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A two-year FHWA one-coat study was launched in November 2006 to evaluate various commercially available coating materials that can be applied as one-coat systems to new steel bridges. Seven one-coat systems, a 3-coat and a 2-coat control were selected and tested in three outdoor environments.
A two-year FHWA one-coat study was launched in November 2006 to evaluate various commercially available coating materials that can be applied as one-coat systems to new steel bridges. Seven one-coat systems, a 3-coat and a 2-coat control were selected and tested in three outdoor environments. After 24 months in marine environment and 18 months in natural weathering exposures in Virginia, the one-coat systems exhibited different degrees of deterioration. Except for urethane mastic, which developed eight medium size blisters and G5 grade rusting after exposed in the marine environment, most of the one-coat systems showed virtually no surface failures. The final mean rust creepage at the scribe ranged from around 2 mm for most of the one-coat systems to 30 mm for polysiloxane. When viewed collectively, none of the one-coat systems performed as well as the 3-coat control in the outdoor exposures.
A new and versatile waterborne solid epoxy resin dispersion with good flexibility and improved shear stability is presented. When this binder is used, high performance metal primers can be formulated without the use of anti-corrosion pigments. This is highly desirable since the toxicological effects of zinc phosphate and other zinc-based salts are causing environmental concerns.
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This paper summarizes the problems encountered by manufacturers and end-users relying on the available standards for materials and performance tests for zinc-rich coatings in today’s industry and presents some suggestions for improving them. The reasons and the need for developing new and only performance based specifications are also explained.
Two coatings were developed for the intended purpose of maintaining steel sheet pile at the waterfront. The new splash zone coatings are free of VOC’s and HAP’s thereby providing a more environmentally friendly alternative to the standard coal tar epoxy system. The new coatings are also more abrasion and impact resistant and applied at more than twice the thickness of coal tar epoxy. All of these factors add up to an anticipated service life of 3 to 4 times that of coal tar epoxy leading to reduced life cycle costs.