I-65 project in downtown Louisville consisted of 27 bridges having approximately 1,493,100 ft2 of steel. The structures had existing coatings that contained lead. The project posed significant operational and public safety and operational constraints due to close proximity of the structures with residences and businesses along the entire route. In 2000, the Central Office Project Design Team developed experimental specifications to abrasive blast and re-paint the bridges. Surface preparation procedures included solvent cleaning, pack rust removal and abrasive blast cleaning. Containment enclosures were employed throughout the project, air monitoring was performed to assure satisfactory containment, and hazardous wastes were collected and disposed of. The I-65 bridges were painted with an organic zinc rich primer and a coat of tinted moisture cure aluminum polyurethane intermediate coat and an acrylic polyurethane finish coat. The project was let at a cost of about $9.30/ft2. The painting project started in April, 2001 and was successfully completed in November, 2001.

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