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Life Cycle Costs For Thermal Spray Zinc Duplex Coatings On Long Lifetime Steel Constructions

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Very often the life of a corrosion protection paint coating system will not meet the design life of the steel structure it is supposed to protect. Decisions about coating selection are usually focusing on the costs for the initial construction, ignoring the certain future maintenance costs. The total cost of ownership includes the initial cost plus the maintenance, operating and finance costs over the life of a structure. Repeated maintenance operations, and resulting downtime, can add significantly to the total cost of ownership.

Product Number: 51322-17803-SG
Author: M. Gagné, O.Ø. Knudsen, K. O. Dahle
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings and Linings , Coatings
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Public infrastructures like bridges typically have a design lifetime of 100 years or more. When selecting protective coatings in such a long term perspective, focus should be on life cycle costs and not only the costs in the construction phase, since the maintenance costs may be considerable and dominate the total cost of ownership. Coating selection standards like ISO 12944 are not intended for such a long timescale, and there is little documentation in the literature of coating performance with lifetimes of more than about 20 years. Owners of structures with very long lifetimes have little information to base their coating selection on, besides their own experiences. Thermal spray zinc (TSZ) duplex coatings have been shown to be highly durable, as evidenced by more than 50 years of successful use since first specified by the Norwegian Public Roads Administration (NPRA). The paper will summarize field examinations, maintenance costs, coating lifetime expectations and life cycle cost estimates for steel bridges as a function of the environmental corrosivity category (C1-C5) and make comparisons to alternative coatings that are less expensive to apply but that have shorter lifetime expectancy.

Public infrastructures like bridges typically have a design lifetime of 100 years or more. When selecting protective coatings in such a long term perspective, focus should be on life cycle costs and not only the costs in the construction phase, since the maintenance costs may be considerable and dominate the total cost of ownership. Coating selection standards like ISO 12944 are not intended for such a long timescale, and there is little documentation in the literature of coating performance with lifetimes of more than about 20 years. Owners of structures with very long lifetimes have little information to base their coating selection on, besides their own experiences. Thermal spray zinc (TSZ) duplex coatings have been shown to be highly durable, as evidenced by more than 50 years of successful use since first specified by the Norwegian Public Roads Administration (NPRA). The paper will summarize field examinations, maintenance costs, coating lifetime expectations and life cycle cost estimates for steel bridges as a function of the environmental corrosivity category (C1-C5) and make comparisons to alternative coatings that are less expensive to apply but that have shorter lifetime expectancy.

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51322-18207-SG
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Combining Thermal Spray Zinc And Hot-Dip Galvanizing To Achieve An All Metallic Zinc Coating System

Product Number: 51322-18207-SG
Author: Bernardo Duran
Publication Date: 2022
$20.00

Corrosion protection of infrastructure and assets is an area of increasing focus due to increasing financial and safety concerns. On a global scale, corrosion has an annual cost of $2.5 trillion (USD).1 To combat the deleterious effects of this natural phenomenon, specifiers and owners have many choices in terms of materials and protective coatings. Consideration of both initial and life cycle costs has become more important in the age of increased competition and shrinking maintenance budgets.  
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(Coating Formulation) Can Low Zinc Epoxy Primers Work as Well as Traditional Zinc Rich Epoxy Primers

Product Number: 47-COAT_DEC21
Author: Alex Yagüe / Pinturas Hempel / David Morton
Publication Date: 2021
$20.00

Zinc-rich primers, with zinc dust loadings of 80-85% by weight in the dry film, are often the preferred primer during new construction of assets placed in environments with high atmospheric corrosivity. Coating standards such as SSPC-Paint 20 and ISO 12944 demand that zinc-rich primers contain at least 65% and 80% zinc dust by weight in the final dry film, respectively. Traditional zinc rich primers need this high zinc loading to achieve galvanic protection of steel. New technology allows us to develop zinc primers with a lower content of zinc and/or different zinc morphology than dust to provide similar or better corrosion protection to the steel.
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Laboratory And Full-Scale Qualification Of An Abrasion Resistant Overcoat Wrap

Product Number: 51322-17633-SG
Author: David B. Futch, Tré Bischof, David D’Ambrosio, Chris Alexander
Publication Date: 2022
$20.00

As onshore pipeline rights-of-way become more congested and urban sprawl increases, the number of horizontal directional drills (HDDs) will likely increase. HDD is a trenchless pipeline installation method that requires drilling a larger pilot hole where the mainline pipe can be subsequently pulled through the drilled hole. However, HDDs have an increased probability for coating damage, even when coated with traditional mill or field applied abrasion resistant overcoat (ARO). This coating damage includes abrasion, impact, gouging, denting, tearing, bending, etc. and that damage may exist for the life of the pipeline due to an HDD being inaccessible for future maintenance.
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