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The U.S. Army Corps of Engineers owns and operates the vast majority of the countries lock and dam structures for inland navigation. The large steel gates on these structures are subjected to a severe impact and abrasive environment while in immersion by debris such as timber, ice, steel drums, etc. High VOC vinyl resin coatings have historically been the best available coatings for these structures in this environment but have exhibited very poor performance at the water line where the impact and abrasion is at its worse.
The U.S. Army Corps of Engineers owns and operates the vast majority of the countries lock and dam structures for inland navigation. The large steel gates on these structures are subjected to a severe impact and abrasive environment while in immersion by debris such as timber, ice, steel drums, etc. High VOC vinyl resin coatings have historically been the best available coatings for these structures in this environment but have exhibited very poor performance at the water line where the impact and abrasion is at its worse. Service life of only 1-2 years for vinyl resin coatings and 5-10 years for metalizing have been the norm. Current demonstrations and laboratory testing of two different ceramic composite coatings and an adhesively applied ultrahigh molecular weight polyethylene (UHMWPE) sheet applied only at the water line have shown to provide superior protection and increased life expectancy, thereby eliminating the need for frequent repair of a high VOC coating
For the last 20 years polyurethane has been the leading topcoat technology in corrosion systems for both marine and industrial use. Performance, protection, appearance and total cost effectiveness are some of the factor’s customers have taken into consideration. Customers have a long list of demands and polyurethane has become a technology choice for a wide number of end markets.
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Common methods of maintenance painting have either involved complete removal of existing paint (e.g., SSPC-SP 10, Near White Blast Cleaning) or highly localized preparation of corroding areas using power or hand tools (e.g., SSPC-SP 2 or SSPC-SP 3). Sometimes projects may be designed to an intermediate level where the intent is to reduce the surface preparation level of effort by allowing “good” coatings to remain. In these cases, abrasive blasting or ultra-high pressure water jetting may be used to prepare the entire surface, but well adhered aged coating is allowed to remain.
There are many factors which need to be considered when making the decision to over coat an existing coating system. With the magnitude of data that need to be evaluated in relation to the existing coating system and potential scenarios that are possible it is important to take multiple details into account. Details including inspection criteria of the existing coating system and substrate, owner’s goals and objectives, asset location and environmental conditions must all be taken into consideration.