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New Ultra-Durable Anti-Corrosion Coating System For Steel Infrastructure in Extreme Environments

Picture for New Ultra-Durable Anti-Corrosion Coating System For Steel Infrastructure in Extreme Environments
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Corrosion’s destructive effects on critical steel infrastructure have costly economic and security
implications for the United States. According to a NACE International report from 2001, the annual
corrosion costs in the United States industrial sector were $47.9 billion per year, with the largest portion
stemming from the maintenance of critical utilities such as gas, water, electric, and telecommunications. Catastrophic failure due to corrosion jeopardizes the resilience of critical utilities, risking the interruption of service to millions and creates weak-points the nation’s homeland security.

Product Number: 51323-19357-SG
Author: Dr. Wei Wang, Anna Sanchez-Fischer, Todd Hawkins
Publication Date: 2023
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$20.00

Climate change poses new challenges in protecting steel infrastructure from corrosion, particularly in
coastal regions experiencing record temperatures, humidity levels and rainfall. These extreme
environmental forces, in the presence of salts and pollution, can accelerate corrosion of critical steel
structures such as bridges, electrical utilities and telecommunications, increasing the likelihood of
catastrophic failure. Conventional anti-corrosion coating systems are vulnerable to degradation under
these same extreme environmental conditions and require costly maintenance programs, multiple timeconsuming re-coats and in severe cases of neglect, early failure. This paper explores a novel multilayer coating solution consisting of a topcoat formulated with an aqueous polyvinylidene fluoride (PVDF)-acrylic dispersion that has demonstrated decades of exceptional coastal durability in architectural applications. Combined with an innovative cathodic primer layer and mid-coat, this system demonstrates benefits in ultraviolet radiation durability and corrosion resistance when compared to conventional anti-corrosion coating systems.

Climate change poses new challenges in protecting steel infrastructure from corrosion, particularly in
coastal regions experiencing record temperatures, humidity levels and rainfall. These extreme
environmental forces, in the presence of salts and pollution, can accelerate corrosion of critical steel
structures such as bridges, electrical utilities and telecommunications, increasing the likelihood of
catastrophic failure. Conventional anti-corrosion coating systems are vulnerable to degradation under
these same extreme environmental conditions and require costly maintenance programs, multiple timeconsuming re-coats and in severe cases of neglect, early failure. This paper explores a novel multilayer coating solution consisting of a topcoat formulated with an aqueous polyvinylidene fluoride (PVDF)-acrylic dispersion that has demonstrated decades of exceptional coastal durability in architectural applications. Combined with an innovative cathodic primer layer and mid-coat, this system demonstrates benefits in ultraviolet radiation durability and corrosion resistance when compared to conventional anti-corrosion coating systems.

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This paper will critically review the current philosophies described in  ISO and NACE anti-corrosive performance test standards, taking into consideration correlation with natural exposure, track record, validity of "acceptance" or "pre-qualification criteria", dry film thickness and suggested areas for improvement.
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