

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2 Immediately following the satisfactory completion of the first stage of the procedure trials, the
Contractor shall carry out the second and third stages, employing the labour and equipment to be
used in the Works.

In order to avoid delay, the trials may be carried out in three stages:

i) surface preparation and primer;

ii) undercoat(s);

iii) finish.

Paint application of the various coats on the remaining parts of the structure shall not be
started until the relevant stage of the procedure trials are confirmed as satisfactory.

3 Procedure trials shall be completed within a 7 day period.

4 Any adjustment to the registered paint formulations shown to be required by the trials, other than
an adjustment to the solvent shall be agreed with the National Roads Authority and made at the
paint manufacturer’s works.

5 The Contractor shall carry out further procedure trials whenever he employs replacement skilled
labour or proposes to use equipment of a different type.

1981 Maintenance Provision - Application of Paint

1 The application of paint shall be supervised at all stages by the Contractor’s supervisory staff.
The companies contracted to apply protective coating systems to steel structures, and their
personnel, shall be capable of carrying out the work properly and safely. The personnel carrying
out the work shall have the necessary skills and/or qualifications.

2 Paint shall be supplied from the Contractor’s paint store to the painters ready for application, the
only adjustment of formulation permitted being as described in sub-Clause 1980.4. In exceptional
circumstances any addition of solvent necessary to improve application shall be advised and if
possible carried out by the paint manufacturer, preferably in the paint process plant with adequate
equipment and controlled measurements.

3 During the application of paint, surfaces to be treated shall be safely accessible and well
illuminated. When using the coating materials, the manufacturer’s technical data sheet shall be
observed. Prior to and during the application, the coating materials shall be verified to ensure:

i) conformity of the container label with the specified product description;

ii) no skin formation;

iii) any sediment present shall be easily redispersible with no irreversible settling;

iv) usability under the given site conditions.

4 Paint shall be applied only to surfaces which have been prepared and cleaned as described in this
Series. Areas of adjacent surfaces which are not to be painted shall be masked before application
of paints to the prepared and cleaned surfaces. Accidental overspray on adjacent unpainted
surfaces shall be removed immediately.

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5 Unless otherwise described in Appendix 19/7, a coat of paint in a system shall be applied by one
of the following methods:

i) brush (B);

ii) airless spray (AS);

iii) air assisted spray (S).

Application of paint by roller is not permitted.

6 Paint shall not be applied when the following conditions will apply during the paint application
and/or curing:

i) when the temperature of the surfaces to be coated is less than 3°C above the Dew point,
and/or when the ambient temperature is at or below 5°C or the relative humidity is
above 80% or the outside temperatures and humidities recommended in the paint
manufacturer’s data sheet.

ii) during rain, snow, fog, mist or in a dust-laden atmosphere;

iii) when moisture is likely to be deposited on the surface by condensation or rain;

iv) when wind-borne dust may have a harmful effect on the paint.

7 Before starting the procedure trials described in Clause 1980, the Contractor shall make available
details of the overall wet film thickness for each coat he proposes to apply. He shall also make
available information as to the total amount of paint he expects to use for each coat of each
system during any Contract for which procedure trials are required. The calculation of the amount
of paint to be used shall be based on the volume solids plus an allowance for waste.

8 The following requirements on paint film thicknesses shall apply:

i) wet film thickness gauges shall be used where practicable to check that the wet film
thickness is not less than:

min dry film thickness (mdft) x 100

volume solids %

ii) during the application of a paint system, the Contractor shall ensure that the progressive
total thickness of the applied coats shall allow the specified minimum total dft of the
system to be attained without exceeding, overall, the proposed wet film thickness
referred to in sub-Clause 7 of this Clause by more than 20%;

iii) in no case shall the total dry film thickness of a paint system or the mdft of the last
undercoat and finish be less than that specified in Appendix 19/6 Form BE/P2
(Maintenance) Paint System Sheet;

iv) the local dry film thickness for any primer shall not exceed the specified mdft by more
than 30% and for other paints by more than 75%.

9 Each coat of paint of a specified system shall have satisfactory adhesion which shall be
determined by testing to ASTM D4541 Type III. A minimum value of 52 kgf/cm2 (750psi) shall
be achieved before any paint film detachment occurs. The satisfactory adhesion of the coating

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system shall be confirmed by representative testing. Damage resulting from the adhesion testing
shall be restored in accordance with Clause 1907.

10 Each applied specified paint coat, shall be free from defects, including bloom, cratering, pin-
holing blistering, rivelling, sagging, bittiness, dry spray and cissing etc. The presence of these
defects shall be determined by unaided visual assessment supplemented by other appropriate test
methods. The presence of pin-holing or porosity shall be determined by low or high-voltage
detectors (at corners, bolted joints and welds pin-holing shall be exempted). The finished system
shall have an even and uniform appearance with no defects and the finishing paint in visually
sensitive areas shall be from the same batch.

11 The gloss level of the finishing paint shall be established before the procedure trials. A painted
tinplate reference panel, 150 mm x 100 mm, shall be provided by the Contractor for this purpose.

12 Unless otherwise specified, patch painting described in Appendix 19/6 shall only be applied over
areas of an existing system which have been prepared to sound paint.

13 All coats in a system including the stripe coat(s) (see sub-Clauses 1981.14 to 20), but excepting
repeat coats of the same patch paint, shall be in contrasting colours to aid identification. Before
starting the procedure trials described in Clause 1980, the Contractor shall provide a reference
panel, coated with the stepped-back paint system to indicate the contrast between each coat of
paint.

14 Two-pack chemically cured and moisture cured paints shall not be applied when the steel
temperature falls below 3ºC above dew point and/or 0ºC or when the steel or ambient
temperatures are below those advised by the paint manufacturer, nor shall such paints be applied
when the temperatures are likely to fall below the advised temperatures during the curing period.

Stripe Coat(s)

15 All stripe coats shall be applied by brush over all welds, edges and all fasteners including washers
and to all external corners except those of RHS members.

16 In areas prepared down to the substrate or to a metal coating, the first stripe coat, using second
undercoat paint, shall be applied over the primer or the first undercoat; when a second stripe coat
is specified it shall be separated from the first stripe coat by an undercoat. The first stripe coat on
fasteners treated with Item 155 shall be applied by brush; other stripe coats may be applied by
brush or airless spray as appropriate.

17 In areas prepared down to sound paint, the stripe coat(s) shall be applied before the priming coat.

18 Stripe coat(s) applied on existing paint coats shall be applied by brush.

19 The first stripe coat on fasteners treated with Item 155 shall be applied by brush.

20 Wet cleaning as described in sub-Clause 1972.8 shall be used to remove final traces of grease
from fasteners before treatment with Item 155.

21 The Contractor shall enter the details of the stripe coats he has selected in Appendix 19/6 Form
BE/P1 (Maintenance) Paint System Sheet giving the Item No., colour and method of application.

22 Square solid infill bars shall, after the second undercoat has been applied, be given an extra coat
of the thickest undercoat in lieu of stripe coat or coats.

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Exposure times for prepared steel surfaces and for metal coated surfaces.

23 Clean steel prepared by dry blast cleaning or bright steel prepared by abrading or by grinding
shall be primed within 4 hours.

24 Clean steel prepared by wet blast cleaning only, shall be primed within 4 hours of being dry
enough for painting.

25 Clean steel prepared by combined wet/dry blast cleaning shall be primed within 4 hours of dry
blast cleaning.

26 Sa2½ or St3 steel prepared by dry blast cleaning or abrading shall be overcoated within 48 hours.

27 Sa2½ steel prepared by wet blast cleaning or combined wet/dry blast cleaning shall be primed
within 24 hours of being dry enough for painting or within 48 hours of dry blast cleaning.

28 Steelwork which has been thermally aluminium metal spray coated at site shall be primed or
sealed within 4 hours and in any case before the surfaces have been affected by moisture.

29 Areas prepared down to bright or sound thermally sprayed metal coating shall be sealed or primed
within 4 hours of preparation by dry blast cleaning or abrading and in any case before the surfaces
have been affected by moisture.

30 Hot dip galvanizing which has been abraded to bright metal prior to painting shall be primed
within 4 hours, or within 4 hours of being dry enough for treatment if wet abraded, and
overcoated within 48 hours of priming.

31 Gaps at joints or plies shall be sealed in accordance with sub-Clause 1971.10 either before or after
the application of the primer as appropriate.

Paint Overcoating Times

32 Unless otherwise specified in Appendix 19/8, overcoating times shall be as follows:

i) primers on steel or sealed thermally aluminium sprayed metal coating or first coats over
Item 155 or etch primed hot dip galvanizing shall be overcoated within 72 hours and the
next coat applied within 14 days or as recommended by the paint’s manufacturer;

ii) surfaces of existing paint coats which have been prepared to sound paint, cleaned down
only or abraded only to remove gloss, shall be overcoated within 7 days;

iii) coats following those referred to in i and ii above, shall be applied within 14 days of
each coat or as recommended by the paint’s manufacturer.

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1982 Maintenance Provision - Form BE/P1 (Maintenance) Paint System

Sheet (Appendix 19/6) Form BE/P2 Paint Data Sheet (Appendix 19/3)
1 As soon as the Contract has been awarded the Contractor shall prepare and make available a copy
of Appendix 19/6 Form BE/P1 (Maintenance) Paint System Sheet, of which he shall have
completed parts 10 to 14 together with relevant copies of Form BE/P2 Paint Data Sheet
(Appendix 19/3).

2 Following any relevant approvals in accordance with the Contract, Appendix 19/6 Forms BE/P1
(Maintenance) Paint System Sheet shall be adopted for the Works.

1983 Maintenance Provision - Access, Containment and Lighting

1 Without prejudice to the Conditions of Contract, access for inspection shall be provided, erected
and maintained by the Contractor. The access shall be adequate in all respects for inspection
purposes.

2 Manual surface preparation and coating application work shall not be carried out when light
intensity at the workface is less than 500 lux. When the natural light intensity falls below this
level, the Contractor shall install and maintain temporary lighting which shall provide a minimum
light intensity of 500 lux over at least 1.0 m² at the workface during the work and also for
inspection when required

1984 Maintenance Provision - Additional Requirements for the Protection of

CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket
Arms
Applicable Clauses

1 Unless otherwise described in Appendix 19/8, the work described in this Clause shall be carried
out in compliance with Appendix 19/6 and with Clauses 1970 to 1983 except that, only one stripe
coat in undercoat paint is required.

June 2014 66
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