Paint System Condition Assessment

Evaluation of the Existing Paint System

The existing condition of the painted surfaces on a steel bridge can vary radically from minor chalking of the outside beams to delamination of the paint system and corrosion with steel section loss.  Depending on the existing condition of the paint system, the approach to the design and more importantly the project budgeting can be significantly affected.

Bolton Perez & Associates (BPA) will provide a Paint System Condition Assessment (PSCA) on the existing paint system to determine the overall conditions and specific attributes so an applicable specification can be designed.  BPA staff (typically two personnel) will perform the PSCA.  The “field review/testing” staff will include (at a minimum), a NACE Certified Coating Inspector experienced in maintenance bridge painting and the report prepared by a certified Society for Protective Coatings (SSPC), Protective Coatings Specialist (PCS).

Our approach to evaluating the condition of paint systems is broken down into three levels: (1) Basic Visual Review, (2) Limited Study, and (3) Detailed Assessment.  Depending on the need and limitations (e.g. time, cost, access etc.) the suitable level of PSCA can be selected by FTE.

Basic Visual Review

The intent of this type of assessment is to prioritize and categorize the structure based on the obvious conditions that can be observed from the roadway and/or right of way.  The data generated typically includes written descriptions of conditions and corresponding digital photographs.  This type of assessment is also known as a “drive by” but should never be used to generate a maintenance painting specification.

Limited Study

The intent of this type of assessment is to perform test methods on readily assessable surfaces without the need for significant rigging, access equipment or requirements for Maintenance of Traffic (MOT).  Similar to the Basic Visual Review, the conditions are observed from the roadway and/or right-of-way, digital photographs are taken but includes actual performance tests relating to the following:

Dry film thickness (DFT)

Adhesion

Generic type of the finish coat

and,Visual test methods based on written standards (corrosion, chalking, blistering, cracking etc.)

The data generated includes a written report outlining the results of the performance tests corresponding digital photographs.  This type of assessment can be used to “refresh/update” a previously performed PSCA as conditions change and condition assessment reports should not be considered good for an unlimited timeframe.

Note about Hazardous Paint Screening:  Paint chip samples can be retrieved during this type of assessment although we recommend that samples be retrieved from a wide range of  surfaces and locations to uncover a more comprehensive representation of the existing paint system.  Painting histories can vary in different locations (e.g. spot painting or component replacement) outside of the locations that are tested in this type of assessment.

Detailed Assessment

This type of condition assessment is the most comprehensive and gives the designer the largest amount of information to establish the project requirements.  Like the Limited Study, the conditions are observed from the roadway and/or right of way and detailed visual reviews are performed in areas accessed.  The same type of test methods are performed in each area accessed and digital photographs should document all conditions, observations and test methods.

Special equipment is used to access multiple locations and occasionally there are requirements for Maintenance of Traffic (MOT). 

This type of assessment should also include paint chip removal to be laboratory tested (e.g. Hazardous Paint Screening).  The existing FDOT document entitled “Florida Method of Test for Sampling of Existing Coatings Systems,” (Designation 5-564 and dated July 1996 and renewed 1999) provides guidance on the following:

A specific procedure for obtaining paint samples

Outlines laboratory test methods to perform

Dictates the minimum number of samples to retrieve (four)

Describes sample handling and protocol

Hazardous Materials Risk Assessment

After the condition assessment has been performed, including the laboratory analysis of the existing paint system, a “risk assessment” can be accomplished.  The term “risk assessment” is generally associated with the EPA/HUD guidelines for residences or child occupied facilities.  The Toxic Substances Control Act (TSCA) states that the goal of a risk assessment is to “determine, and then report, the existence, nature, severity, and location of lead-based paint hazards.”

Aspects of the EPA/HUD programs can offer similar benefits to industrial projects such as bridge painting and further reduce potential liability involved in construction activities.  Essentially, the risk assessment is related to the “potential exposures” during maintenance operations and sometimes demolition.  The potential exposures include, but are not necessarily limited to, on-site personnel, the traveling public and the population (commercial and residential) within close proximity to the bridge structure.

Risk assessment factors the following in determining risk:

The condition of the painted surfaces (e.g. peeling, corrosion, chalking etc.)

Percentage of hazardous constituents

Proximity to “sensitive receptors” (e.g. waterways, occupied residential and/or commercial facilities etc.)

Requirements for maintenance

kevin@bpacoatings.com