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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.
"New Lead Regulations" (PDF 102Kb) This paper addresses two recent regulatory actions regarding lead. The first is the October 15, 2008 revision to the National Ambient Air Quality Standards for Lead. The second regulation is the August 14, 2008 update to the OSHA Instruction: National Emphasis Program – Lead, which describes OSHA’s nation-wide emphasis on reducing occupational lead exposures. The authors will overview the regulatory actions and discuss potential impacts on the painting industry.
Alison B. Kaelin, CQA, KTA-Tator, Inc.
Daniel O'Malley, KTA-Tator, Inc.
"What is Needed for a Bridge Coating to Last 100 Years or More?" (PDF 62Kb) Although bridge construction extends back thousands of years, steel bridge painting is
in its infancy. The first iron bridge was built in 1779, and the first steel was used in a bridge in
1828. Coated bridges from the 19th century survive, raising the question, “Can coatings protect
steel bridges for the next hundred years?” The author discusses how to achieve 100 years of
service life using current materials and offers recommendations for improving steel bridge
painting.
Eric S. Kline, PCS, KTA-Tator, Inc.
Scott B. Rice,
KTA-Tator, Inc.
John M. Ekiert, PE, KTA-Tator, Inc.
"Galvanic Drilling and Problems With Coating Dissimilar Metals in Corrosive Environments" (PDF 421Kb) The installation of protective coating systems must be accomplished in a manner that will avoid adverse electrolytic coupling between dissimilar metals in water tanks, process equipment, and even some atmospheric applications where condensing humidity and rainwater provide the aqueous medium for electrolytes. This paper discusses several examples of premature coating and structural failures resulting from the mixing of dissimilar metal types in systems where the anode and cathode areas are not optimized by design or engineering controls.
David S. Leyland, KTA-Tator, Inc.
E. Bud Senkowski, PE, KTA-Tator, Inc.
"Cleaning and Painting of the Sunshine Skyway Cable Stay Bridge: A Challenging Repainting Project of a Signature Florida Bridge" (PDF 3932Kb) The Sunshine Skyway Cable Stay Bridge is the signature bridge in the State of
Florida. During 2004 the decision was made to repaint the stay cables for corrosion
protection and aesthetic issues. The authors participated in a coatings condition assessment,
plan development for refurbishing the coating system, and project execution. This paper
identifies areas that made the Sunshine Skyway Bridge a challenging project such as:
coatings condition assessment, paint specifications, access, containment system, execution,
and final acceptance.
Jose (Pepe) Garcia, PE, FDOT
Beth Steimle, PE, PB Americas, Inc.
Greg Richards, KTA-Tator, Inc.
"Coating Failures-Causes and Corrections" (PDF 87Kb) Industrial and marine protective coating systems are most commonly applied without incident, and perform as expected over their anticipated service life. However, occasionally, a coating system will fail prematurely, for unexpected reasons, and with expensive consequences. This paper addresses those unexpected failures, and provides reasons and remedies for such occurrences.
Kenneth B. Tator, PE, KTA-Tator, Inc.
"Rehabilitation of an Aging Concrete Reservoir Adit Tower" (PDF 126Kb) Adit towers are generally vertical, large diameter concrete pipes that serve as vaults for valves used to drain and fill a reservoir. The tower runs from several feet above the waterline down through the reservoir and into the reservoir bed for some distance. Many of these towers and reservoirs are old and deteriorating, as the United States suffers from an aged infrastructure. External cracking is common above the waterline; weeping and leaking cracks are often present on the interior, and the valves, piping and infrastructure (stairways, pipe supports and structural steel) are often corroded. This paper describes the process (assessment, testing and construction) used to rehabilitate a decades old tower that was experiencing all of the problems identified above. The paper discusses the procedures that were performed to (1) repair cracks in the exterior walls above the waterline, (2) stop leaking cracks on the interior walls below the waterline, (3) line the interior walls with a moisture vapor resistant epoxy and (4) coat the interior steel surfaces.
Raymond S. Tombaugh, KTA-Tator, Inc.
Mongkol Mahavongtrakul, PE, San Francisco Public Utilities Commission
"Coating Failures and Misapplications in Commercial Painting" (PDF 58Kb) While commercial painting is often thought to be less rigorous or less technical than industrial painting, the commercial painting industry has its own set of demands on a coating and is not without its share of coating problems. The authors experience demonstrates that there are commonalities in failures of coatings in commercial painting. This paper discusses a number of failures that are commonly found in the commercial painting field including painting of galvanized surfaces, coating of concrete surfaces (both floors and exterior building facades), use of elastomeric coatings, painting intricate surfaces, and painting plaster, drywall and wood surfaces. The paper describes both the cause of the failures and the appropriate methods of remediation and prevention.
Raymond S. Tombaugh, KTA-Tator, Inc.
"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.
"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
"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.
| FDOT | KTA |
| Steve Duke Linda Houk |
Ernst Toussiant Douglas Reardon William Wallhausser |
"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.
PACE2005 Papers
"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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