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SSPC Papers

KTA-Tator, Inc. gratefully acknowledges SSPC for their permission to post the following papers presented at past PACE conferences.

PACE2008 Papers

"Coating Failures on Painted Galvanized Mast Arms" (PDF 543 Kb) Galvanized mast arms support uncounted numbers of traffic signals and signage throughout the United States. The proportion of these that have a “duplex” coating system (both galvanizing and organic coatings) is unknown. However, the number is surely significant, and the number of coating system failures is also significant. The Florida Department of Transportation has estimated there are at least 2,400 mast arm coating failures throughout the State, 150 in the Jacksonville, FL area alone. The authors will discuss findings and experiences from investigating the causes for failures of the mast arm duplex systems and remedies available to owners.
Paul Vinik, MSChE, P.E., Florida Department of Transportation
Richard A. Burgess, B.S, M.S, KTA-Tator, Inc.

"Overcoming Obstacles to Repaint a Unique Structure – From Initial Planning through Project Completion" (PDF 239 Kb) The paper chronicles and discusses the challenges, options, choices and solutions from the design phase through the actual blast cleaning and painting of one of the most unique steel structures in the world, the largest radio telescope at Arecibo, Puerto Rico. Challenges included: almost daily thunder storms, a truss structure consists of 900 tons of steel elevated on cables approximately 450 feet above an 18 acre aluminum dish, penalties for dropping anything, access from only a single suspended 700 ft walkway, limitations on weight distribution and weight loads, removal of lead and mill scale in total containment, structural limitations affecting containment installation, protection of numerous delicate wires, cables, sensors and other equipment, locating/importing equipment, bureaucratic requirements, and more.
David S. Leyland, Senior Coatings Consultant, KTA-Tator, Inc.

"Maintenance Painting Management – Evaluation of 10 PacifiCorp Power Generation Facilities" (PDF 473 Kb) PacifiCorp Energy, a division of PacifiCorp, provides 7,750 megawatts of electricity every hour from 12 coal, gas and geothermal fired generating plants located in Utah and Wyoming. MidAmerican Energy Holdings Company acquired PacifiCorp in 2006 and identified coatings maintenance as a priority, both in terms of corrosion protection and aesthetics. To that end, PacifiCorp Energy’s Generation Engineering group engaged the services of an independent coatings expert to assess the painted surfaces throughout 10 of their 12 facilities, to establish painting priorities, painting cost estimates, and specifications for maintenance of the coatings. This paper describes the consultant selection process, the field survey process, results of the field surveys, and the next steps to be taken.
Lon Udy – PacifiCorp Energy, Salt Lake City, UT
Kenneth A. Trimber and Kirk Wissmar– KTA-Tator, Inc., Pittsburgh, PA

"Regulatory Update: Current and Emerging Trends in Occupational and Environmental Health" (PDF 136 Kb) This paper takes a look at emerging environmental, health and safety issues that may impact painting contactors and facility owners. Specific topics include OSHA’s hexavalent chromium standard, recent rulings related to multi-employer worksite policy and OSHA’s use of threshold limit values (TLVs®). The expected final rule on employer-paid personal protective equipment (PPE), the proposed confined space entry standard for construction, the proposed revisions to the hazard communication standard, and the American National Standards Institute standard on Hearing Loss Prevention in construction are described. EPA’s review of the NAAQS for lead and the potential implications of PM2.5 standard enforcement are reviewed. Additionally, recently enacted New York City regulations regarding scaffolding, noise mitigation, and emission control from construction vehicles are discussed. Much of the information is taken directly from the respective agency’s published regulatory agenda, supplemented by anecdotal information gathered from various professional journals, seminars and conferences.
Alison B. Kaelin, CQA and Daniel OMalley, KTA-Tator, Inc.

"Thermal Imaging as a Forensic Tool in Coating Failure Investigations" (PDF 218 Kb) This paper discusses the use of thermal imaging as an analytical tool in forensic investigations of moisture-related coating failures applied over hollow core building walls. The success of thermal imaging depends upon detecting subtle temperature differences arising from differences in thermal conductivity of the coated wall surfaces. The method is a valuable adjunct to contemporary failure investigation methodology.
E. Bud Senkowski, P.E., Senior Consultant, KTA-Tator, Inc.

"A 20 Year Performance Evaluation of an Organic Zinc Rich Paint Ssystem" (PDF 135 Kb) A five-year coatings research project was initiated by the Pennsylvania Department of Transportation in 1986 to evaluate the performance of an organic zinc rich coating system. The coating system consisted of a moisture cured urethane zinc rich primer, an epoxy intermediate, and an aliphatic polyester urethane finish coat. The system was applied to the Windgap Bridge located in McKees Rocks, Pennsylvania (near the City of Pittsburgh) in 1986 and 1987. Coating system performance was tracked for the next five years using a preestablished protocol of visual inspections and physical testing. The coating system, which has now reached a twenty-year milestone, was re-inspected in 2007. Even though no coating maintenance work was performed since the initial installation, the coating system continues to provide good corrosion protection and has maintained a good appearance.
James D. Machen, Senior Coatings Consultant, KTA-Tator, Inc.

PACE2007 Papers

"The Hal Adams Bridge: A Challenging Repainting Project on a Unique Florida Bridge" (PDF 867Kb) The Hal Adams Bridge is the only suspension bridge in the state of Florida. During the 2001 routine bridge inspection the bridge was identified as a candidate to be repainted. The authors Don Buwalda, Stephen Haney, and Greg Richards participated in the assessment, plan development, and project execution. This paper identifies areas that made the Hal Adams Bridge: “A Challenging Repainting Project on a Unique Florida Bridge.” A history of actual experiences and lessons learned will be presented from the point of view of the owner and third party inspection firms.
Don Buwalda - District 2, Florida DOT
Stephen Haney - JEAces, Inc.
Greg Richards - KTA

"Practical Considerations for the Life Cycle Evaluation of Zinc-Rich Coatings, Galvanized Steel and Thermal Sprayed Metals for Industrial Structures in Moderate Environmental Exposures" (PDF 224Kb) This paper provides an objective review of the life cycle costs of zinc-rich coating systems used in moderate industrial exposure environments. The coating systems include conventional inorganic/organic coatings, galvanizing, and thermal sprayed metal coatings (metallizing). Service life and installation cost data from previous studies is used to calculate the life cycle costs over a specified design life of an industrial structure. The life cycle costs are based on a suggested maintenance painting sequence that is outlined. A review of the costs for both shop and field coating application are discussed.
Jayson L. Helsel, P.E.

"Avoiding Problems With Coating Wood: A Review of Substrate Condition and Preparation, Moisture Issues and Coating Selection" (PDF 134Kb) This paper provides a review of key items to consider in coating wood. The most important considerations are ensuring a sound wood substrate surface, elimination of moisture as a problem, adequate surface preparation, and the proper choice of coatings. Coatings for wood can be categorized as film-forming or penetrating finishes. This paper expands on a recent related article published in the Journal of Architectural Coatings.
Jayson L. Helsel, P.E.

"Variables That Affect Calcium Moisture Chloride Testing" (PDF 78Kb) The calcium chloride moisture vapor transmission test has steadily gained acceptance in the floor coating industry. This paper discusses variables that affect the results of moisture vapor transmission testing, and presents the results of testing designed to measure the affects of certain environmental parameters on the results of calcium chloride moisture vapor transmission testing.
Rick Huntley

"Specifications and MasterFormat™ 2004" (PDF 182Kb) This paper will describe the fundamentals of MasterFormat™ 2004 and how its use can simplify the specification writing process. MasterFormat™ 2004 is jointly produced by the Construction Specifications Institute (CSI), and Construction Specifications Canada (CSC). Contractors, Owners and Specifiers can all benefit from the use of these guiding principals of specification development, especially when surface preparation, hazardous remediation, and coatings and linings are part of a larger overall scope of work. The coatings (sub) contractor can benefit by knowing how to find all pertinent data so that bids can be prepared properly. The owner can benefit by having a clearly organized specification. The specifier can benefit, as the logical format for organizing large specifications will result in less of a chance for conflicting information. MasterFormat is becoming the standard of care for the preparation of specifications.
Mike MeLampy

"Properties of Air Barrier Materials" (PDF 909Kb) This paper will describe the fundamental properties of many of the air barrier materials available for environmental separation and air tightening of buildings. It will discuss the basic requirements for an air barrier; however, there are many different air barriers materials available, and many of these materials can provide other needed properties including vapor, moisture, and thermal barriers. Each material may be fabricated to provide the needed properties to accomplish one or several of these functions. Specific material properties must be developed during manufacturing or application at specific thicknesses to allow the material to perform. The paper will discuss the application of these materials, and how their placement within the wall is effected by their intended function(s), and the expected exterior and interior environmental conditions to which they may be exposed during and after construction.
Mike MeLampy

"Cure Temperature Effects on Standard Cure and Low Temperature Cure Epoxies" (PDF 163Kb) This paper examines the effect that curing temperature has on the physical characteristics and performance of standard cure polyamide epoxies as compared low temperature cure epoxies. The purpose for this paper is threefold: FIRST, to determine if the low temperature curing epoxies are viable substitutes for the standard cure epoxies. SECOND, to determine if curing temperature can adversely affect the cure of epoxy coatings, thereby compromising corrosion protection. THIRD, to determine if a product from one manufacturer is an acceptable substitute for a similar product from another manufacturer?
David S. Leyland
Cindy O'Malley

"Factors Influencing Anchor Profile" (PDF 69Kb) Anchor profile achieved during field blast cleaning operations is often found to be deeper than expected, even when available information suggests the size of the abrasive selected was appropriate. Three parameters long identified as influencing anchor profile depth were evaluated under laboratory conditions. This paper discusses the results obtained by changing blast nozzle pressure, angle of attack (incidence) and stand-off distance on the anchor profile achieved when blast cleaning with steel grit. Anchor profiles obtained from preliminary field data are also briefly described.
Ken Barnett, PE - Texas Department of Transportation
Richard A. Burgess - KTA

PACE2006 Papers

"Ben Franklin Bridge Painting Project"(PDF 106Kb) This paper identifies the unique steps taken to safely remove lead based paint from a major highway/commuter railroad bridge connecting Philadelphia, Pennsylvania with Camden, New Jersey, followed by the application of a new long lasting protective coating system. The paper addresses project phasing by the owner and coordination with the commuter train to keep costs down and to minimize inconvenience to the public. Project innovations in equipment and accessibility are presented together with a significant partnering effort undertaken by the owner, contractor and engineering/inspection firm. Steps taken to protect the workers and the public during lead paint removal are discussed.
Lou G. Lyras - Corcon, Inc.
Vijay Pandya, P.E.- Delaware River Port Authority
Kenneth A. Trimber - KTA

"Waterproofing Concrete: A Guide to Using Water Repellent Sealers and Thick Film Barrier Coatings" (102Kb) Concrete and other cementitious surfaces are porous materials that will allow water and soluble contaminants to penetrate the structure leading to degradation. The effects of degradation can include efflorescence, laitance and physical defects such as cracking and spalling. Waterproofing concrete can protect it from freeze/thaw cycles, increase chemical resistance, and provide protection to imbedded reinforcing steel. Waterproofing coatings for concrete may include silicon based water repellant sealers and a variety of organic coatings. Water repellent materials have minimal dry film thickness over the concrete surface, are generally not opaque and need replaced periodically. Thicker film coatings function by providing a physical barrier ranging from a few mils to 100 mils and greater depending on the coating type. Typical organic coating types include acrylic, vinyl, epoxy, polyurethane and specialized elastomeric coatings. Concrete surfaces must be properly prepared before the application of any waterproofing coatings. Methods may include mechanical abrasion, pressurized water cleaning and acid etching.
Jayson L. Helsel, P.E.

"The 'Single Coat Paint System of the Future' for Steel Bridges Research Project Update" (220 Kb) Corrosion on steel bridges has long been recognized as a major concern. Over the years, technology has advanced from lead-based paints used for a century to three-coat systems. Recently, two-coat systems have been developed and are gaining acceptance. Research which is now underway to develop a one-coat system is described in this paper.
Eric Kline and Bill Corbett

"Current Trends in Occupational & Environmental Health" (51 Kb) Much of the focus of environmental, health and safety issues in the 1990’s centered on lead. No single hazard occupied the regulatory, public and media spotlight more than lead, and its impact was felt across the entire construction community. As lead fades from the spotlight, other potential hazards begin to emerge. OSHA is considering a comprehensive health standard on hexavalent chromium, the American National Standards Institute is drafting a standard on Hearing Loss Prevention in Construction, EPA and state environmental agencies are focusing attention on asbestos on bridges. These and selected other emerging issues are briefly discussed to identify health and safety issues on the horizon that may impact painting contractors and facility owners. Much of the information is taken directly from the respective agency’s published regulatory agenda, supplemented by anecdotal information gathered from various professional journals, seminars and conferences. All issues are presented in the order of reported implementation date, with OSHA related activities discussed first, followed by EPA activities. Daniel P. Adley CIH, CSP, Alison Kaelin, Stanford Liang CIH, CSP, Chris Lovelace

"An Air Barrier System in Cambridge," MIT Brain and Cognitive Sciences Project Spray Applied Air/Vapor Barrier System (1045 Kb) The 400,000 square-foot Brain and Cognitive Sciences Center (BCSC) at Massachusetts Institute of Technology in Cambridge, Massachusetts combines three different research groups to create a world-class brain research center. Designed to include both wet and dry laboratories for research, biology, biochemistry, neurobiology, and behavioral and cognitive research, the BCSC is intended to be a world class teaching and learning center. The building itself includes a multi-story day lit atrium defined by small meeting rooms, offices and seating areas for interaction among the scientists.
Kevin Knight - Retro-Specs Consultants
Mike MeLampy

"Steel Bridge Shop Painting Issues and Answers: The FDOT Experience" (240 Kb)The Florida Department of Transportation (FDOT) spends over $50 million in steel bridge fabrication and shop painting annually. According to a recent Federal Highway Administration (FHWA) sponsored study by Appleman, approximately 7% of the cost of a steel bridge is budgeted for blast cleaning and primer application in most shops. FDOT knows that proper surface preparation and primer application are the best ways to assure long-term corrosion protection. To that end, FDOT has created a system whereby shops are qualified in accordance with the American Institute of Steel Construction (AISC) Shop Certification Program (SCP), and its fabricators are required to have the coveted designation as SSPC: The Society for Protective Coatings (SSPC) Painting Contractor Certification Programs (PCCP) Quality Procedure Three (SSPC-QP 3) Certification or the AISC Sophisticated Paint Endorsement (SPE). Only coating systems which have passed through the National Transportation Product Evaluation Program (NETPEP) testing protocol and met the FDOT criteria are specified.

"Time Tested Performances of Bridge Coatings" (1627 Kb) The purpose of this study was to determine the actual service life of some commonly used bridge coating systems. A study authored by Gordon H. Brevoort and updated by KTA-Tator, Inc. in 1996 (1) provided a table of projected service life based largely on a survey of coating manufacturers. Are industry wide predictions of coating life accurate? That is the central issue this study examined. The results may help bridge owners select coating protection that provides the lowest life cycle cost. Bridge owners may also find the information useful to pro-rate the remaining value of the coating system and to plan maintenance activities.
Dave Leyland - KTA
L. Brian Castler - Connecticut Dept. of Transportation

"Qualification Teseting of Fusion Bonded Epoxy Coatings for Pipeline Exteriors" (897 Kb) The selection of a coating for suitable use on the exterior of a pipeline is an important consideration due to the safety and cost consequences of potential corrosion. Because there are numerous fusion bonded epoxy (FBE) mainline and field joint coating systems available, the selection of the optimum coating system is as much an art as a science. Kenneth B. Tator, P.E.

"Quality Control and Quality Assurance: Defining the Roles and Responsibilities of the Contractor's QC and the Owner's QA" (PDF 254Kb) With the success of the SSPC painting contractor certification programs (PCCP) and increasing Owner requirements for both quality control (QC) by the contractor and quality assurance (QA) by third party inspectors, there is more confusion than ever over which types of inspections, and to what level of detail, should be performed by whom. Alison B. Kaelin

"Cleaning and Painting of the Main Street Bridge, Jacksonville, Florida - 'A Super Bowl Face-Lift' Part 2" (PDF 1718Kb) On November 1, 2000, the National Football League named the city of Jacksonville, Florida as the site for the 2005 Super Bowl. It wasn’t long before the Florida Department of Transportation was contacted to help the city “spruce up” the Main Street Bridge for the occasion.Greg Dutton and Don Buwalda, District 2, Florida DOT; Stephen J. Haney, JEAces, Inc.; and Chris F. Lovelace and Frank D Rea, KTA

"Streamlining the Specification Development Process for Bridge Painting" (PDF 91Kb) NEPCOAT (Northeast Protective
Coating Committee) developed an innovative approach for streamlining coating material testing and selection on a regional basis. Following their success, AASHTO took the concept nationwide within their NTPEP program. Based on the success of both programs, why not carry the concept an additional step and create a "NTSPEC" document? Kenneth A. Trimber

"Thermal Spray Coatings - Past, Present, and Future" (PDF 95Kb) Thermal spray coatings (TSC) have been successfully used in all major sectors of the marine and industrial corrosion control coatings market. Approximately twenty years ago they were introduced to the bridge coatings sector of the market on a trial basis. The overall positive results of these TSC tests in the bridge market have generated a wealth of information and much is known today about their origin and benefits. Ted Call

"An Ounce of Prevention - The Reliability of Field Methods for Detecting the Presence of Amine Blush on Epoxy Coatings" (PDF 155Kb) Shop and field conditions of high humidity and cool temperature during curing of amine-cured epoxy coatings can produce a haze or oily residue on the surface. This is commonly referred to as “amine blush.” The residue is caused by the presence of unreacted amine on the surface of the epoxy coating reacting with carbon dioxide and moisture in the air to form a carbamate. Cynthia L. O'Malley and Carly M. Pravlik, KTA; and John L. Simser, PPG Industries, Inc.

"Epoxy Linings - Solvent-Free But Not Problem-Free" )PDF 128Kb) Solvent-free epoxy coatings have been widely specified and used over recent years in Australia as linings for a variety of immersion service exposures, specifically for potable water storage and tank linings for some petroleum products. However, they have not always delivered the durability or performance hoped for. Mark Dromgool, KTA-Tator Australia Pty, Ltd.

"Effective Relationships Between Applicators, Inspectors, Owners, and Coating Manufacturer Representatives" (PDF 85Kb) Successful relationships are dependent upon effective communication between all of the parties involved in an industrial maintenance painting project. Owner expectations can only be met when the parties involved work together to meet basic project requirements. Jonathan Palo

"Polyurea Coatings - If You Knew What Could Go Wrong" (PDF 98Kb) The use of polyurea-based thick film coating materials for substrate protection and corrosion prevention has taken an exponential rise in the marketplace in the past 10 years or so. When properly installed, polyurea coatings offer a variety of performance characteristics. Cynthia L. O'Malley

"Designing a Maintenance Painting Management Program" (PDF 140Kb) Computerized maintenance painting management programs are used to inventory painted items, maintain historical coating data, optimize the scheduling of painting activities, and develop budget estimates for the work. Kenneth A. Trimber and Kirk Wissmar

"Calculating a Target Wet Film Thickness Using Published Volume Solids Data - Fact Versus Fiction" (PDF 382Kb) Published percent volume solids data have been used for years by painting contractors, coating manufacturers, and inspectors to calculate the target wet film thickness to apply.William D. Corbett and Frank Mozelewski

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