708 PAINT

Before approval, submit to the Engineer of Tests, 1600 W. Broad St., Columbus, Ohio 43223, copies of the manufacturer’s certified test data showing that the material complies with the qualitative, quantitative, and performance requirements of this specification. Use an independent testing laboratory, approved by the Laboratory, to develop the test data. Include with the test data the brand name of the paint, name of manufacturer, number of the lots tested, and date of manufacture. Additionally, submit the following items to the Laboratory before approval: manufacturer’s technical data sheet for each coating, Material Safety Data Sheet for each coating, enough components to produce a 1-gallon (4 L) sample of each coating; and a 1-quart (1 L) sample of the thinner to be used with each coating.

Once the Director approves the paint, the Department will not require further performance testing by the manufacturer unless the formulation or manufacturing process has been changed, in which case the Department will require new certified test results.

708.02 OZEU Structural Steel Paint. This specification covers the formulation and testing of a three-coat structural steel paint system consisting of an organic zinc prime coat, an epoxy intermediate coat, and a urethane finish coat (OZEU). Material requirements for the respective coats are as follows:

A. General. For each lot of all coatings, furnish a coated card (Drawdown card) that shows the color, gloss, and general appearance of the material covered by the lot. Use a minimum card size of 3-inches by 5-inches. The color must match the color card furnished for the Contract or order within visual limits determined by the Engineer. In case of disagreement, provide test data according to ASTM D 2244 showing a color difference of no greater than 2.0, Delta E* (sub:ab) (CIELAB).

B. Organic Zinc Prime Coat. Provide an organic zinc prime coat consisting of a zinc dust filled, two or three-component epoxy polyamide, and selected additives as required. The coating shall also meet the following:

a.      Total solids, % by weight of paint, ASTM D 2369. 70 percent minimum.
b.      Pigment, % by weight of total solids, ASTM D 2371. 83 percent minimum.
c.      Total zinc dust, % by weight of pigment. 93 percent minimum.
d.      Total zinc, % by weight of total solids (by calculation). 77 percent minimum.
e.      Total solids, % by volume, ASTM D 2697. 45 percent minimum.
f.       Color. Greenish gray, approximating FS-595B-34159, visual comparison.
g.      Pot life. 6 hours minimum at 77 °F (25 °C) and 50 percent relative humidity (RH).

By observation of Ford B cup viscosity, pot life is deemed exceeded if the viscosity rises more than 30 percent or if gelled particles appear in the mix. A 1-quart (1-liter) container of mixed material is used.

a.      Mixing. Section 5.2, SSPC-Paint 20 using only a high shear (Jiffy) mixer.
b.      Storage Life. Section 5.4, SSPC-Paint 20.
c.      Mudcracking. Section 5.7, SSPC-Paint 20.

Test	Variance
Nonvolatiles, % by weight	±2
Density	±0.2 lb/gal (±0.02 g/mL)
Viscosity	±5 KU or ±5 sec., Ford Cup

Test	Variance
Nonvolatiles, % by weight	±2
Density	±0.2 lb/gal (±0.02 g/mL)
Viscosity	±5 KU or ±5 sec., Ford Cup

Test	Variance
Total zinc metal, % by weight	±2

Test	Variance
Total zinc metal, % by weight	±2
Density	±2 %
Viscosity	Dependent on test
Nonvolatiles, % by weight	±2

Test	Variance^[1]
Nonvolatiles, % by weight	±2
Density	±0.2 lb/gal (±0.02 g/mL)
Viscosity	Dependent on test
[1] Variance shall be within the noted range based upon the test average of the previously submitted sample.

C. Epoxy Intermediate Coat. Provide a two-part epoxy intermediate coat composed of a base component and a curing agent suitable for application over the epoxy-polyamide zinc rich primer.

The base component shall contain an epoxy resin together with color pigments, mineral fillers, gellant, leveling agent, and volatile solvents. The curing agent component shall contain a liquid polyamide resin and volatile solvent. The coating shall also meet the following:

By observation of Ford B cup viscosity, pot life is deemed exceeded if the viscosity rises more than 30 percent or if gelled particles appear in the mix. A 1-quart (1 L) container of mixed material is used.

(1)     Set-to-touch, ASTM D 1640. 4 hours, maximum at 77 °F (25 °C).
(2)     Dry-to-recoat, ASTM D 1640. 24 hours, maximum at 77 °F (25 °C).
(3)     Full cure. 7 days, maximum at 50 °F (10 °C).

g. Volatile Organic Compounds (VOC), maximum, ASTM D 3960. 3.5 lb/gal (0.419 g/mL), as applied.

Test	Variance^[1]
Density, %	±2
Viscosity	Dependent on test
Total solids, % by weight	±2
Pigment, % by weight	±2
Nonvolatile vehicle, % by weight	±2
[1] Variance shall be within the noted range based upon the test average of the previously submitted sample.

D. Urethane Finish Coat. Provide a two-component urethane finish coat composed of a polyester and/or acrylic aliphatic urethane and suitable for use as a finish coat over the white epoxy polyamide intermediate coat. The coating shall also meet the following:

a. Finish, Specular gloss, ASTM D 523. 70 percent minimum after 3000 hours weathering resistance.

c. Curing time, at 77 °F (25 °C) and 50% RH. Set-to-touch, ASTM D 1640: 30 minutes, minimum; 4 hours, maximum.

e. Volatile Organic Compounds (VOC), maximum, ASTM D 3960. 3.5 lb/gal (0.419 g/mL), as applied.

Brown	FS-595B, 10324
Green	FS-595B, 14277
Blue	FS-595B, 15526
[2] Contractor’s choice unless specified on plans

Full gloss	minimum 80% unless specified on the plans
Semi-gloss	30 to 45%
Lusterless (Matte)	maximum 6%

Test	Variance^[1]
Density, %	±2
Viscosity	Dependent on test
Total Solids, % by weight	±2
Pigment, % by weight	±2
Nonvolatile Vehicle, % by weight	±2
[1] Variance shall be within the noted range based upon the test average of the previously submitted sample.

Performance Requirements. Test the coating system, which consists of the organic zinc prime coat, the epoxy intermediate coat, and the urethane topcoat, prior to use.

Prepare three panels for each of the specified tests according to ASTM D 609, except provide a minimum thickness of 1/8 inch (3 mm) and use ASTM A 36/A 36M hot rolled steel. Blast clean (using coal slag abrasive) the surface to equal, as nearly as is practical, the standard Sa 2 1/2 of ASTM D 2200 (Steel Structures Painting Council SSPC-SP10 meets this requirement). Ensure that the surface has a nominal height of profile of 1 to 3.5 mils (25 to 88 mm) verified by using appropriate replica tape. Coat and cure the panels according to the manufacturer’s printed instructions. Provide a dry film coating thickness for the system to be tested as follows:

Organic Zinc:	3.0 to 5.0 mils (75 to 125 mm)
Epoxy:	5.0 to 7.0 mils (125 to 175 mm)
Urethane:	2.0 to 4.0 mils (50 to 100 mm)

A. Fresh Water Resistance Test (ASTM D 870). Scribe the panels according to ASTM D 1654 to the depth of the base metal in the form of an “X” having at least 2-inch (50 mm) legs, and immerse panels in fresh tap water at 75 ± 5 °F (25 ± 3 °C). After 30 days of immersion, examine the panels to verify that they show no rusting and that the coating shows no blistering, softening, or discoloration. Rate blistering according to ASTM D 714.

B. Salt Water Resistance Test (ASTM D 870). Scribe the panels as specified in “A” above, and immersed panels in a water solution of 5 percent sodium chloride at 75 ± 5 °F (25 ± 3 °C). After 7, 14, and 30 days of immersion, examine the panels to verify that they show no rusting and that the coating shows no blistering or softening. Rate blistering according to ASTM D 714. Replace the sodium chloride solution with a fresh solution after examination at 7 and 14 days.

C. Weathering Resistance Test. Test the panels according ASTM D 4587, Method D, using Ultra Violet A 340 bulbs. Place the panels on test at the beginning of a wet cycle. After 3000 hours of continuous exposure, examine the panels to verify that they show no rusting and that the coating shows no blistering or loss of adhesion. Perform the 60 degree specular gloss measurements on the sprayed panels utilized for this test. Average the three initial measurements (one per panel) together. Also, average the three final measurements together.

D. Salt Fog Resistance Test. Scribe the panels as specified in “A” above, and test them according to ASTM B 117. After 3000 hours of continuous exposure, examine the coating to verify that it shows no loss of bond and that it shows no rusting or blistering beyond 1/16 inch (2 mm) from the center of the scribe mark. Rate blistering according to ASTM D 714.

E. Elcometer Adhesion Test, ASTM D 4541. Test the panels according to the following:

1.      Lightly sand the coating surface and aluminum dolly, and apply a quick set adhesive.
2.      Allow adhesive to cure overnight.
3.      Scribe the coating and adhesive around the dolly before testing.
4.      Make a minimum of 4 trials to failure, and report the 4 trials. Ensure that each trial is less than 400 pounds per square inch (2.8 MPa). Reject trial if fracture at the primer-blast interface occurs.

Prequalification. Before approval, submit copies of the manufacturer’s certified test data showing that the coating system complies with the performance requirements of this specification to the Engineer of Tests, 1600 W. Broad St., Columbus, Ohio 43223. Ensure that the certified test data also states the following physical properties for each coating: Density, pounds per gallon (g/mL); Solids, percent by weight; Solids, percent by volume; Viscosity; Drying time; and VOC content, pounds per gallon (g/mL).

Use an independent testing laboratory, approved by the Laboratory, to develop the test data. Include with the test data the brand name of the paint, name of manufacturer, number of lots tested, and date of manufacture.

Additionally, submit the following items to the Laboratory before approval: manufacturer’s technical data sheet for each coating, Material Safety Data Sheet for each coating, enough components to produce a 1-gallon (4 L) sample of each coating; and a 1-quart (1 L) sample of the thinner to be used with each coating.

Once the Director approves the coating, the Department will not require further performance testing by the manufacturer unless the formulation or manufacturing process has been changed, in which case the Department will require new certified test results.