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The study objective was to evaluate the cost effectiveness and feasibility of a paint system warranty from a coatings manufacturer for a specified coating to be applied over steel with minimum surface preparation (without removing completely the existing coating or tightly adhering rust) and to evaluate the coating performance at the conclusion of the warranty period.
Quality Assurance/Quality Control (QA/QC), often referred to as inspection, is critical to the success of a protective coating or lining project. Several parties can and do get involved in inspection including the owner, specifier, third party inspector, general contractor, painting contractor, equipment supplier, and coating manufacturer.
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The Federal Highway Administration, through its Innovative Bridge Research and Construction Program, requested research in the performance of paint coatings applied to bridges. The Maryland State Highway Administration tested two different, two ─ coat systems in a side-by-side comparison with its standard three ─ coat paint system consisting of organic zinc primer / epoxy polyamide intermediate / aliphatic urethane finish coat (currently the “State of the Art” system for most States).
Duplex systems, also known as painting over hot dip galvanized steel, are extremely effective corrosion protection systems. However, careful surface preparation techniques need to be used to alleviate potential coating failures. The age and characteristics of the galvanized coating should be used to determine what type of surface preparation is needed. Surface preparation should develop an anchor profile for the paint without removing the zinc coating.