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This is a general outline of different types of high-performance coatings used for industrial steel structures and maintenance. We will be discussing the different types of coatings and where and when they are to be used, the make-up of these coatings, application methods, advantages/disadvantages, tolerance, and limitations. I was going to discuss the cost range of each but due to the different performance levels that each brand offers it is hard to put cost in perspective without digging into specific brands of coatings.
All protective coatings are thoroughly tested using accelerated laboratory tests. Accelerated testing has the advantage of providing data and results in a relatively short timeframe and the conditions of testing are pre-defined and controlled throughout the test. However accelerated testing also has disadvantages. Accelerated testing at e.g. tougher environmental conditions or higher temperatures may give different degradation mechanisms than at in service conditions.Field exposures can be used as a supplement to accelerated testing and can be utilized as a verification of the test setup.In this paper results from several atmospheric accelerated laboratory exposure tests for numerous protective coating systems have been compared to results obtained from up to nine years of field exposure testing in a marine environment corresponding to corrosion category C5 according to ISO 12944-2.The comparison shows varying correlation between accelerated laboratory tests and field exposures. This indicates that high performance of a coating system during accelerated laboratory testing is not necessarily predictive for high long term performance under in-service conditions. Potentially causing premature coating failures under in service conditions.The authors therefore propose ailormade test scheme for the various generic coatings and the in-service conditions and for the industry to accept a more holistic view on coating performance.
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A continuing problem with coatings applied to sharp edges of a structure is the corrosion that often develops at the apex of the edge. The conventional wisdom is that the reduction of film thickness, due to coating pulling away at the edge during the curing of the coating, is the primary cause for the onset of corrosion. This theory, however, is not necessarily correct, both from a mechanistic and practical point of view.
This paper provides an overview of the Spray-applied Fire Resistant Materials and intumescent mastic materials used to protect structural steel in commercial and industrial buildings and structures. Intumescent fireproofing materials are specifically discussed including the initial testing by UL, their listings, uses, applications and inspection in the field