New Jersey

Department of Transportation

Standard Specifications

for Road and Bridge Construction


Division 550 – Structure Rehabilitation
  Section 551 – Bridge Deck Rehabilitation
    551.01 Description
    551.02 Materials & Equipment
    551.03 Construction
      551.03.01 Repair of Concrete Deck
      551.03.02 Scarification
    551.04 Measurement and Payment
  Section 552 – Pressure Injection Sealing
    552.01 Description
    552.02 Materials & Equipment
    552.03 Construction
      552.03.01 Pressure Injection Sealing
    552.04 Measurement and Payment
  Section 553 – Pneumatically Applied Mortar
    553.01 Description
    553.02 Materials & Equipment
    553.03 Construction
      553.03.01 Pneumatically Applied Mortar
    553.04 Measurement and Payment
  Section 554 – Painting Existing Bridges
    554.01 Description
    554.02 Materials & Equipment
    554.03 Construction
      554.03.01 Pollution Control System
      554.03.02 Cleaning and Painting
      554.03.03 Testing, If and Where Directed
    554.04 Measurement and Payment

Division 550 – Structure Rehabilitation

Section 551 – Bridge Deck Rehabilitation

551.01 Description  back to top

This Section describes the requirements for repairing or scarifying existing concrete bridge decks.

551.02 Materials  back to top

551.02.01 Materials

Provide materials as specified:
  Coarse Aggregate 901.06.01
  Fine Aggregate 901.06.02
  Concrete 903.03
  Quick-Setting Patch Materials 903.07
  Curing Materials 903.10
  Reinforcement Steel 905.01
  Rebar Coupling Devices 905.04

551.02.02 Equipment

Provide equipment as specified:
  Spreading and Finishing Machine for Concrete Bridge Decks 1005.03
  Vibrator 1005.04
  Scarification Equipment 1006.09
  Straightedge 1008.02
  Mechanical Sweeper 1008.03
  Pavement Saw 1008.04
  Concrete Batching Plant 1010.01
  Concrete Trucks 1010.02
  Mobile Mixer 1010.03
  Small-Batch Mixer 1010.04

Submit technical data sheets for the proposed pneumatic hammers to the RE for approval.

551.03 Construction  back to top

551.03.01 Repair of Concrete Deck

  1. Deck Condition Survey. The RE will perform the deck condition survey before scarification, if scheduled, and after the removal of any existing HMA overlay and waterproofing membrane. Submit written notice to the RE at least 15 days before the work site is available for a deck condition survey. The Department will schedule surveys during daylight hours unless the working time is restricted in the Contract. The RE will perform surveys only if the ambient temperature has been above 40 °F for at least 72 hours before the beginning of the survey and only if the deck is dry. The RE will use the data obtained to determine the repair limits.

  2. Sawcut and Removal. When Type C repair is specified or full depth repair is required, provide temporary shielding, as specified in 201.03.03, to prevent debris from falling below the deck. Saw cut repair areas to a 3/4-inch depth.

    Remove loose and disintegrated concrete from the areas to be repaired to a sound concrete surface. Ensure that the remaining concrete is not damaged during concrete removal. Ensure that the reinforcement steel is not damaged or debonded during concrete removal. The Contractor may remove concrete or prepare and shape repair areas with power chipping or hand tools. Do not use pneumatic hammers heavier than 33 pounds. The Contractor may start such tools in the vertical position but must immediately tilt to a 45-degree operational angle. Do not operate pneumatic hammers and chipping tools at an angle exceeding 45 degrees relative to the surface of the deck slab. Do not use pneumatic hammers heavier than 20 pounds for chipping areas directly below the top longitudinal reinforcement steel or within 6 inches of the primary girder reinforcement steel, such as stirrups in prestressed concrete girder configurations.

    Remove concrete to the depth specified for the following type of repair.

    1. Type B Repair. For Type B repair, remove delaminated, deteriorated, and designated deck concrete to a minimum depth of 1 inch below the bottom of the top layer of existing reinforcement steel to a maximum depth of 50 percent of the thickness of the existing concrete deck. The RE may require the Contractor to remove sound concrete to achieve the limits of the designated repairs.

    2. Type C Repair. For Type C repair, remove delaminated, deteriorated, and designated deck concrete for the full depth of the existing deck. The RE may require the Contractor to remove sound concrete to achieve the limits of the designated repairs. Collect the concrete and reuse as specified in 202.03.07.A.

  3. Cleaning and Splicing Reinforcement Steel. Clean corroded, uncoated reinforcement steel by sandblasting, waterblasting, or wire brushing. For coated steel, clean areas where the coating is damaged by wire brushing and repair the coating according to AASHTO M 284. For reinforcement steel that has lost 25 percent or more of its original cross-sectional area, splice in or couple new epoxy-coated reinforcement steel of the same size. Lap the reinforcement steel at least 15 bar diameters from each end of the damaged area and wire tie together. If necessary, perform additional chipping of adjacent concrete to provide for this lap. Where reinforcement steel is broken or missing, lap new bars at least 30 bar diameters from each end of the break.

  4. Patching. The Contractor may use Class A concrete or Type IA or IB quick-setting patch material, whichever is specified. For Type C Repair, provide forms for placing the patch material.

    1. Class A Concrete. Perform patching within the limitations specified in 504.03.02.C. Place concrete as specified in 405.03.02.D.1.b; consolidate and strike-off as specified in 405.03.02.D.1.c; and texture with a broom. Cure the repair areas as specified in 504.03.02.F.

      Do not place traffic, equipment, or other loading on the patch material until the concrete has cured 72 hours and has attained a minimum strength of 4000 pounds per square inch as determined from 2 test cylinders cast during placement and field cured.

    2. Quick Setting Patch. For Type IA or IB quick-setting patch material, place according to the manufacturer’s recommendations. Wet cure the patched area using wet burlap, as specified in 504.03.02.F.2, immediately after placing and finishing. Keep the patched area covered for 3 hours.

      Do not open repair to traffic until compressive strength as measured by the average of 2 test cylinders is more than 2000 pounds per square inch. If the required compressive strength is not met by the time the roadway must be opened to traffic, open to traffic. Remove and replace the repair during the next available roadway closure.

551.03.02 Scarification

Before beginning concrete removal, perform a field survey for each stage of construction to establish existing grades and cross slopes and determine finished grades and cross slopes. Take elevations longitudinally every 10 feet and transversely at the gutterlines, breaklines, and the center of each lane and shoulder. The RE may direct additional elevation checks in areas with rapid changes in grade so that intermediate longitudinal checks can be made. Submit the field survey to the RE 5 days before scarifying.

Scarify the surface and ensure that the existing transverse and longitudinal joints are not damaged. Remove concrete and other materials that result from scarifying by hand, mechanical sweeper, or vacuum, and reuse as specified in 202.03.07.A. Do not use water or air to remove the scarified material.

If the RE designates additional areas of deteriorated concrete for repair after scarification, repair the areas as specified in 551.03.01.

551.04 Measurement and Payment  back to top

The Department will measure and make payment for Items as follows:
  Item Pay Unit
Additional Reference Material
Item Number List

At bridge deck repair areas outlined as either Type B or Type C Repair on the Plans or at locations designated, the Department will make final payment for each outlined area for only one of the 2 repair types as determined by the final depth as measured in the field and as specified in the construction details regardless of original designation or preparatory work for another repair type.

Section 552 – Pressure Injection Sealing

552.01 Description  back to top

This Section describes the requirements for repairing cracks in concrete using pressure injection sealing.

552.02 Materials  back to top

552.02.01 Materials

Provide materials as specified:
  Epoxy Injection Material 919.11

Use an epoxy crack sealant recommended by the epoxy injection material manufacturer.

552.02.02 Equipment

Provide equipment as specified:
  Epoxy Resin Injection Equipment 1005.07

Submit technical data sheets for the proposed core stopper drill or an equivalent drill to the RE for approval.

552.03 Construction  back to top

552.03.01 Pressure Injection Sealing

  1. Crack Repair Survey. The RE will examine the structure to verify the repair limits shown on the Plans. At least 15 days before the start of crack repair, notify the RE in writing and make the work site available for this examination. The RE may increase or decrease the limits of repair based on the examination. The RE will schedule surveys during daylight hours unless the working time is restricted in the Contract.

  2. Preparing for Repair. Remove deteriorated, damaged, and loose concrete from the crack area. Drill port holes at 3-foot intervals along the crack. Perform additional surface preparation requirements according to the epoxy manufacturer’s recommendations.

  3. Sealing Surface Cracks. Seal the surface of the crack with an epoxy crack sealant. Ensure that this sealer does not obstruct the port holes for the pressure injected epoxy resin and is capable of containing the injected epoxy resin. Ensure that the sealant is hard before injecting the epoxy resin adhesive.

  4. Injecting Epoxy Resin Adhesive. Mix and apply the epoxy resin adhesive according to the manufacturer’s recommendations and the following. Begin by injecting the lowest entry port and continue until the epoxy adhesive has reached the next port hole in the crack. Stop injection and immediately seal the port hole before moving the injection to the next port hole. Continue the operation by injecting the epoxy resin adhesive into the next port hole in the crack. Continue the operation until the crack is filled.

  5. Finishing the Surface. When the crack has been filled and the epoxy resin adhesive has cured, grind smooth the surface of the crack repair area to match the surrounding concrete.

552.04 Measurement and Payment  back to top

The Department will measure and make payment for Items as follows:
  Item Pay Unit
Additional Reference Material
Item Number List

Section 553 – Pneumatically Applied Mortar

553.01 Description  back to top

This Section describes the requirements for removing and restoring deteriorated concrete with pneumatically applied mortar.

553.02 Materials  back to top

553.02.01 Materials

Provide materials as specified:
  Fine Aggregate 901.06.02
  Cement 903.01
  Curing Materials 903.10
  Reinforcement Steel 905.01
  Water 919.08

553.02.02 Equipment

Submit technical data sheets for the proposed pneumatic hammers to the RE for approval.

553.03 Construction  back to top

553.03.01 Pneumatically Applied Mortar

  1. Limits of Repair. The RE will examine the structure to verify the repair limits shown on the Plans. Submit written notice to the RE at least 15 days before the work site is available for examination. The RE may increase or decrease the limits of repair based on the examination. The RE will schedule surveys during daylight hours unless the working time is restricted in the Contract.

  2. Preparing and Cleaning. Remove deteriorated concrete to a sound surface and at least 1 inch beyond the first mat of reinforcement steel. Do not use pneumatic hammers heavier than nominal 30-pound class (33 pounds maximum) to remove the concrete. For abutment, pier seat, or column repairs, do not extend removal under the bearing seats without approval of the RE. Clean and replace reinforcement steel as specified in 551.03.01.C.

    Chip concrete encasement cavities so their sides are perpendicular to the exposed surface for at least 1/2 inch in depth. Remove loose particles from the areas receiving mortar by flushing or scouring with compressed air jets

  3. Test Panels. Construct test panels using the equipment, materials, and mix proportions proposed for each type of repair on the Project. Construct test panels that are at least 30 × 30 × 3 inches for each mix, for each type of repair, and for each shooting position to be encountered on the job, including the overhead position. Construct test panels to the same thickness as the repair, but not less than 3 inches thick. Apply the mortar for the test panels, against similar support conditions to simulate actual field conditions for concrete repairs. The ME will mark the test panels at the time of application. Field cure panels in the same manner as the work for 7 days. Deliver the test panels to the ME after the field cure is complete.

    The ME will take 3 cores from each test panel. If the average compressive strength at 28 days is less than 3500 pounds per square inch, the test panel fails. Modify the mix proportions or the shooting procedure and construct a new test panel for approval of the repair.

  4. Applying Mortar. Protect pedestrian, vehicular, and other traffic upon, underneath, or adjacent to the structure, and all portions of the structure against damage or disfigurement by spatters and splashes. If RE determines that the Contractor’s method is deficient, cease applying mortar and submit working drawings for approval detailing a new method.

    Apply mortar according to the manufacturer’s recommendations. Ensure that successive layers fully bond to the previous layer during application. Blend the edges of the repair area to meet the existing surface.

    Immediately remove mortar dropped or splattered on adjacent surfaces, the superstructure, and the substructure.

  5. Curing. After applying the final layer of mortar, apply 2 coats of curing compound each at a rate of 1 gallon per 200 square feet of surface in a continuous, uniform film with power-operated pressure spraying equipment. Apply the second coat between 15 and 30 minutes of applying the first coat. If the method of applying the curing compound produces a nonuniform film, discontinue application and correct procedure.

553.04 Measurement and Payment  back to top

The Department will measure and make payment for Items as follows:
  Item Pay Unit
Additional Reference Material
Item Number List

Section 554 – Painting Existing Bridges

554.01 Description  back to top

This Section describes the requirements for cleaning and painting structural steel and metal surfaces on existing bridges using an epoxy mastic coating system or an organic zinc coating system.

554.02 Materials  back to top

554.02.01 Materials

Provide materials as specified:
  Structural Steel Paint 912.01.01

Use an organic zinc paint system or epoxy mastic paint system as shown on the Plans.

Use a reclaimable abrasive blast cleaning medium capable of providing the specified anchor profile. If the RE determines that work site conditions prohibit the use of a reclaimable abrasive medium, the Contractor may use low dusting, silica-free abrasives. Ensure that the pH level of the abrasive is between 6.0 and 8.5. At least 5 days before blast cleaning, submit samples of the proposed abrasive to the RE for approval.

554.02.02 Equipment

Ensure that equipment that uses compressed air has oil traps and moisture separators installed in the air supply lines. Change the traps and separators on a regular basis, according to the manufacturer’s recommendations. Ensure that compressed air complies with the requirements of the blotter test according to ASTM D 4285.

Only use approved rubber rollers on scaffold fastenings or other protective devices that will not mar the coated surface.

554.03 Construction  back to top

554.03.01 Pollution Control System

At least 30 days before removing paint, submit a pollution control system to the RE for approval. Keep a copy of the approved plan on Project Limits. Submit updates to the plan to the RE for approval as necessary to reflect new information, new practices or procedures, changing site environmental conditions, or other situations that may affect site workers. Do not change or deviate from the approved pollution control system without the approval of the RE. The pollution control system applies to all personnel entering the Project Limits.

Ensure that the pollution control system and any other equipment does not encroach upon the bridge clearances over traveled roads or navigable water, unless approved by the RE.

If any part of the pollution control system fails to function at the required level of efficiency during operations, immediately suspend the operations. Do not resume work until modifications to correct the cause of the failure have been made and approved by the RE. If the failure is due to adverse weather conditions such as high winds, immediately suspend the operations until the weather conditions become favorable.

Include the containment plan, the waste disposal plan, the lead health and safety plan, and the equipment storage plan in the pollution control system. Ensure that the certified industrial hygienist (CIH) certifies monthly, in writing, to the RE that the Contractor is in compliance with the Pollution Control System.

  1. Containment Plan. Describe, in detail, the method of providing, erecting, maintaining, and removing enclosures as required to contain and collect waste resulting from the removal of coatings in the preparation of steel surfaces for painting. Ensure that the containment system is at minimum a Level-1 Containment System according to SSPC Guide 6i (con). Ensure that visible emissions meet or exceed Section, Level 1 Emissions. Containment may consist of “local” systems, such as small enclosures where power tools are used, or certain enclosed vacuum blasting techniques where suction captures the abrasive and paint residue directly from the surface, removes paint and fine particles, and returns the abrasive to the blast nozzle.

    Submit working drawings for approval that include, at a minimum, the following:

    1. Specific design of the containment plans to be employed.
    2. Types of materials used.
    3. Method for reclaiming the blasting medium.
    4. Design of hangers.
    5. Assembly and disassembly procedures.
    6. An analysis of maximum loading and deflection signed and sealed by a Professional Engineer that will be added to the existing structure by the proposed system when put into use. Ensure that the proposed system does not induce a load on the superstructure or substructure that creates an adverse overstress condition or otherwise induces an undesirable effect on the structure and affected members.
    7. Type of solid/rigid floor (specify maximum load). Detail how the floor will be constructed, dimensions, and how funnels may be used. When using the ground as solid/rigid flooring, describe how it will be secured and incorporated into the containment enclosure. When using a floating or suspended platform, include details about its construction. Describe how waste is to be off-loaded from the platform, how the platform is to be tied off, and how storage drums are to be handled if they are to be loaded onto the platform.
    8. Type of dust proof and wind resistant enclosures designed to contain, as well as facilitate, the collection of waste resulting from the surface preparation.
    9. Type of connection to structure. Do not weld; obtain RE approval before bolting.
    10. Type of lighting inside the containment structure during blasting and inspection.
    11. Type of dust collection equipment. Design air flow inside the containment structure to meet applicable OSHA standards. Describe how the dust collector will be incorporated in the containment enclosure and how make-up air will be provided.
    12. Type of vacuum truck or equivalent method to capture, contain, collect, store, and dispose of all rust and paint particles, dust, and all other contaminated material generated by the work, either in the vicinity of or within the containment system.
    13. The run-off route from existing deck drains through the enclosure.

    Include an emergency management plan outlining specific procedures to be followed in the event that the primary containment system fails to contain the materials and results in pollution of the environment. Provide details of equipment, materials, and methods that will effectively contain material that escapes during a failure of the primary system. Provide the necessary components of the emergency management plan at the Project Limits at all times when the work is in progress.

    Also include an outline of people to be notified in the event of a failure resulting in pollution of the environment according to the rules and regulations of the applicable agencies.

  2. Waste Disposal Plan. Describe, in detail, the means of handling, storing, transporting, and disposing of the waste generated by the removal of the existing paint systems. Include the following:

    1. Description and quantity of storage containers sized for the job that conform to 49 CFR 173 and 178. Ensure that each storage container has a protective liner and removable lid.
    2. The proposed method to contain the stored material and all necessary permits or licenses required.
    3. The location and design of temporary storage and loading facilities.
    4. Commitment letters from properly licensed and insured waste transporters; the name and EPA identification number of the transporter; name, address, and telephone number of responsible contact for the transporter; list of all types and sizes of transportation vehicles and equipment to be used; transportation methods and procedures for transporting waste materials; necessary permit authorizations; and previous experience in performing the type of work.
    5. The transportation/storage/disposal (TSD) facility, including a commitment letter from the TSD facility indicating that it has the capacity to accept the estimated volume of waste material and stating that it will be open for business during the Contract duration to accept the estimated volume of waste materials specified herein. Also submit at least 2 alternative TSD facilities in the event the approved facility ceases to accept waste materials generated under the Contract.

  3. Lead Health and Safety Plan (LHASP). Employ a CIH to develop the LHASP. Include in the plan the means to implement and maintain the protocols necessary for protecting personnel from hazards associated with the Project operations and activities. Establish and describe how policies, programs, and procedures that are necessary to comply with all Federal, State, and local laws, rules, and regulations will be maintained. Do not modify or change this plan without approval of the CIH and the RE. At a minimum, include the following elements:

    1. Introduction. Include scope; structure locations; names, addresses, and telephone numbers for the Contractor’s project manager, field superintendent, CIH, occupation physician, health and safety officer (HSO), and available emergency assistance; organization and responsibilities; and an approval sheet with the signatures of the project manager, field superintendent, and qualified person.

    2. Physician Requirements. Qualification and responsibilities of the physician, certified in occupational medicine by the American Board of Preventive Medicine, that will provide the medical surveillance, removal, and protection program.

    3. HSO Requirements. Qualifications of HSO, including laboratory experience, studying field conditions, formal experience necessary to perform technical monitoring, consulting, testing, and inspecting and the authority to take prompt corrective measures to eliminate the hazards.

    4. Exposure Monitoring Procedures. Ensure that no employee is exposed to lead at concentrations greater than 50 micrograms per cubic meter of air averaged over an 8-hour period. Include the method of compliance for determining if any employee is or will be potentially exposed to airborne concentrations of lead at or above the action level. The Contractor may use the task “trigger” method outlined in 29 CFR 1926.62(D)(2) until the actual exposure assessment is documented.

    5. Protective Equipment. Provide the following:

      1. Type and number of respiratory protection according to 29 CFR 1926.62 (F).
      2. Type and number of protective work clothing and equipment according to 29 CFR 1926.62 (G), 1926.28(A), 1910.132, and 1910.94

    6. Facilities. Provide the following:

      1. Hygiene facilities and practices including changing and showering facilities.
      2. Eating facilities for employees exposed above the permissible exposure level, without regard to respirators, including method to ensure that employees do not eat or drink in contaminated areas according to 29 CFR 1926.62 (I), 1926.21, 1926.51, and 1910.141.
      3. Method to keep all work sites clean and free of lead to the extent that the work process allows according to 29 CFR 1926.62 (H), 1926.25, and 1926.20. Only use a vacuum with a H.E.P.A. filter or wet cleaning methods when removing lead dust.

    7. Medical Surveillance Program. Include removal and protection procedures according to 29 CFR 1926.62 (J). Include, at a minimum, the following:

      1. Method of providing a pre-employment physical exam for all employees that consist of a medical questionnaire that ascertains previous medical history related to lead exposure and symptomatology of lead exposure or exposure to any other toxins; blood lead and zinc protophrphyrin (ZPP) counts together with hemoglobin and hematocrit, blood urea nitrogen, and serum creatinine; physician’s approval for employee to wear negative pressure respirators; and a thorough hands-on physical exam that includes special attention to systems affected by lead, such as renal, hematological, neurological, gastrointestinal, cardiovascular, and reproductive.
      2. Method of conducting monthly blood lead sampling and ZPP counts and evaluating and posting the levels monthly, at the Project Limits, for the duration of the lead-exposed portion of any Project.
      3. Method of removing workers whose blood lead levels exceed 50 micrograms per 100 grams of whole blood from further airborne lead exposure in excess of 30 micrograms per cubic meter of air averaged over an 8-hour period, based upon biological monitoring or a physician’s determination.
      4. Method for retraining employees, and upgrading respiratory protection for employees whose blood lead levels exceed 40 micrograms per 100 grams of whole blood at any time during their employment.
      5. Method of conducting post employment or yearly physical exams (whichever comes first) for employees who had blood lead levels in excess of 40 micrograms per 100 grams of whole blood at any time during their employment. This examination shall include as a minimum, blood lead and ZPP counts and a thorough hands-on physical.
      6. Ensure that any physician who provides these physical exams and tests has been made aware of the employee’s job duties, any airborne lead levels, the inherent lead exposure, and if applicable, all previous medical history and blood levels generated by other physicians.
      7. Name and address of New Jersey clinical laboratory approved by OSHA that has demonstrated proficiency in blood lead analyses to conduct blood monitoring.
      8. Method of providing copies of individual blood lead levels and ZPP levels and explaining results to the employee within 5 days of receiving the results.

    8. Information Distribution. Provide the following:

      1. Employee information and training procedures that inform employees of the hazards of lead and train in the precautions to take when working with lead.
      2. System of posting warning sign where exposure is above the permissible exposure limit. Use illuminated, clean, and visible signs according to 29 CFR 1926.21 and 1926.59.

    9. Protection Procedures. Procedures to protect personnel and the general public in case of emergencies including potential emergency situations such as, but not limited to, overt personnel exposure, personnel injury, fire or explosion, and environmental incident.

    10. Chain of Command. Include the chain of command and responsibilities for emergency situations, including a contingency plan for large-scale emergencies such as site evacuation or other situations requiring significant outside emergency services and interactions.

    11. Decontamination procedures. Provide a detailed decontamination method.

  4. Equipment Storage Plan. Describe, in detail, the locations of non-working hour storage of equipment to be utilized, the type and number of additional and special traffic control devices needed to safely maintain the storage area, and any permits and local permissions, if required. Ensure that the plan is site specific for each stage of operation, and provide an escort vehicle to assist slow-moving equipment entering or exiting the work zone.

554.03.02 Cleaning and Painting

  1. Protection of Environment, Structure, Person, and Property. Protect pedestrian, vehicular, and other traffic upon, underneath, or adjacent to the bridge, and all portions of the bridge superstructure and substructure against damage or disfigurement by spatters, splashes, and smirches of paint or paint materials. Provide canopies and drop cloths for such protection. Do not use drilling holes, field welding, or bolted connections to secure the containment system to the bridge structure.

    The Contractor is hereby advised that the existing paint systems on the bridges may include red lead or basic lead silica chromate paint or both red lead and basic silica chromate paint as components.

    For contracts that involve lead paint abatement, ensure that the personnel that perform the lead paint abatement are trained and certified in the applicable workers’ programs that concern health and safety compliance and that concern environmental regulations regarding lead abatement. The Department of Health and Senior Services shall train personnel. The Department of Community Affairs, Division of Codes and Standards, shall certify personnel.

    Ensure that only trained and certified personnel perform lead abatement activities. Only use lead abatement practices as described in the Industrial Lead Paint Removal Handbook. The Department of Labor will monitor contracts for compliance with the training and certification requirements.

  2. Cleaning. Remove signs mounted on the fascia beams of the structures before cleaning. Mount vertical under clearance signs on the fascia beam or containment system until the cleaning is finished.

    Ensure that the containment enclosure extends from the bottom of the deck down to ground level or to a solid work platform. Frame and fasten materials for the enclosure to prevent billowing or opening from the weather. When using tarpaulins, ensure that all edges and seams have a flap that clamps over the connecting edges for the entire enclosure. Fasten these flaps along the tarpaulin edges to prevent dust from escaping.

    Do not begin cleaning or blasting until the pollution control system and all required permits for the handling, storage, and transportation of waste have been approved and the RE approves the containment enclosure.

    When organic zinc coating is specified, only blast-clean structural steel members.

    When spot blast cleaning is specified, before the cleaning operations, remove accumulated dirt and dust, and complete a thorough examination and survey of the existing surfaces to identify areas of paint failure and corrosion that will require blast cleaning outside the limits designated.

    Clean existing structural steel that has been previously painted and surfaces of other metal. Protect all components and materials that are not scheduled for blast cleaning during those operations.

    1. Hand or Power Tool Cleaning. Before hand or power tool cleaning, remove all visible oil, grease, and salts by solvent cleaning as specified in SSPC-SP 1. Roughen all existing paint left on the surface after hand or power tool cleaning before applying paint. Ensure that existing surfaces to be prepared by hand or power tool cleaning, or a combination of both, complies with the requirements of SSPC-SP 2 and SSPC-SP 3, respectively.

    2. Blast Cleaning. Before blast cleaning, scrape the tops of bottom flanges to remove accumulated dust, dirt, and debris. Remove all visible oil, grease, and salts by solvent cleaning according to SSPC-SP 1.

      Prepare existing surfaces by near-white blast cleaning according to SSPC-SP 10. Ensure that the blast cleaning produces the required anchor profile of 1.5 to 3.0 mils, in a dense, uniform pattern of depressions and ridges. Verify the profile depth by the Testex replica tape.

      Do not blast clean a surface area of steel greater than the surface area of steel that can be prime coated within 24 hours.

      Remove all fins, tears, slivers, and burred or sharp edges that are present on any steel member or that appear during the blasting operations by grinding. Reblast the ground area and ensure that the reblasted area meets the required anchor profile.

      Contain, capture, and collect blasting residues, spent blasting medium, rust particles, paint particles, and dust associated with the work.

      Collect blast medium and paint residue from steel surfaces with a commercial grade vacuum cleaner equipped with a brush-type cleaning tool or by double blowing with clean air. If the double blowing method is used, vacuum the top surfaces of all structural steel after the double blowing operations are completed. Keep the steel clean until the prime coat is applied.

      Protect freshly coated surfaces from subsequent blast cleaning operations. Thoroughly wire brush blast damaged primed surfaces. If visible rust occurs, reblast to the required condition. Vacuum and reprime the wire brushed or blast cleaned surfaces.

      During blast cleaning, if the containment enclosure is allowing waste to escape, stop work until the enclosure is repaired. Clean up any waste released from the enclosure immediately. If the wind velocity is high enough to cause the containment enclosure to billow, cease blast cleaning and lower the enclosure after cleaning up all the waste.

  3. Waste Disposal. Provide, install, and maintain any temporary loading and storage facilities on-site as required until completion of material handling activities.

    The RE will review the storage containers and storage location. Locate storage containers so as not to prevent a traffic or safety hazard. Locate storage containers in areas that are properly drained and where run-off water will not pond around or near the containers. Close storage containers and cover with tarpaulins at all times except during placement, sampling, and disposal of the waste.

    After removing and collecting the waste from surface preparation work, the RE will designate the rust, paint particles, and dust associated with the work as “Hazardous Waste,” with the corresponding USEPA hazardous waste code D008.

    Place expendable material and decontamination liquids generated from construction activities within the containment area, including respirator cartridges, protective clothing, boots, and gloves, in watertight containers. Separately store all personnel protection equipment, decontamination liquids that become contaminated due to contact with hazardous waste or materials containing hazardous substances, and other expendable wastes, and dispose in containers identified in the waste disposal plan. Ensure that these containers do not have indentations or shipping damage that would allow leakage of the contained material.

    Store waste in the on-site loading facility and storage area until transportation vehicles arrive for off-site disposal. Dispose of all hazardous waste within 75 days or before Substantial Completion, whichever comes first.

    Continuously monitor the quantity of the waste captured, contained, collected, stored, and disposed of. Document the handling, sampling, manifesting, transporting, and disposal of hazardous waste. Maintain a complete and accurate record, located with the Project Limits, of all blasting medium purchased, delivered, and used during the execution of the Work. To allow for verification inspections, submit, to the RE on a weekly basis, both the record of the blasting medium delivered and used, and the waste handling, sampling, manifesting, transporting, and disposal documentation.

    Move the contained waste materials to the storage area or dispose of at regular intervals (once each working day, minimum) during the work, according to the waste disposal plan, field conditions, and the direction of the RE. Remove errant waste from the bridge deck, structural steel, piers, abutments, and other areas, at least once a day or more frequently if required or directed. Clean any spillage of waste that may occur during disposal operations, including during the loading, transport, and unloading of materials, according to NJDEP regulations N.J.S.A. 58:10-23.11, et seq.

    Only use the transporters identified in the waste disposal plan. Do not substitute or use additional transporters without approval from the RE. Do not combine contaminated material from other projects with material from this Project. Obtain and submit a copy of the test results of the waste from the TSD facility to the RE.

    Comply with the manifesting requirements specified in 202.03.09.

    Ensure that the waste transporter’s vehicles and operating practices prevent spillage or leakage of hazardous or contaminated material while transporting to the final disposal site.

  4. Conditions for Painting. Provide a suitable facility for the storage of paint that will comply with the latest OSHA regulations. Store and protect paint and thinners from the weather in enclosed structures at 40 to 110 °F. Equip the enclosure with a recording thermometer.

    Comply with the conditions for painting according to SSPC-PA 1.

    Do not apply epoxy coating or organic zinc coating when the temperature is below 50 °F or when the relative humidity is above 90 percent. Do not apply the urethane coating when the temperature is below 40 °F or when the relative humidity is above 90 percent. Do not apply any coatings when the wind velocity exceeds 20 miles per hour, when the air is misty, or when, in the opinion of the RE, conditions are unsatisfactory for the work. Also, do not paint on damp or frosted surfaces or when the metal is hot enough to cause the paint to blister, produce a porous paint film, or cause the vehicle (binder) to separate from the pigment.

    Do not paint when the steel surface temperature is lower than 5 °F above the dew point. The RE will determine the dew point using a psychrometer and appropriate tables. The Contractor may presume the dew point requirement to be satisfied if a thin, clearly defined film of water, applied to the cleaned vertical surface with a damp cloth, evaporates within 15 minutes, as determined by the RE.

    Do not apply coatings when the temperature of the air, paint, or metal, or the relative humidity is expected to be outside of specified limits before the paint is fully cured.

  5. Paint Application.

    1. Mixing Paint. Mix coatings according to SSPC-PA 1 and the manufacturer’s recommendations.

    2. Thinning Paint. If it is necessary to thin the coating for proper application, thin the paint according to the manufacturer’s recommendations.

      In cool weather, the Contractor may warm the paint to reduce the viscosity. The Contractor may heat the paint by placing the paint containers in water or on steam radiators.

    3. Preparing the Surface. When surfaces requiring repainting are in contact with concrete, use a non-aluminum epoxy mastic primer approved by the Department’s Bureau of Materials.

      When full depth deck repair or replacement is specified, apply a prime coat to the top surfaces of top flanges of existing steel girders excluding the shear connectors.

      Do not paint aluminum alloy metal work, copper, SIP forms for concrete decks, and bridge deck grid flooring.

      Remove zinc salts, oil, dust, dirt, and other contaminants before applying each coat of paint and any repair coats in the field. Clean the primed surfaces with a high pressure water washing (800 pounds per square inch minimum).

      When applying paint to a galvanized surface, use epoxy intermediate and urethane finish coats only. When using the epoxy mastic coating system, apply the full coating system.

    4. Applying Paint. Apply paint only on clean dry surfaces according to SSPC-PA 1. Apply paint using brushes, rollers, spray equipment, or any combination of equipment that will attain satisfactory results and the film thickness specified. Apply paint uniformly and smoothly so that every part of the surface will be covered with the minimum specified thickness. On surfaces that are inaccessible for painting by regular means, apply paint by sheepskin daubers or spray, or by other means if necessary, to ensure coverage of the proper thickness of paint.

      Whenever painting operations are interrupted, expel the remaining paint in the fluid hose from the hose. Thoroughly clean spray equipment at the end of each workday with an approved solvent. Properly dispose of the left over solvent and paint waste material.

      If the paint coating is too thin or if areas of the surface are not completely coated, repaint these areas of the work. Where excessive coating thickness produces surface defects such as “mud-cracking,” remove coating back to soundly bonded coating, and recoat the area to the required thickness. In areas of deficient primer thickness, recoat according to the manufacturer’s recommendations.

    5. Coating Thickness. The RE will use a magnetic dry film thickness gauge to determine the dry film thickness for each coat. Calibrate the gauge and use according to SSPC-PA 2. Use a Tooke film thickness gauge according to ASTM D 4138 to verify the coating thickness when requested by the RE. If the Tooke gauge shows that the prime coat is less than the specified minimum thickness, the RE will reject the entire coating system.

      1. Epoxy Mastic Coating System. Apply at least 1 coat of each of the following in the field: spot prime (over blast cleaned or exposed surfaces), prime, and finish coats. Place a full prime coat over the entire surface, including areas that have been spot primed.

        Ensure that the dry film thickness of the paint is at least 5 mils for the spot prime coat, at least 3 mils for the prime coat, and at least 2 mils for the finish coat.

      2. Organic Zinc Coating System. Apply at least 1 of each of the following coats in the field: prime, intermediate, and finish coats.

        Ensure that the dry film thickness of the paint is at least 5 mils for the prime coat, at least 3.5 mils for the intermediate coat, and at least 2 mils for the finish coat.

    6. Prime or Spot Prime Coat. Tint the primer to contrast the base metal. Apply the prime or spot prime coat immediately after obtaining RE approval of the surface preparation. Apply the prime or spot prime coat the same day the metal is cleaned, but not until the cleaning operation is far enough ahead to eliminate the danger of dirt or other material from the cleaning operations from falling or blowing onto the fresh paint. Prime or spot prime all blast cleaned surfaces the same day before any contamination, formation of rust, or any other deterioration of the prepared surface.

    7. Curing. Comply with the manufacturer recommended curing time between coats. If the manufacturer’s recommended curing time is exceeded, follow the manufacturer’s recommendation to prepare the surface for succeeding coats.

    8. Striping. Before applying the full prime coat, apply a prime coating (striping) to all edges of plates and rolled shapes, corners, crevices, welds, and exposed parts of bolts. Do not apply the full prime coat until the striping has set to touch.

    9. Cleanup. Replace signs that were removed during cleaning and painting to their original position. Remove paint dropped on concrete surfaces and all debris from the cleaning operations from the superstructure and the substructure. Remove over-sprays on adjacent portions of the structures. Remove paint containers and refuse from the Project Limits.

  6. Stenciling. Stencil the following information on the outside web of both fascia beams, on both ends of the structure, and as specified below:

    1. The 7-digit structure number.
    2. The month and year of completion.
    3. The paint system code number.

    Stencil uniform 4-inch high, C-series letters or numerals with the same type of paint except use a color that contrasts the structure. Locate markings at least 2 inches above the lower flange and not more than 3 feet from the abutment. In the case of a bascule bridge, stencil information 3 feet from the heel of the bascule span.

    In addition, thoroughly clean all memorial or commemorative metal plaques that are affixed to the structure or appurtenance. Submit the method of cleaning along with a sample of the materials intended for use to the RE for approval. Clean the plaques to the satisfaction of the RE according to the approved method, and ensure the removal of accumulated dirt, extraneous markings, and corrosion without marring, eroding, or staining the plaques in any way.

  7. Unsatisfactory Paint Performance and Removal. The Department will consider the paint performance unsatisfactory if rusting occurs, if the paint coat lifts, blisters, wrinkles, has excessive runs or sags, or shows evidence of application under unfavorable conditions, if the workmanship is poor, if impure or unauthorized paint has been used, or for other such reasons determined by the RE.

    Remove any unsatisfactory paint, and reclean and repaint the metal.

554.03.03 Testing, If and Where Directed

The RE may direct the Contractor to conduct or to obtain the services of others to conduct air quality, water quality, or such other testing that will determine the quantity of any materials that may be escaping from the containment plan employed on the Project. If it is determined that pollution of the environment adjacent to the site has occurred due to the Contractor’s operations, stop cleaning and painting and immediately submit a plan to the RE for approval detailing the corrective actions necessary to restore the area. Correct the containment measures. Do not continue cleaning or painting until the RE directs the work to begin.

The Department may conduct additional testing using the Department Laboratory.

554.04 Measurement and Payment  back to top

The Department will measure and make payment for Items as follows:
  Item Pay Unit
  Pollution Control System LUMP SUM
Additional Reference Material
Item Number List

The Contract quantity of Testing, If and Where Directed is lump sum and the bid price is $10,000 for each occurrence in the Contract. The Department will base payment for Testing, If and Where Directed on the actual cost as evidenced by paid receipts from the testing laboratory. The Department will not make payment for overhead or profit for this item.

Last Document Correction:
May 13, 2008