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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).
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.
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There seems to be a trend for bridge owners to believe that applying all three coats of paint in the shop is more cost effective and will provide for a better coatings job on new steel. This paper will discuss the differences between shop coating and field painting and the pros and cons of shop applied coatings versus field applied coatings on new steel.
Coating performance and longevity is highly dependent on the quality of substrate surface preparation. The effect of profile height, profile type (e.g., type of tool used to perform the prep, angularity of profile, etc.), extent of cleanliness, and amount of chloride contamination on coating performance were all studied to determine the correlation between these factors in an attempt to identify the primary factor in coating failure due to improper surface preparation.