A 2 Coating systems (Explanations of structural component numbers in Figures A 4.3.1 to A 4.3.3) Table A 4.3.2: Coating systems 1 2 3 4 5 6 7 Comp. No Basic corrosion load Coating system Nominal dry film thickness (m) Surface preparation grade Materials in Annex E Sheet No Other notes No 1 Bridge superstructures 1.1 sides of roadway slabs 1.1.1 Welded deck plates for railway bridges (with ballast bed) 1) Load from rail traffic and superstructure equipment is significant 1 thin coat EP/PUR quartz sand 0.4-0.7 mm 4000 Sa 2½ 84 Annex 84 2 thin coat PUR 4000 Sa 2½ 84 Annex 3 1 GB EP quartz sand 0.4-0.7 mm 1 ZB EP 1 DB EP-coarse mortar 300 300 4000 Sa 2½ 84 84 84 84 Apply DB to wet ZB. Compaction and levelling of the surface by power trowel 1.1.2 Riveted deck plates for railway bridges (with ballast bed) 1) Load from rail traffic and superstructure equipment is significant 1 thin coat EP/PUR quartz sand 0.4-0.7 mm 4000 Sa 2½ 84 Annex 84 2 thin coat PUR 4000 Sa 2½ 84 Annex 3 1 GB EP quartz sand 0.4-0.7 mm 1 DB thin coat EP/PUR quartz sand 0.4-0.7 mm 300 4000 Sa 2½ 84 84 84 84 4 1 GB EP quartz sand 0.4-0.7 mm 1 DB thin coat PUR 300 4000 Sa 2½ 84 84 84 Annex 1.1.3 Vertical surfaces in contact with ballast (ballast boundary)1) Load from rail traffic and superstructure equipment is significant 1 thin coat EP/PUR quartz sand 0.4-0.7 mm 2000 Sa 2½ 84 84 2 thin coat PUR 2000 Sa 2½ 84 Annex 3 1 GB EP quartz sand 0.4-0.7 mm 1 DB EP-fine mortar 300 2000 Sa 2½ 84 84 84 Ballast boundary side walls with EP fine mortar Table A 4.3.2 continued 1 2 3 4 5 6 7 Comp. No Basic corrosion load Coating system Nominal dry film thickness (m) Surface preparation grade Materials in TL/TP-KOR- Stahlbauten, Annex Sheet No Other notes No 1.1.4 Deck plates, with and without road pavement
as in 2.2.1b) with frequent moisture from different ventilation as in 2.2.1b) but with an additional intermediate coating 0.50 m above and below top edge of prospective railings 2.2.4 surfaces in the ground, anchoring elements in the ground soil non-aggressive 1 generally no special protection, potentially corrosion supplement 2 hot dip galvanising — -- if surfaces in the air are to be galvanised anyway soil aggres sive, (particularly at spec. soil resistance of < 2000 cm) Category IM3 1 Corrosion supplement 1 GB EP zinc dust 16) 1 DB EP-combi 16) 70 120 Sa 2½ 87 81 independent of the object’s working life 2 1 GB EP zinc dust 1st ZB EP-combi 2nd ZB EP-combi 1 DB EP-combi 70 120 120 120 Sa 2½ 87 81 81 81 3 construction elements 3.1 railings (including foot plates), touch guards in enclosed spaces 1 hot dip galvanising — -- 2 hot dip galv. 1 ZB 1K HS 1 DB 1K HS 80 80 — -- 93 93 if colouring is necessary 3 hot dip galv. 1 ZB wv AY on Zn 100 — -- 91 if colouring is necessary 11) 4 1 GB 1K HS 1 DB 1K HS 80 80 Sa 2½ 93 93 A 4.3.2 continued 1 2 3 4 5 6 7 Comp. No Basic corrosion load Coating system Nominal dry film thickness (m) Surface preparation Materials in TL/TP-KOR- Stahlbauten, Annex E Sheet No Other notes No 3.1 railings, guards outdoor weathering: corrosiveness category up to C3 1 hot dip galv. 1 ZB 1K HS 1 DB 1K HS 80 80 93 93 15) 2 hot dip galv. 1 ZB wv AY on Zn 1 DB wv AY 80 80 — 91 92 wv AY-DB are 11) 3 hot dip galv. 1 ZB wv AY on Zn 1 DB PUR 80 80 — -- 91 87 under heavy mechanical load 11) 4 1 GB EP-zinc dust 1 ZB 1K HS 1 DB 1K HS 70 80 80 Sa 2½ 87 93 93 water spray area. crushed stone impact 1 hot dip galv. 1 ZB EP 1 DB PUR 80 80 14) -- 87 87
Form B 4.3.2 Test record for corrosion protection Application conditions Page Works number (ASB) Building project Construction phase (factory □ const. site □) Structural component Contractor Principal Measuring instruments (for Columns 6-9): Struct. (ref. surface No) Date / time Process (e.g. surface preparation) GB, ZB, DB Application procedure Weather conditions Temperature [°C] relative humidity [%] dew point [°C] abrasive/ coating material (designation/ subst. No) Colour No Preparation grade Observations (particular occurrences, irregularities Air Struct. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Signatures: (Contractor) (Place) (Date) (Principal) (Date)
C 2 Planning resources for Sheet 75 Coating materials on PVC base on hot dip galvanised steel (PVC) General description of material: one-component coating material Binders: ZB and DB: vinyl chloride copolymer (PVC) Pigments: ZB and DB: micaceous iron oxide, tone pigments Solvent content: maximum 45 % Thinner: substance No 675.99; maximum 5 % addition Additional notes: object temperature at least 5 °C and at least 3 K above dew point Table C 4.3.2: Planning resource for materials according to Sheet 75 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet Hot dip galvanised steel structures like: - railings - doors - inspection trolleys, - inspection catwalks, - drainage pipes, - signal gantries and brackets - railway platform roof structures. Hot dip galvanising as per DIN EN ISO 1461) Be ) hot dipping none ZB: 1K-PVC-EG No 675.61 to 675.74) clean depending on the surface condition and dirt 100) 240 Spraying, spreading, rolling) 8 h DB: 1K-PVC-EG subst. No 675.61 to 675.743,4) Materials according to 75 are not suitable: − for prolonged contact with water, − for high mechanical stress, e.g. gratings − for objects at risk of fire
C 4 Planning resources for Sheet 81 Coating materials based on epoxy resin combination (EP-combi) General description of material: two-component coating material Binders: ZB and DB: modifiers, resin + curing agents Pigments: tone pigments Solvent content: maximum 25 % Thinner: substance No 681.90; maximum 5 % addition Additional notes: object temperature at least 5 °C and at least 3 K above dew point Table C 4.3.4: Planning resources for materials according to Sheet 81 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet - steel surfaces in contact with water or soil, such as: posts, supports and sheet to pile walls - inaccessible areas and areas that can no longer be reached in steel structures - interior coatings of drainage gutters and pipes - footpath plates - bearings and bearing GB: 2K-EP-zinc dust No 687.03/04/05 Sa 2½ 70 100 spraying, spreading 16 h zinc spraying Sa 3 100 spraying none hot dip galvanising as per DIN EN ISO 1461) Be ) hot dipping none ZB: 2K-EP-combi subst. No 681.11 or 681.12) clean depending on the surface condition and dirt 120 170 spraying, spreading, rolling) 16 h DB: 2K-EP-combi subst. No 681.12 or 681.11) Substances according to Sheet 81 are not suitable: − for surfaces in contact with drinking water, − for prolonged contact with oils and fats
C 10 Planning resources for 89 Coating material based on polyurethane, air moisture-cured (1K-PUR) General description of material: one-component coating material Binders: GB and ZB: aromatic polyisocyanate (PUR) DB: aliphatic polyisocyanate (PUR) Pigments: GB: zinc dust with/without micaceous iron ZB and DB: micaceous iron oxide, tone pigments Solvent content: GB maximum 20 %, ZB maximum 32 %, DB maximum 30 % Thinner: substance No 689.150; maximum 5 % addition Additional object temperature at least 3 °C and at least 3 K above dew point cleaning of spraying apparatus only with particular dilution Table C 4.3.10: Planning resources for materials according to Sheet 89 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet - initial protection - full renewal on the construction site GB: 1K- PUR - zinc dust subst. No 689.03 or subst. No 689.04 Sa 2½ 70 100 spraying 3 h zinc spraying Sa 3 100 spraying none ZB: 2K-PUR-EG (also edge protection) subst. No 689.12 to 689.14) clean depending on the surface condition and dirt 80 140 spraying, spreading, rolling) 5 h DB: 1K-PUR-EG No 689.30 to 689.74 or 1K-PUR subst. No 689.75 to 689.99 (colour tones according to RAL) or 2K-PUR according to Sheet 689.74 with/without EG subst. No 689.75 to 689.99 80 150 coating of weld joints and repair of the factory coating on the construction site GB: 1. GB: 2K-EP-zinc phosphate subst. No 687.02 2nd GB: 2K-EP- zinc phosphate subst. No 687.06 PSa 2½ PSt 3 80 150 spraying, spreading 16 h ZB, DB: see above
C 11 Planning resources for Sheet 91 Water-dilutable coating materials based on acrylate or acrylic copolymer for hot dip galvanised steel (wv AY on Zn) General description of material: one-component coating material Binders: ZB and DB: acrylic copolymer or polyacrylate Pigments: ZB and DB: micaceous iron oxide, tone pigments Solvent content: maximum 4.5 % Thinner: water Additional notes: observe application window: temperatures between 17 °C and 25 °C, relative humidity between 40 and 70 % observe sufficient air movement C 3.11: Planning resources for materials according to Sheet 91 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet hot dip galvanised structures like: - railings, doors, inspection trolleys, - inspection catwalks, - drainage (external), - signal gantries and brackets - railway platform roof structures. - sheet-pile walls (in the air), - supporting trestles of standard walls with 2K-PUR as final top coating. Hot dip galvanising as per DIN EN ISO 1461 Be ) hot dipping none ZB: wv Ay on Zn – EG subst. No 691.30 to 691.74 clean depending on the surface condition and dirt 120 200 spraying, spreading, rolling) 6 h DB: wv Ay on Zn – EG No 691.30 to 691.74 or 1K-WL according to Sheet 92 subst. No 692.75 to 692.99 (colour tones according to RAL) or 2K-PUR according to Sheet 87 with/without EG 80 150 Substances according to Sheet 91 are not suitable: − for prolonged contact with water, − for high mechanical stress, e.g. gratings − where in contact with de-icing salt (without DB according to Sheet 87), − where under chemical stress.
C 13 Planning resources for Sheet 93 1K-coating materials free of polyvinyl chloride and polyvinylidene chloride, low-solvent, also for repair (1K HS) General description of material: one-component coating material Binders: GB, ZB, DB: synthetic resins e.g. based on alkyd or acryl, free of polyvinyl chloride and polyvinylidene chloride Pigments: GB: corrosion protection pigments, inhibitors ZB and DB: micaceous iron oxide, tone pigments solid content (vol. %): GB, ZB and DB minimum 57 % Solvent content: GB maximum 23 %, ZB, DB maximum 25 % Thinner: substance No 693.150, maximum 3 % addition Additional notes: object temperature at least 5 °C and at least 3 K above dew point Table C 4.3.13: Planning resources for materials according to Sheet 93 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet - initial protection - full renewal on the construction site GB: 1. GB 1K HS-active pigment subst. No 693.01/02 2nd GB and/or edge protection No 693.06 Sa 2½ 80 140 spraying, spreading 16 h 80 140 2K-EP-zinc dust No 687.03/04/05 Sa 2½ 70 100 spraying zinc spraying Sa 3 100 spraying none hot dip galvanising as per DIN EN ISO 1461)) Be ) hot dipping none ZB: 1K HS-EG No 693.12 to 693.14) clean depending on the surface condition and dirt 80-120 140-190 spraying, spreading 16 h DB: 1K HS-EG subst. No 693.30 to 693.74) 1K HS No 693.80 to 693.99) (colour tones according to RAL) 80-120 140-190 spraying, spreading, rolling6) continued on next page Substances according to Sheet 93 are not suitable: − for high mechanical stress, − for chemical stress, − for hot dip galvanising without pre-treatment.
Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet repair/ partial renewal of old coatings based on drying oils, AK 4) as well as EP and PUR GB: 1st GB (for spotting out) 2K-EP-active pigment subst. No 694.02 2nd GB (poss. for edge protection) 2K-EP-active pigment subst. No 694.06 PSa 2½ PSt 3 80 120 spraying, spreading 16 h 80 120 ZB: 2K-EP-EG (for spotting out) subst. No 694.12 to 694.145,) clean depending on the surface condition and dirt 80-150 spraying, spreading 24 h DB: 2K-PUR-EG No 694.30 to 694.74 or 2K-PUR subst. No 694.75 to 694.99 (colour tones according to RAL) 80 130 spraying, spreading, rolling6) 2K-PUR according to Sheet 87 with/without EG subst. No 687.30 to 687.99 80 150 Substances according to 94 are not suitable: − for hot dip galvanising without surface preparation by means of sweep blast cleaning.
C 15 Planning resources for 97 2K-coating materials based on epoxy resin and polyurethane, quick-drying General description of material: two-component coating material Binders: GB and ZB: Epoxy resin + curing agents (EP) DB: polyacrylate cured with polyisocyanate (PUR) Pigments: zinc dust and zinc phosphate Solvent content: 1st GB maximum 20 %, 2nd GB maximum 23 %, ZB maximum 23 %, DB maximum 35 % Thinner: maximum 5 % addition for EP: subst. No 697.150 for PUR: subst. No 697.151 Additional notes: object temperature at least 3 °C and at least 3 K above dew point Table C 4.3.15: Planning resources for materials according to Sheet 97 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet - initial protection - full renewal on the construction site GB: 1st GB 2K-EP-active pigment subst. No 697.02 or dust 03/04 2nd GB und/or edge protection pigment No 697.06 Sa 2½ 80 120 spraying, spreading 4 h 80 120 zinc spraying Sa 3 100 spraying none Hot dip galvanising ),) as per DIN EN ISO 1461 Be ) hot dipping none ZB: 2K-EP-EG subst. No 697.12 to 697.14 ), ) clean depending on the surface condition and dirt 80 150 spraying, spreading 8 h DB: 2K-PUR-EG subst. No 697.30 to 697.74 or 2K-PUR subst. No 697.75 to 697.99 (colour tones according to RAL) 80 150 spraying, spreading, rolling) 16 h continued on next page Substances according to Sheet 94 are not suitable: − for hot dip galvanising without surface preparation by means of sweep blast cleaning
Table C 4.3.15: continued: Planning resources for materials according to Sheet 97 Area of application Protective system Application Minimum waiting time before subsequent coating at approx. 20 °C System structure Surface preparation Nominal dry film thicknesses [μm] dry wet coating of weld joints and repair of the factory coating on the construction site GB: 1. GB: 2K-EP-zinc phosphate subst. No 697.02 2nd GB: 2K-EP-zinc phosphate subst. No 697.06 PSa 2½ PSt 3 80 150 spraying, spreading 4 h ZB, DB: see
Table D 4.3.2 continued Limit values for the estimated results of the eluate analyses where mineral blasting abrasives are used Characteristics Blast cleaning debris groups 6 7 8 9 10 pH value 7.2 ± 0.2 Conductivity μS/cm < 42 Total dissolved solids mg/l < 34 AOX 0.02 COD < 35 TOC < 13 Phenol index 0.1 0.02 PCB (according to Ballschmiter) μg/l < 0.6 Total PAH (EPA) < 130 < 0.15 Cyanide, total mg/l < 0.01 Cyanide, easily released Fluoride 0.01 Chloride < 1.0 Phosphate < 0.1 Sulphate < 3.0 Nitrate < 1.0 Nitrite < 0.05 Ammonium < 0.1 Chromium (VI) < 0.025 Antimony < 0.1 Arsenic < 0.01 Barium < 0.8 Lead < 0.2 < 0.02 Cadmium < 0.002 Chromium, total < 0.01 Iron < 0.02 Cobalt < 0.01 Copper < 0.01 Manganese < 0.03 Nickel < 0.02 Mercury < 0.0002 Selenium < 0.1 Thallium < 0.001 Vanadium < 0.1 0.01 Zinc < 1.0
Table D.4.3.3 continued: Limit values for the estimated results of the solids analyses using melting chamber slag (MSK) and copper mill slag (MCU) as a blasting abrasive Characteristics Blast cleaning debris groups 13 14 15 Blasting abrasive MSK MCU MSK MCU MSK MCU Dry residue Mass % 100 Ash content of dry residue > 99.5 Mineral oil hydrocarbons mg/kg DM 1) < 50 extractable substances < 2300 < 470 < 1040 8) < 470 < 1040 8) < 2300 EOX < 17 < 17 < 17 < 250 8) < 17 < 17 Total PCB (according to Ballschmiter) ug/kg DM 1) < 6 Total BTEX mg/kg < 0.5 Total VHH < 0.1 Total PAH (EPA), mg/kg DM 1) < 0.15 9) < 620 11) < 1100 10) < 0.15 < 0.15 9),12) < 620 11) < 1100 10) Chromium (VI) < 0.5 Sulphur, total < 300 < 3500 < 300 < 3500 < 300 < 3500 Aluminium ~200 000 2) ~25 000 2) ~200 000 2) ~25 000 2) ~200 000 2) ~25 000 2) Antimony < 3.3 < 300 < 3.3 < 300 < 3.3 < 300 Arsenic < 6.5 < 73 < 6.5 < 73 < 6.5 < 73 Barium < 1400 < 230 < 1400 < 230 < 1400 < 230 Beryllium < 41 < 7 < 41 < 7 < 41 < 7 Lead < 150 < 3200 < 150 < 3200 < 150 < 3200 Cadmium < 4.5 < 31 < 4.5 < 31 < 4.5 < 31 Chromium 300 7) 420 7) < 170 < 290 < 170 < 290