MANUAL OF CONTRACT DOCUMENTS FOR HIGHWAY WORKS

VOLUME 1 SPECIFICATION FOR HIGHWAY WORKS

SERIES 5000
maintenance painting of
steelwork

Contents
NATIONAL ALTERATIONS OF THE
Clause Title Page
OVERSEEING ORGANISATIONS OF
SCOTLAND, WALES AND NORTHERN
IRELAND
5001 Introduction 2
5002 Surface Preparation - General
Requirements 2 Scotland
5003 Surface Preparation - Materials
and Methods 3
Clause Title Page
5004 Surface Preparation -
Workmanship Standards 4
5007SE Paint and Similar Protective
5005 Metal Coatings 6 Coatings S1
5006 Testing of Metal Spray Coatings 6
#5007 Paint and Similar Protective
Coatings 7
# denotes a Clause which has a substitute National Clause for one
5008 Surface Preparation and or more of the Overseeing Organisations of Scotland, Wales or
Protective Systems 7 Northern Ireland.
#5009 Testing of Paints 15
5010 Storage Requirements and
Keeping Periods for Paints 16
5011 Procedure Trials 16
5012 Application of Paint 17
5013 Form HA/P1 (Maintenance)
Paint System Sheet
(Appendix 50/1) 19
Form HA/P2 Paint Data Sheet
(Appendix 50/3) 19
5014 Access, Containment and
Lighting 19
5015 (11/03) Additional Requirements
for the Protection of CCTV Masts,
Cantilever Masts, Steel Lighting
Columns and Bracket Arms 19

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Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

maintenance painting of steelwork

5001 Introduction 3 Clean water, which does not leave any harmful
residues on the surface shall be used for cleaning and
1 Surface preparation and the maintenance painting rinsing.
of steelwork shall be carried out in compliance with
Clauses 5001 to 5015, using systems appropriate to the 4 Only cleaning agents which do not leave harmful
information given in Appendix 50/1, Form HA/P1 residues on the surface after final rinsing shall be used
(Maintenance) Paint System Sheet (parts 3 to 9) and for cleaning.
Appendix 50/2 if applicable, as appropriate to the 5 (05/05) Surface preparation shall be continued until
design, accessibility and condition of the components. the required standard has been achieved. The surfaces
2 (05/05) The Manual of Paints for Structural are required to be free from condensation, oil, grease,
Steelwork, which is included in Standard BD 35 dust residues and detrimental contamination such as
(DMRB 2.4.1), provides data on paints and similar chlorides and sulphides. These shall be tested using the
materials for use in the Overseeing Organisation’s procedures of DD ENV ISO 8502-1: 2001,
contracts. The Manual contains item numbers and a BS EN ISO 8502-2 BS EN ISO 8502-3,
summary is also given in Table 50/1. BS EN ISO 8502-4, BS EN ISO 8502-6 and
‘BS EN ISO 8502-9, BS 7079-B9’.
3 Subject and without prejudice to the Conditions of
Contract, the Contractor shall comply with any 6 After dry surface preparation of internal surfaces
measures to contain people, plant, materials, dust and and before any wet cleaning, all dust and debris shall be
debris described in Appendix 50/5. removed from accessible areas by sweeping and
vacuum cleaning.
4 Compliance with sub-Clause 3 of this Clause does
not confer immunity from relevant legal requirements. 7 Immediately before application of each coat of
paint, the Contractor shall ensure that the surfaces:
5 The appropriate level of surface preparation and the
suitable protective system shall depend on reported (i) meet the required standard of preparation;
results from the assessment of the existing protective (ii) are free from harmful residues, including
system, which is determined as described in Clause 2.5 mortar, concrete, dust, grit and paint
of BD 87 (DMRB 3.2.2). degradation products;
6 (11/08) Corrosion protection of steelwork shall (iii) are free from detrimental contamination;
comply with National Highways Sector Scheme 19A
‘For corrosion protection of ferrous metals by industrial (iv) are free from moisture detrimental to the
coatings’, described in Appendix A and be undertaken coating to be applied.
by a Contractor registered to the scheme by an approved 8 The edges of existing coatings adjacent to abraded
UKAS accredited certification body. or blast cleaned areas shall be bevelled back where
practicable into sound and firmly adhering material.

5002 Surface Preparation - General 9 (05/05) Unless otherwise specified in

Requirements Appendix 50/5, fasteners shall be prepared and painted
to the same standard as adjacent main surfaces.
1 The general requirements are specified in 10 After surface preparation by methods using water
sub-Clauses 5002.2 to 5002.11. The various materials or when the steelwork has been exposed to the weather
and methods are specified in Clause 5003. The after surface preparation by other methods or when
standards to be achieved are specified in Clause 5004. there are deck leaks, areas containing riveted or bolted
Definitions of terms used are given in Clause 5004. The joints or built up sections shall be freed of any standing
particular requirements for surface preparation for the water which may be present in the nominal joint gaps;
structure(s) included in the Contract are specified in compressed air or other approved methods shall be
Appendix 50/1. used. When drying out has been completed or when
2 (05/05) Areas contaminated by oil or grease shall be surfaces are dry after surface preparation, line gaps
prepared by wet cleaning the affected areas as described around the perimeter of joint or along plies shall be
in sub-Clause 5003.8, prior to surface preparation by sealed effectively by successive applications of
other specified methods. Unless otherwise described in undercoat paint. All wider gaps shall be sealed with a
Appendix 50/5, solvents shall not be used. sealant compatible with the primer.

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Specification for Highway Works Maintenance Painting of Steelwork

11 (05/05) The use of an inhibitor during wet blast Dry or Wet Cleaning
cleaning or cleaning shall not be permitted.
8 Wet cleaning shall be carried out by scrubbing with
a stiff bristle brush using water and a cleaning agent or
5003 Surface Preparation - Materials and a pressure washer. Immediately after cleaning down, the
Methods surfaces shall be thoroughly rinsed using clean cold
water.
Abrading 9 Dry cleaning shall be carried out by scrubbing with
1 (05/05) Any encrusted rust, foreign matter or paint a dry stiff bristled brush.
which may be difficult to remove by abrading alone 10 Where the existing surfaces are affected by
shall be dislodged by scraping, aided by hand or power embedded metallic grit or other abrasive particles, they
wire brushing. This work shall be completed before shall be scraped to dislodge looser particles and then
abrading of the areas so affected. dusted off. This work shall be carried out after any final
2 Abrading shall be carried out using abrasive paper rinsing and when the surface is dry.
or other material or a flexible abrasive disc mounted on Dry Blast Cleaning using Dry Air/Abrasive System
a power drive flexible pad, or a power driven arbor or
spindle-mounted flexible abrasive flap wheel. Abrading 11 (05/05) Unless otherwise specified in
tools may be used to remove weld spatter. Wet abrading Appendix 50/5, chilled-iron grit complying with
may be employed for the preparation of finishes over ‘BS EN ISO 11124-2, BS 7079-E2’; high carbon cast-
sound undercoats, over unsound systems over hot dip steel grit complying with ‘BS EN ISO 11124-3,
galvanizing, or hot dip galvanizing. Wet abrading shall BS 7079-E3’ with a hardness value greater than 650
not be allowed to come into contact with exposed HV; fused aluminium oxide complying with
thermally sprayed metal coatings unless the metal BS EN ISO 11126-7; non-metallic abrasive such as
coating is to be entirely removed. almandite garnet to ‘BS 7079-F10, ISO 11126-10’,
3 (05/05) All equipment including tools, abrasive copper slag to ‘BS EN ISO 11126-3, BS 7079-F3’ or
recycled glass complying with BS EN ISO 11126-7
sheets, abrasive discs and abrasive wheels shall be of a
shall be used.
type, capacity and in a condition appropriate for the
work. The use of hard grinding wheels for abrading Grades for metallic abrasives shall comply with the
shall not be permitted. following:
4 A polished surface appearance caused by the
polishing in of old paint, rust or dirt shall not be Profile (see sub-Clause 5004.3) Grade
acceptable.
Fine G050 or S060
5 Areas of corroded steel or unsound metal coatings,
which have been prepared by abrading down to St3 Medium G070 or S100
steel, bright steel or bright metal coating, as appropriate,
Coarse G100 or S120
shall be protected by the primer and next coat of paint
before any cleaning down or other preparation of
adjacent surfaces specified in Appendix 50/1 is 12 The particle size of metallic abrasive in plant or
undertaken. equipment shall not exceed the maximum for the
6 Areas of unsound hot dip galvanizing which have relevant grade as specified above.
been prepared down to bright steel by abrading shall be 13 Before the start of blast cleaning and during blast
protected by the application of the primer and next coat cleaning the Contractor shall ensure that the abrasive is
of paint before cleaning down or other preparation of free from matter which could leave detrimental
adjacent surfaces specified in Appendix 50/1 is contamination, as defined in sub-Clause 5004.1 (vii), on
undertaken. the surfaces to be coated.
7 After surface preparation by wet abrading of hot 14 Metallic grit or aluminium oxide abrasive shall be
dip galvanizing, but prior to any cleaning down of used for dry blast cleaning of relatively small areas on
adjacent painted or hot dip galvanised surfaces specified site which are to be thermally sprayed metal coated,
in Appendix 50/1, any exposed areas of steel shall be such as at areas prepared to clean steel. The Contractor
dry abraded down to bright steel and protected by the shall ensure that the grade and particle shape of non-
primer and the next coat of paint, including the stripe metallic abrasives are adequate for the purpose
coat, before cleaning down or other preparation of intended. Excepting for aluminium oxide non-metallic
adjacent surfaces specified in Appendix 50/1 is abrasives shall not be recycled.
undertaken.
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Specification for Highway Works Maintenance Painting of Steelwork

Wet Blast Cleaning using Low Pressure Air/Water/ Other Requirements

Abrasive System
20 When surface preparation is to be carried out by
15 Unless otherwise specified in Appendix 50/5, the dry blast cleaning and, on adjacent surfaces by wet
air/water pressure at the nozzle shall not exceed cleaning down and/or abrading, then unless otherwise
7.0 kgf/cm2 and shall be fully adjustable below this dictated by traffic management requirements etc., the
level. The system shall incorporate a mechanical wet cleaning down and any wet abrading shall be
metering device, remote controlled by the operator from carried out first.
the nozzle, to regulate from zero to maximum the
21 When surface preparation is to be carried out by
quantity of non-metallic abrasive being fed into the
wet blast cleaning, any wet cleaning down and/or wet
air/water mixture. During abrasive blast cleaning the abrading of adjacent surfaces may be carried out after
air/water/abrasive shall be thoroughly mixed and the the wet blast cleaning. In such cases areas to be blast
mixture shall be projected onto the surface to be cleaned cleaned and/or abraded shall be cleaned down in
through a single bore nozzle/tube. The use of an accordance with sub-Clause 5002.8, and thoroughly
inhibitor during wet blast cleaning or washing shall not rinsed using the blast cleaning equipment before any
be permitted. final preparation by dry blast cleaning or dry abrading
is carried out.
Wet Blast Cleaning using High Pressure Water/
Abrasive System or Ultra High Pressure Water 22 Any prepared steel surfaces shall be protected from
System the effects of any further wet method of surface
preparation by the application of a minimum 75
16 Unless otherwise specified in Appendix 50/5, the microns dry film thickness of paint.
water pressure shall not exceed 562 kgf/cm2 for high
pressure or between 1750 and 2860 kgf/cm2 for ultra Grinding
high pressure. The system shall incorporate a
23 Grinding wheels and discs shall be of the size,
mechanical metering device controlled by the operator
shape and grade of coarseness appropriate to the
at the nozzle, to regulate from zero to maximum the
particular operation. The speed of revolution shall be
quantity of non-metallic abrasive being fed into the
appropriate for the work.
water.
24 Grinding shall normally be carried out after surface
17 (05/05) Within 60 minutes of wet blast cleaning, the
preparation by other methods, including cleaning down,
whole of the cleaned surface shall be thoroughly
has been completed, except where it is necessary to
washed using the blast cleaning equipment with air and
achieve a blast profile and this would necessitate blast
water. Any further deposits of abrasive on already
cleaning after grinding.
rinsed surfaces shall be removed in a similar manner
also within 60 minutes of being deposited. All 25 Surfaces prepared by grinding to bright steel shall
accumulated deposits of abrasive and debris on other be protected by the application of the primer and the
parts of the structure shall be removed by the same next coat of paint, including any stripe coats, before
method before the end of the working day. After cleaning down or other preparation of adjacent surfaces
washing, the surfaces shall be free from all specified in Appendix 50/1 is undertaken.
contamination. Tests for freedom from detrimental
contamination shall be made after the washing.
5004 Surface Preparation - Workmanship
Combined Wet/Dry Blast Cleaning Standards
18 (05/05) Wet blast cleaning using the low pressure 1 Definitions of terms in sub-Clause 5004.2
air/water/abrasive system in accordance with describing coatings, the extent of surface preparation
sub-Clause 5003.15 and 17 shall be followed, at a and chemical cleanliness of surfaces are given below:
minimal interval, by dry blast cleaning in accordance
with sub-Clauses 5003.11 to 14 of all the previously (i) ‘unsound paint’. Paint showing signs of
wet blast cleaned areas. disruption, rusting through, having
inadequate adhesion or covering, rust scale,
19 The specified standard of surface preparation shall loose rust, loose mill scale or other
have been achieved in full, initially by wet blast detrimental products;
cleaning and washing to achieve the required
cleanliness, before any later dry blast cleaning of the (ii) ‘sound paint’. Paint which is sound down to
same areas to remove flash rusting or to restore the a metal substrate;
required surface profile.

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Specification for Highway Works Maintenance Painting of Steelwork

(iii) ‘unsound metal coating’. A metal coating particles and shall have a bright
showing signs of disruption, inadequate appearance overall;
adhesion or penetration by rust or other
(b) ‘bright metal coating’ by abrading
corrosion products;
Appearance:
(iv) ‘sound metal coating’. A metal coating
which complies with Clause 5005 or a metal The surface shall be free from surface
coating restored to these requirements by corrosion and corrosion products and
blast cleaning, but with a reduced thickness; shall have a bright appearance overall;
(v) Visual cleanliness of a steel substrate (vii) ‘freedom from ‘harmful residues’ or
prepared to: contamination’: Surfaces shall only be
deemed to be free from ‘harmful residues’ or
(a) ‘clean steel’ by blast cleaning
‘contamination’ after surface preparation
Appearance: when any such remaining matter shall not
reduce the required durability of the
There shall be a blast cleaning pattern
specified protective system.
overall. The surface profile shall be free
from mill scale, rust and foreign matter 2 The following standards of surface preparation
when viewed by normal vision; shall be achieved:
(b) (05/05) Sa2 to ‘BS EN ISO 8501-1, (i) areas containing existing sound finishing
BS 7079-A1’ and ‘BS EN ISO 8501-2, paint shall be freed of:
BS 7079-A2’ by blast cleaning
(a) any visible gloss which may prevent
Appearance: adequate adhesion of the next coat; and
The surface shall be free from all rust (b) contamination;
scale, loose rust and loose mill scale;
(ii) areas of existing unsound paint coating(s)
(c) ‘bright steel’ by abrading over a steel substrate shall be freed of:
Appearance: (a) any unsound paint down to sound paint;
The surface shall be free from all (b) any unsound paint down to clean steel;
surface rust, mill scale and defects, and
(c) any unsound paint down to Sa2 or St3
shall have an overall bright appearance;
quality steel;
(d) (05/05) St3 to ‘BS EN ISO 8501-1,
(d) any unsound paint down to bright steel;
BS 7079-A1’ and ‘BS EN ISO 8501-2,
BS 7079-A2’ by abrading (e) all paint down to Sa2 or St3 quality
steel;
Appearance:
(f) all paint down to clean steel; and
The surface shall be free from all rust
scale, loose rust and loose mill scale; (g) contamination;
(e) ‘Bright steel’ by grinding (iii) areas of existing unsound paint coating(s)
over a metal coated steel substrate shall be
Appearance:
freed of:
The surface shall be free of weld spatter,
(a) any unsound paint down to sound paint
shelling, internal discontinuities and
or to sound metal coating;
other surface defects, leaving an overall
bright appearance. Rounding of sharp (b) any unsound metal coating down to
edges shall be to a radius of about bright metal coating;
1 mm; (c) any unsound metal coating down to
(vi) visual cleanliness of a metal coating restored clean steel;
or prepared to: (d) any unsound metal coating down to
(a) ‘sound metal coating’ by blast cleaning bright steel;
Appearance: (e) all paint and unsound metal coating
down to sound metal coating or to clean
The surface shall be free from corrosion
steel;
products and embedded abrasive

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Specification for Highway Works Maintenance Painting of Steelwork

(f) all paint and metal coating down to Thermally Sprayed Metal Coatings
clean steel; and
2 Thermally sprayed metal coatings shall, unless
(g) contamination; otherwise described in the Contract, comply with
(iv) areas of sound hot dip galvanizing exposed BS EN 22063 and with the following:
through a paint system during surface (i) aluminium coating shall be of a material
preparation shall be abraded to an extent with minimum quality in accordance with
necessary to ensure effectiveness of adhesion type Al 99.5 (1050A) of ISO 209-1. Zinc
promoter and/or adhesion of the primer; coating shall have a composition in
(v) areas of unsound metal coating over a steel accordance with type Zn 99.99 of ISO 752;
substrate shall be freed of: (ii) the thickness of either coating shall be not
(a) any unsound metal coating down to less than 100 microns;
bright metal coating; (iii) The strength of adhesion of thermally
(b) any unsound metal coating down to sprayed metal coatings shall not be less than
sound metal coating; the following:
(c) any unsound metal coating down to Aluminium 50 kgf/cm2
clean steel; Zinc 50 kgf/cm2;
(d) any unsound metal coating down to (iv) thermally sprayed metal coatings shall be
bright steel; applied continuously over each 0.5m2 per
(e) all metal coating down to clean steel; gun or the area of the component whichever
and is the lesser until the specified thickness has
been achieved;
(f) contamination.
(v) the application of thermally sprayed metal in
(vi) when either ‘clean steel’, ‘Sa2 or St3 quality separate layers shall not be permitted;
steel’ or ‘bright steel’ is exposed through a
metal coating during surface preparation, the (vi) (05/05) all
surfaces to be thermally metal
standard shall be as defined in sub-Clause sprayed shall be blast cleaned and the
5004.1 as appropriate, except for the profile standard shall be Sa3 quality to
of previously blast cleaned steel surfaces. In ‘BS EN ISO 8501-1, BS 7079-A1’, medium
the case of aluminium and zinc metal spray, profile;
remnants of soundly adhering and clean (vii) thermally sprayed metal coatings shall be
aluminium or zinc may be retained. Any de-nibbed.
sound metal spray which is contaminated by
lead shall be completely removed. Other Requirements
3 (05/05) The surface profile to be achieved by blast 3 When a metal coating is required on only part of a
cleaning, either ‘Fine’ ‘Medium’ or ‘Coarse’ as component it shall be applied before the rest of the
appropriate, shall be within the limits set by the Surface component receives paint.
Profile Comparator for the Assessment of Abrasive
Blast Cleaned Surfaces, conforming to 4 New items that are electroplated and that are under
‘BS EN ISO 8503-1, BS 7079-C1’. torque or tension conditions shall be stress relieved by
heat treatment at appropriate temperature and time to
prevent failure by hydrogen embrittlement.
5005 Metal Coatings

Hot Dip Galvanised Coatings 5006 Testing of Metal Spray Coatings

1 Unless otherwise specified in Appendix 50/5, 1 (05/05) At the start of the Works, and subsequently
structural members which were originally hot dipped at intervals scheduled in the Contract (with the
galvanised and display signs of deterioration shall be exception of coatings on steel in bearings, curved
replaced by newly hot dipped galvanised members or surfaces, repairs to mechanical damage, local failure of
alternatively the surface shall be cleaned to bright metal thermally sprayed metal coating at site joints or areas
and protected by the application of coatings. restored on site), the Contractor shall demonstrate by
means of a tensile test in accordance with
BS EN 22063, that the minimum adhesion requirement

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Specification for Highway Works Maintenance Painting of Steelwork

is being attained as detailed in sub-Clause 5005.2 (iii). 4 (05/05) The Contractor shall ensure that the
In the excepted areas, the Contractor shall demonstrate properties of the paints he has selected are compatible
that the adhesion is satisfactory by means of grid tests with the existing system and suitable for the
in accordance with BS EN 22063. Areas affected by the atmospheric conditions on site, including temperature
tests shall be restored in accordance with Clause 1907. and humidity, and that he is able to apply the paints
satisfactorily to all parts of the structure in these
2 The tensile tests shall be carried out initially on flat
conditions.
panels 150 mm x 150 mm x 6 mm which are of the
same grade of steel as the parent material and which 5 (05/05) Unless otherwise described in
before blast cleaning had the same surface condition. Appendix 50/5, all paints forming any one protective
The panels shall be blast cleaned and thermally metal system or overlapping systems, shall be obtained from
sprayed together with the parent material to the same the same manufacturer as named by the Contractor in
standard and using the same technique. Appendix 50/1 Form HA/P1 (Maintenance) Paint
System Sheet.
3 The Contractor shall ensure that adhesion tests
have been carried out satisfactorily before any further
work continues. 5008 Surface Preparation and Protective
4 If the adhesion requirement on any test panel is not Systems
met, the Contractor shall carry out a further test on the
parent material adjacent to the test panel position. In the 1 The particular methods of surface preparation are
case of adhesion failure on the steelwork itself by either to be detailed in Appendix 50/1 Form HA/P1
method of test, unsound thermally sprayed metal (Maintenance) Paint System Sheet, parts 1 to 9.
coating shall be restored and the tests repeated. 2 (05/05) Protective systems
5 If more than two local areas of faulty adhesion Note: mdft = minimum dry film thickness
occur on any one component, the whole of the B = apply by brush
thermally sprayed metal coating on the component shall AS = apply by airless spray
be considered as having failed, and it shall be restored. HB = High Build (dft: above 75 µm)
NB = Normal Build (dft: between 50 and
75 µm)
#5007 Paint and Similar Protective Coatings LB = Low Build (dft: below 50 µm)
1 (05/05) The term paint shall be deemed to refer to (i) (05/05) Itemnumbers in the Protective
protective coatings in general. Systems are listed in the Manual of Paints
2 (05/05) The paints permitted for use by the for Structural Steelwork which is included in
Overseeing Organisation in the Works are listed in the BD 35 (DMRB 2.4.1) and a summary is
Manual of Paints for Structural Steelwork which is shown in Table 50/1.
included in BD 35 (DMRB 2.4.1) and which also (ii) (05/05) Details
of Protective Systems for
contains details of the quality assurance scheme for Steelwork are given in Table 50/2.
paints and similar protective coatings. All paints shall
have a current BBA HAPAS Roads and Bridges
Certificate or equivalent.
3 (05/05) All paints shall be supplied in sealed
containers of not more than 25 litres capacity and these
shall be used in order of manufacture and batch number.
Each container shall have a completely removable lid
and be clearly marked on the side to show the name of
the manufacturer, registered description of the material
(including purpose, e.g. whether primer, undercoat or
finish), colour, Item No, paint manufacturer’s reference
number, batch number and date of manufacture. Where
date of manufacture is coded, the Contractor shall
provide the code key. In addition paints shall be
supplied in sealed containers of no greater than 5 litre
capacity for testing purposes in accordance with
Clause #5009, for ‘A’ samples.

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Specification for Highway Works Maintenance Painting of Steelwork

TABLE 50/1 - (05/05) BD 35: Quality Assurance Scheme for Paints and Similar Protective Coatings - Annex A
Manual of Paints for Structural Steelwork Current Paint Item Numbers
Item Description Coat Type Build Applied by
14 Zinc Phosphate Epoxy Ester Primer/Undercoat LB or NB B or AS
(single-component)
32 MIO Modified Phenolic Undercoat LB B or AS
(single component)
35 MIO Modified Phenolic Undercoat/Finish LB B or AS
(single component)

47 MIO Phenolic (single component) Undercoat LB B or AS

50 MIO Phenolic (single component) Undercoat/Finish LB B or AS

70 Silicone Alkyd (single component) Finish LB B or AS

74 Silicone Alkyd (single component) Undercoat LB B
110 Zinc Phosphate Epoxy (two-pack) Blast Primer/Sealer NB B or AS
(B to small areas only)
111 Zinc Phosphate High Build Quick Blast Primer HB AS
Drying Epoxy (two-pack) (B to small areas only)
112 MIO High Build Quick Drying Undercoat/Finish HB AS
Epoxy (two-pack)
113 Water based epoxy primer for blast Primer HB B or AS
cleaned internal surfaces (two-pack)
114 Water based epoxy undercoat/sheen Undercoat/Sheen Finish HB B or AS
finish for internal use (two-pack)
115 High Build Aluminium Epoxy Surface tolerant HB B or AS
(two-pack) maintenance primer
(e.g. for abraded
surfaces)
116 High Build Epoxy (two-pack) Surface tolerant HB B or AS
maintenance undercoat
121 Extended Cure Epoxy MIO (two-pack) Primer, Undercoat, HB AS
and/or Finish (B to small areas only)
123 High Build Glass Flake Epoxy Undercoat for blast HB AS (stripe coats and
(two-pack) cleaned steel new small repairs only by brush)
construction
124 High Build Glass Flake Polyester Undercoat for blast HB AS (stripe coats and
(two-pack) cleaned steel new small repairs only by brush)
construction
132 Vinyl/Vinyl Copolymer MIO Zinc Primer NB or HB B
Phosphate (single-component)
133 Vinyl/Vinyl Copolymer Zinc Phosphate Primer NB or HB B
(single-component)
134 Vinyl/Vinyl Copolymer MIO Zinc Primer/Undercoat/Finish NB or HB B
Phosphate (single-component)
135 Vinyl/Vinyl Copolymer Sheen Finish Finish NB or HB B
(single-component)
(05/05) Notes:

1 Colour reference shall be as per the manufacturer’s declared colour given with reference to BS 4800 and/or BS 381C where
appropriate.
2 Dry Film Thickness (dft) range shall be as per the manufacturer’s data sheet. The minimum dry film thickness of the paint coats and
paint system shall be as per the protective systems detailed in Table 50/2 where given.

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Specification for Highway Works Maintenance Painting of Steelwork

TABLE 50/1 - (05/05) BD 35: Quality Assurance Scheme for Paints and Similar Protective Coatings - Annex A
Manual of Paints for Structural Steelwork Current Paint Item Numbers (continued)
Item Description Coat Type Build Applied by
141 Thixotropic Bitumen (single-component) Primer/Finish HB B or AS
150 Pitch Epoxy (two-pack) Polyamide Cured Undercoat/Finish HB B or AS
151 High Build Epoxy (two-pack) Finish HB B or AS
Hydrocarbon Resin Modified
155 ‘T’ Wash Adhesion promoter for LB B
hot dip galvanized steel
156 Ultra low VOC adhesion primer To promote substrate LB B or AS
(single-component) adhesion properties of
coating systems for hot
dip galvanised steel,
aluminium and stainless
steel surfaces
157 Adhesion promoting (single-component) To promote substrate LB B or AS
adhesion properties of
coating systems for hot
dip galvanised steel,
aluminium and stainless
steel surfaces
159 Aluminium Epoxy (two-pack) Sealer/Primer LB B or AS
160 Red Oxide Moisture Cured Polyurethane Primer/Blast Primer for LB B or AS
(single-component) maintenance or new
works
162 MIO Moisture Cured Polyurethane Undercoat/Finish NB or HB B or AS
164 Moisture Cured Polyurethane Semi-gloss Finish LB B
(single-component)
NB AS
168 Polyurethane (two-pack) Gloss Finish LB B
NB AS
169 Polyurethane (two-pack) Semi-gloss Finish NB B (small areas by brush)
HB AS
185 Organic Modified Polysiloxane Gloss Finish for new NB B
(two-pack) works or maintenance
HB AS
200 Grease Paint Primer B (AS for difficult
access areas)
201 Grease Paint Undercoat/Finish HB B or AS

(05/05) Notes:

1 Colour reference shall be as per the manufacturer’s declared colour given with reference to BS 4800 and/or BS 381C where
appropriate.
2 Dry Film Thickness (dft) range shall be as per the manufacturer’s data sheet. The minimum dry film thickness of the paint coats and
paint system shall be as per the protective systems detailed in Table 50/2 where given.

Amendment - May 2005 9

 TABLE 50/2: (05/05) Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket Arms and
Amendment - May 2005

Specification for Highway Works

Volume 1
other Highway Structures: Protective Systems

Type Substrate Type Surface 1st Coat 2nd Coat 3rd Coat Minimum total dry
preparation film thickness of the
paint system (microns)
I (M) – High Steel Clean, bright Sa2 or Item No. 115 116 168
Build Epoxy St3 quality steel
(two-pack) / Min dry film thickness (µm) 100 50 300
Polyurethane
(two-pack) Aluminium metal spray, zinc Bright or sound metal Item No. 115 116 or 112 168
finish metal spray coating
Min dry film thickness (µm) 100 50 300
Existing paint coats Sound finishing coat Item No. Nil Nil 168
or last undercoat
Min dry film thickness (µm) - - 50 50
Other sound coats Item No. Nil 116 or 112 168
Min dry film thickness (µm) - 100 50 175

STRIPE COATS:

Item 116 or 112. Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal coating. Applied over 1st coat

PATCH COATS: NIL

NOTES:
1. (05/05) When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 169 Polyurethane Finish, may be used in lieu of Item 168 to provide a semi-gloss
finish, alternatively Item 164 (Moisture Cure Polyurethane finish) can provide a semi-gloss finish and is tolerant of surface moisture (but not running water) and low temperatures
during application and curing.
2. (05/05) Types I (M) and II (M) can be combined to allow paint maintenance to proceed when temperature falls and relative humidity increases and for night work.

Maintenance Painting of Steelwork

HEALTH AND SAFETY: (05/05)
Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be injurious to health if not used correctly. An assessment of the risks and controls for
their safe use shall be carried out before use.

Series 5000
10
 TABLE 50/2: (05/05) Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket Arms and
Amendment - May 2005

Specification for Highway Works

Volume 1
other Highway Structures: Protective Systems (continued)

Type Substrate Type Surface 1st 2nd 3rd 4th Minimum total dry
preparation Coat Coat Coat Coat film thickness of the
paint system (microns)
II (M) – MC/ Steel Clean or bright steel Item No. 160 162 162 164 /169
Polyurethanes
Min dry film thickness (µm) 40 70 40/50 275/325
Sa2 or St3 quality Item No. N/A N/A N/A N/A
steel
Min dry film thickness (µm) - - - -
Aluminium metal spray, Bright or sound Item No. 160 162 162 164 /169
zinc metal spray metal coating
Min dry film thickness (µm) 40 70 40/50 275/325
Existing paint coats Sound finishing coat Item No. - - - 164 /169
or last undercoat
Min dry film thickness (µm) - - - 40/50 50/100
Other sound coats Item No. - 162 162 164 /169
Min dry film thickness (µm) - 70 70 40/50 225/275

STRIPE COATS:

Item 162: Brush or airless spray. Two stripe coats, the first applied over 1st coat, the second coat applied over 2nd coat

PATCH COATS: NIL

NOTES:
1. Item 168, Polyurethane (two-pack) gloss finish may be used in lieu of Item 164 MC Polyurethane semi-gloss finish (two-pack Polyurethane gloss finishes are less tolerant of

Maintenance Painting of Steelwork

moisture and low temperatures during application and curing than MC Polyurethanes and shall therefore only be specified when conditions preclude the formation of moisture on
surfaces and when the ambient temperature is likely to remain above 5oC during application and the curing period).
2. Types I (M) and II (M) can be combined to allow paint maintenance to proceed when temperature falls and relative humidity increases and for night work.

HEALTH AND SAFETY:

Moisture cured Polyurethane and Polyurethane (two-pack) paints contain isocyanate and can be injurious to health if not used correctly. An assessment of the risks and controls for
their safe use shall be carried out before use.

Series 5000
11
 TABLE 50/2: (05/05) Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket Arms and
Amendment - May 2005

Specification for Highway Works

Volume 1
other Highway Structures: Protective Systems (continued)

Type Substrate Type Surface 1st Coat 2nd Coat 3rd Coat Minimum total dry
preparation film thickness of the
paint system (microns)
III (M) – Hot dip galvanizing Bright or sound Item No. 155 or other 121 164, 168
Extended Cure metal coating adhesion or 169
Epoxy/ promoter
Polyurethanes
Min dry film thickness (µm) 100 40/50/50 175/250
III (M) Hot dip galvanizing Bright or sound Item No. 121 164, 168
(alternative) – metal coating or 169
Extended Cure
Epoxy/ Min dry film thickness (µm) 100 50 175
Polyurethanes

STRIPE COATS:

Item 121: Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal coating. Applied over 1st coat

PATCH COATS: NIL

NOTES:
1. Some Item 121 formulations have been developed for direct application to hot dipped galvanised surfaces with excellent adhesion without the need for an adhesion promoter (to
be checked with and guaranteed by paint manufacturer).
2. When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 164, Moisture Cured Polyurethane Finish, may be used in lieu of Item 168 to provide a
semi-gloss finish tolerant of surface moisture (but not running water) and low temperatures during application and curing.

HEALTH AND SAFETY:

Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be injurious to health if not used correctly. An assessment of the risks and controls for

Maintenance Painting of Steelwork

their safe use shall be carried out before use.

Series 5000
12
 TABLE 50/2: (05/05) Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket Arms and
Amendment - May 2005

Specification for Highway Works

Volume 1
other Highway Structures: Protective Systems (continued)

Type Substrate Type Surface 1st Coat 2nd Coat 3rd Coat Minimum total dry
preparation film thickness of the
paint system (microns)
IV (M) – Steel Clean, bright or Sa2 Item No. 160 116 or 112 164 or 168
MC/Epoxy/ or St3 quality steel
Polyurethane Min dry film thickness (µm) 50 50 250

STRIPE COATS:

Item 112: Brush or airless spray. One stripe coat in area prepared to clean steel or sound metal coating. Applied over 1st coat

PATCH COATS: NIL

NOTE:
1. When a light tint gloss finish is required an extra coat of Item 168 shall be applied. Item 164, Moisture Cured Polyurethane Finish, may be used in lieu of Item 168 to provide a
semi-gloss finish tolerant of surface moisture (but not running water) and low temperatures during application and curing.

HEALTH AND SAFETY:

Polyurethane (two-pack) and Moisture Cured Polyurethane paints contain isocyanate and can be injurious to health if not used correctly. An assessment of the risks and controls for
their safe use shall be carried out before use.

Maintenance Painting of Steelwork

Series 5000
13
 TABLE 50/2: (05/05) Requirements for Bridges, Parapets, Bearings, CCTV Masts, Cantilever Masts, Steel Lighting Columns and Bracket Arms and
Amendment - May 2005

Specification for Highway Works

Volume 1
other Highway Structures: Protective Systems (continued)

Type Substrate Type Surface 1st Coat 2nd Coat 3rd Coat Minimum total dry
preparation film thickness of the
paint system (microns)
V (M) - Steel Clean, bright or Sa2 Item No. 200 201 201
Grease Paints or St3 quality steel
Min dry film thickness (µm) - 150 150 350
Aluminium metal spray, zinc Bright or sound Item No. Nil 201 201
metal spray or hot dip metal coating
galvanizing Min dry film thickness (µm) - 150 150 350
Existing paint coats Sound finishing coat Item No. Nil Nil 201
or last undercoat or
other sound coats Min dry film thickness (µm) - - 150 150

STRIPE COATS:

Item 201, 150 µm mdft. Brush

One stripe coat in all areas over 2nd coat

PATCH COATS:

Item 201, Brush, over 2nd coat

The total dft of existing coats plus new coats including patch coats, shall not be less than 400 µm. Number of patch coats to suit.

Maintenance Painting of Steelwork

Series 5000
14
Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

#5009 Testing of Paints 8 (05/05) Immediately after selection, the ‘A’ samples
shall be despatched by the Contractor to the testing
Provision of Samples authority, together with Appendix 50/4 Form HA/P3.

1 (05/05) Unless otherwise described in 9 (05/05) Paint shall be supplied in sufficient time to
Appendix 50/5, the Contractor shall provide unopened allow for sampling, delivery to the testing authority and
5 litre samples, known as ‘A’ samples, for quality testing before the start of application.
assurance purposes, for each type of paint to be used for 10 (05/05) Except for procedure trails, paint shall not
the Works in accordance with this Clause. In addition be applied until the ‘A’ sample from the paint to be
the Contractor shall supply at least 500 ml samples, applied has been tested and confirmed as being
known as ‘B’ samples, for application control purposes. satisfactory for use.
2 (05/05) ‘A’ and ‘B’ samples are tested for paint ‘B’ Samples
composition and/or properties against the original
formulation issued by the paint manufacturer to the 11 (05/05) For single component coatings the
certifying body. Contractor shall take ‘B’ samples from painters’ kettles
or from nozzles of airless spray guns directly into clean,
‘A’ Samples new 500 ml tins which shall be filled and then sealed
prior to despatch to the testing authority. The
3 (05/05) ‘A’ samples are required where more than Contractor shall take ‘B’ samples for two-pack systems
1000 litres of paint for any one coat are supplied to a as separate unmixed samples of the base and activator
single Contract. For two-pack systems separate samples (cure) components. The ‘B’ samples shall be taken
of the base and activator shall be despatched by the following the stirring of the individual components and
Contractor to the testing authority. immediately prior to mixing the two components for
4 (05/05) ‘A’ samples are not required for footbridge use in the Works. The samples shall be decanted
steelwork or CCTV masts, cantilever masts, steel directly into clean, new 500ml tins which shall be filled
lighting columns and bracket arms. and immediately sealed prior to despatch to the testing
authority. ‘B’ samples shall be taken as site spot checks,
5 (05/05) The first ‘A’ samples shall be taken from the
with a minimum of, say, one batch in three being
first representative batch of each type of paint delivered
sampled. Also for each set of ‘A’ samples taken, a
to site.
further ‘B’ set of samples is required to be submitted for
6 (05/05) If paint is to be supplied in tins of greater testing. ‘B’ samples are required for footbridge
than 5 litre capacity then, for ‘A’ sampling, a minimum steelwork and CCTV masts, cantilever masts, steel
of four 5 litre tins of paint taken from each batch to be lighting columns and bracket arms even though ‘A’
sampled shall be provided by the paint manufacturer. samples are not required.
The ‘A’ samples shall be selected from these 5 litre tins.
12 (05/05) Immediately after selection, the ‘B’ samples
7 (05/05) Additional ‘A’ samples of paints subject to shall be despatched by the Contractor to the testing
testing under sub-Clause 3 of this Clause shall be authority, together with Appendix 50/4 Form HA/P3.
provided by the Contractor depending on the volume of For two-pack systems separate tins containing the
paint for each coat to be used in the Contract. activator and the base shall be dispatched to the testing
Additional samples shall be provided in accordance authority.
with the following:
Provision of 500ml Tins, Packing and Transport of
(i) for ‘Ready or Difficult Access’ steelwork.
‘A’ and ‘B’ Samples
Over 1000 litres: a further set of samples for
each part or whole 1000 litres. 13 (05/05) The Contractor shall provide 500 ml tins
with lids and lid clips for ‘B’ samples at the start of
The Contractor shall also provide an ‘A’ sample: painting or before any procedure trials required by
(ii) of any replacement batch of paint subject to Clause 5011. The quantity of tins supplied shall be
testing under sub-Clause 3 of this Clause; sufficient to avoid any delay in taking ‘B’ samples
throughout the work.
(iii) of any returned paint described in
sub-Clause 5010.4; 14 (05/05) The Contractor shall ensure that the lids of
(iv) when the paint is showing unsatisfactory all tins of sample paint are securely clipped down when
application characteristics under they are despatched for testing.
Clause 5012.

Amendment - May 2005 15

Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

15 (05/05) The Contractor shall be responsible for confirming that such paints have been inspected and
handling, packing as necessary, prompt despatch and where necessary reconstituted and conform in all
transit of ‘A’ and ‘B’ samples, including collection of respects to the Contract.
samples from the testing authority for use or disposal as
5 (05/05) Each tin of reconstituted paint returned to
appropriate, following satisfactory testing and
site by the manufacturer shall have an additional label
reporting.
affixed stating ‘Extended Shelf Life to (date)’. The
16 (05/05) The Overseeing Organisation shall report previous date marking shall remain and not be
back to the Supervising Firm, as stated on obscured. Testing in compliance with Clause #5009
Appendix 50/4 Form HA/P3, all results of the testing, shall apply to reconstituted paints.
who shall then notify the Contractor of the results.

5011 Procedure Trials

5010 Storage Requirements and Keeping
Periods for Paints 1 (05/05) Unless otherwise described in
Appendix 50/5, at the start of the Works, the Contractor
1 (05/05) On delivery to site, paint shall be unloaded shall carry out procedure trials on areas totalling
directly into one or more secure paint stores which shall between 2 m2 and 10 m2, employing the labour and
be located approximately within 100 metres of the equipment to be used in the Works. The Contractor
painting area. Insulation and means of heating and shall demonstrate his ability to carry out the specified
ventilation shall be provided as necessary to maintain methods of surface preparation to the standard required
the temperature of paint stores between 5ºC and 27ºC. and to apply the paints he has selected in accordance
with the specification. The Contractor shall supply
If at any time or place, paint in tins, painters’ kettles or
sufficient paint for the trials as required for the size of
airless spray containers is allowed to reach
the test area. The remaining surface preparation shall
temperatures outside the 5ºC and 27ºC limits, or the
not be started until the first stage of the procedure trials
paint manufacturer’s recommended storage
specified in sub-Clause 2 of this Clause are confirmed
temperature, the paint shall be discarded and not used
as satisfactory.
for the Works. Two pack products which produce an
exothermic reaction when mixed, may be allowed to 2 (05/05) Immediately following the satisfactory
exceed the specified higher temperature limit. The completion of the first stage of the procedure trials, the
Contractor shall also implement any additional storage Contractor shall carry out the second and third stages,
restrictions recommended by the paint manufacturer. employing the labour and equipment to be used in the
Works.
2 (05/05) Unless excepted in sub-Clause 4 of this
Clause, paint which has not been used within the shelf In order to avoid delay, the trials may be carried out in
life recommended by the manufacturer or within 18 three stages:
months of the date of manufacture, which ever is the (i) surface preparation and primer;
lesser, shall be discarded or returned to the
manufacturer and not used in the Works. (ii) undercoat(s);
3 Chemically cured or moisture cured paints shall not (iii) finish.
be used after the expiry of the pot life stipulated by the Paint application of the various coats on the remaining
paint manufacturer. They shall be discarded on expiry parts of the structure shall not be started until the
of the pot life or at the end of each working day/night relevant stage of the procedure trials are confirmed as
whichever is the less. All other paints in opened tins or satisfactory.
open containers including painters’ kettles shall be
returned to store and kept in sealed containers with not 3 Procedure trials shall be completed within a 7 day
more than 10% ullage. period.
4 (05/05) Exceptionally, components of two-pack 4 (05/05) Any adjustment to the registered paint
epoxy paints may have their keeping periods extended formulations shown to be required by the trials, other
to 24 months from the date of manufacture provided than an adjustment to the solvent shall be agreed with
that the Contractor returns the paints to the paint the Overseeing Organisation and made at the paint
manufacturer and ascertains that the manufacturer manufacturer’s works.
examines the contents of each tin and reconstitutes the 5 The Contractor shall carry out further procedure
paints as necessary so that such paints are equal in all trials whenever he employs replacement skilled labour
respects to the paints described in the Contract. The or proposes to use equipment of a different type.
Contractor shall provide a Certificate of Conformity

Amendment - May 2005 16

Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

5012 Application of Paint (ii) during rain, snow, fog, mist or in a dust-
laden atmosphere;
1 The application of paint shall be supervised at all
stages by the Contractor’s supervisory staff. The (iii) when the amount of moisture likely to be
companies contracted to apply protective coating deposited on the surface by condensation or
systems to steel structures, and their personnel, shall be rain before or after painting, may have a
capable of carrying out the work properly and safely. harmful effect on the paint;
The personnel carrying out the work shall have the (iv) when wind-borne dust may have a harmful
necessary skills and/or qualifications. effect on the paint.
2 Paint shall be supplied from the Contractor’s paint 7 Before starting the procedure trials described in
store to the painters ready for application, the only Clause 5011, the Contractor shall make available details
adjustment of formulation permitted being as described of the overall wet film thickness for each coat he
in sub-Clause 5011.4. In exceptional circumstances any proposes to apply. He shall also make available
addition of solvent necessary to improve application information as to the total amount of paint he expects to
shall be advised and if possible carried out by the paint use for each coat of each system during any Contract
manufacturer, preferably in the paint process plant with for which procedure trials are required. The calculation
adequate equipment and controlled measurements. of the amount of paint to be used shall be based on the
volume solids plus an allowance for waste.
3 (05/05) During the application of paint, surfaces to
be treated shall be safely accessible and well 8 The following requirements on paint film
illuminated. When using the coating materials, the thicknesses shall apply:
manufacturer’s technical data sheet shall be observed. (i) wet film thickness gauges shall be used
Prior to and during the application, the coating where practicable to check that the wet film
materials shall be verified to ensure: thickness is not less than:
(i) conformity of the container label with the min dry film thickness (mdft) x 100
specified product description; volume solids %
(ii) no skin formation; (ii) during the application of a paint system, the
(iii) any sediment present shall be easily Contractor shall ensure that the progressive
redispersible with no irreversible settling; total thickness of the applied coats shall
allow the specified minimum total dft of the
(iv) usability under the given site conditions.
system to be attained without exceeding,
4 Paint shall be applied only to surfaces which have overall, the proposed wet film thickness
been prepared and cleaned as described in this Series. referred to in sub-Clause 7 of this Clause by
Areas of adjacent surfaces which are not to be painted more than 20%;
shall be masked before application of paints to the
(iii) in no case shall the total dry film thickness
prepared and cleaned surfaces. Accidental overspray on
of a paint system or the mdft of the last
adjacent unpainted surfaces shall be removed
undercoat and finish be less than that
immediately.
specified in Appendix 50/1 Form HA/P2
5 Unless otherwise described in Appendix 50/2, a (Maintenance) Paint System Sheet;
coat of paint in a system shall be applied by one of the
(iv) the local dry film thickness for any primer
following methods:
shall not exceed the specified mdft by more
(i) brush (B); than 30% and for other paints by more than
(ii) airless spray (AS); 75%.
(iii) (05/05) air assisted spray (S). 9 Each coat of paint of a specified system shall have
satisfactory adhesion.
6 Paint shall not be applied under the following
conditions: 10 (05/05) Each applied specified paint coat, shall be
free from defects, including cratering, pin-holing
(i) when the ambient temperature falls below blistering, rivelling, sagging, bittiness, dry spray and
5°C or the relative humidity rises above 90% cissing etc. The presence of any of these defects shall
or, for types of paints in sub-Clause 5012.14, be determined by unaided visual assessment. The
outside the temperatures and humidities presence of pin-holing or porosity shall be determined
recommended by the paint manufacturer; by low or high-voltage detectors (at corners, bolted
joints and welds pin-holing shall be exempted). The

Amendment - May 2005 17

Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

finished system shall have an even and uniform 21 The Contractor shall enter the details of the stripe
appearance with no defects and the finishing paint in coats he has selected in Appendix 50/1 Form HA/P1
visually sensitive areas shall be from the same batch. (Maintenance) Paint System Sheet giving the Item No.,
colour and method of application.
11 (05/05) The gloss level of the finishing paint shall be
established before the procedure trials. A painted 22 Square solid infill bars shall, after the second
tinplate reference panel, 150 mm x 100 mm, shall be undercoat has been applied, be given an extra coat of
provided by the Contractor for this purpose. the thickest undercoat in lieu of stripe coat or coats.
12 Unless otherwise specified, patch painting
Exposure times for prepared steel surfaces and for
described in Appendix 50/1 shall only be applied over
metal coated surfaces.
areas of an existing system which have been prepared to
sound paint. 23 Clean steel prepared by dry blast cleaning or bright
13 All coats in a system including the stripe coat(s) steel prepared by abrading or by grinding shall be
(see sub-Clauses 5012.14 to 20), but excepting repeat primed within 4 hours.
coats of the same patch paint, shall be in contrasting 24 Clean steel prepared by wet blast cleaning only,
colours to aid identification. Before starting the shall be primed within 4 hours of being dry enough for
procedure trials described in Clause 5011, the painting.
Contractor shall provide a reference panel, coated with
the stepped-back paint system to indicate the contrast 25 Clean steel prepared by combined wet/dry blast
between each coat of paint. cleaning shall be primed within 4 hours of dry blast
cleaning.
14 (05/05) Two-pack chemically cured and moisture
cured paints shall not be applied when the steel 26 Sa2 or St3 steel prepared by dry blast cleaning or
temperature falls below 3ºC above dew point and/or abrading shall be overcoated within 48 hours.
0ºC or when the steel or ambient temperatures are 27 Sa2 steel prepared by wet blast cleaning or
below those advised by the paint manufacturer, nor combined wet/dry blast cleaning shall be primed within
shall such paints be applied when the temperatures are 24 hours of being dry enough for painting or within 48
likely to fall below the advised temperatures during the hours of dry blast cleaning.
curing period.
28 Steelwork which has been thermally metal spray
Stripe Coat(s) coated at site shall be primed or sealed within 4 hours
and in any case before the surfaces have been affected
15 (05/05) Unless otherwise described in by moisture.
Appendix 50/5, the stripe coat(s) shall be applied by 29 Areas prepared down to bright or sound thermally
brush over all welds, edges and all fasteners including sprayed metal coating shall be sealed or primed within
washers and to all external corners except those of RHS 4 hours of preparation by dry blast cleaning or abrading
members. and in any case before the surfaces have been affected
16 In areas prepared down to the substrate or to a by moisture.
metal coating, the first stripe coat, using second 30 Hot dip galvanizing which has been abraded to
undercoat paint, shall be applied over the primer or the bright metal prior to painting shall be primed within 4
first undercoat; when a second stripe coat is specified it hours, or within 4 hours of being dry enough for
shall be separated from the first stripe coat by an treatment if wet abraded, and overcoated within 48
undercoat. The first stripe coat on fasteners treated with hours of priming.
Item 155 shall be applied by brush; other stripe coats
may be applied by brush or airless spray as appropriate. 31 Gaps at joints or plies shall be sealed in accordance
with sub-Clause 5002.10 either before or after the
17 In areas prepared down to sound paint, the stripe application of the primer as appropriate.
coat(s) shall be applied before the priming coat.
18 (05/05) Stripe coat(s) applied on existing paint coats Paint Overcoating Times
shall be applied by brush.
32 (05/05) Unless otherwise specified in
19 The first stripe coat on fasteners treated with Item Appendix 50/5, overcoating times shall be as follows:
155 shall be applied by brush.
(i) (05/05) primerson steel or sealed thermally
20 Wet cleaning as described in sub-Clause 5003.8 sprayed metal coating or first coats over Item
shall be used to remove final traces of grease from 155 or etch primed hot dip galvanizing shall
fasteners before treatment with Item 155. be overcoated within 72 hours and the next

Amendment - May 2005 18

Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

coat applied within 14 days or as 5015 (11/03) Additional Requirements for the
recommended by the paint’s manufacturer; Protection of CCTV Masts, Cantilever Masts,
(ii) surfaces of existing paint coats which have Steel Lighting Columns and Bracket Arms
been prepared to sound paint, cleaned down
only or abraded only to remove gloss, shall Applicable Clauses
be overcoated within 7 days;
1 Unless otherwise described in Appendix 50/5, the
(iii) (05/05) coats
following those referred to in i work described in this Clause shall be carried out in
and ii above, shall be applied within 14 days compliance with Appendix 50/1 and with Clauses 5001
of each coat or as recommended by the to 5014 except that, only one stripe coat in undercoat
paint’s manufacturer. paint is required.

5013 Form HA/P1 (Maintenance) Paint

System Sheet (Appendix 50/1)
Form HA/P2 Paint Data Sheet
(Appendix 50/3)
1 As soon as the Contract has been awarded the
Contractor shall prepare and make available a copy of
Appendix 50/1 Form HA/P1 (Maintenance) Paint
System Sheet, of which he shall have completed parts
10 to 14 together with relevant copies of Form HA/P2
Paint Data Sheet (Appendix 50/3).
2 (05/05) Following any relevant approvals in
accordance with the Contract, Appendix 50/1 Forms
HA/P1 (Maintenance) Paint System Sheet shall be
adopted for the Works.

5014 Access, Containment and Lighting

1 Without prejudice to the Conditions of Contract,
access for inspection shall be provided, erected and
maintained by the Contractor. The access shall be
adequate in all respects for inspection purposes.
2 (05/05) Manual surface preparation and coating
application work shall not be carried out when light
intensity at the workface is less than 500 lux. When the
natural light intensity falls below this level, the
Contractor shall install and maintain temporary lighting
which shall provide a minimum light intensity of 500
lux over at least 1.0 m² at the workface during the work
and also for inspection when required

Amendment - May 2005 19F

Volume 1 Series 5000
Specification for Highway Works Maintenance Painting of Steelwork

NATIONAL ALTERATIONS OF THE OVERSEEING

ORGANISATION OF SCOTLAND

5007SE Paint and Similar Protective Coatings

1 The term paint in this specification shall be deemed
to refer also to similar protective coatings including
specialist coatings such as grease paints.
2 (05/05) The paints permitted for use by the
Overseeing Organisation in the Works are listed in the
Manual of Paints for Structural Steelwork which is
included in BD 35 (DMRB 2.4.1) and which also
contains details of the quality assurance scheme for
paints and similar protective coatings. All paints shall
have a current BBA HAPAS Roads and Bridges
Certificate or equivalent.
3 All paints shall be supplied in sealed containers of
not more than 5 litre capacity and these shall be used in
order of delivery. Each container shall be of the
completely removable lid type and be clearly marked on
the side to show the name of the manufacturer,
registered description of the material (including
purpose, e.g. whether primer, undercoat or finish),
colour, Item No, paint manufacturer’s reference
number, batch number and date of manufacture. Where
date of manufacture is coded, the Contractor shall
provide the code key.
4 The Contractor shall ensure that the properties of
the paints he has selected are suitable for the conditions
on site, including temperature and humidity, and that he
is able to apply the paints satisfactorily to all parts of
the structure in these conditions.
5 Unless otherwise described in Appendix 50/5, all
paints forming any one protective system, or
overlapping systems, shall be obtained from the same
manufacturer, as named by the Contractor in
Appendix 50/1 Form HA/P1 (Maintenance) Paint
System Sheet.
6 (05/05) The requirements of Clause #5009 and their
respective Tables shall apply in Scotland.

Amendment - May 2005 S1F