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Chemically Bonded Phosphate Ceramic coating was investigated in various environments such as inland, beach and salt-fog exposure. After 8-month outdoor testing, the coating was evaluated by visual inspection, coating thickness, adhesion measurement and X-ray diffraction. Long term testing ensued, up to 24 months.
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Coatings are widely used to mitigate corrosion of structural steel in aggressive humid environments. Zinc-rich primer three-coat paint systems are widely used to mitigate corrosion of steel bridges. However, the associated costs of its required maintenance are high. As part of a research program, chemically bonded phosphate ceramics (CBPC), thermal diffusion galvanizing (TDG) and metallizing coatings along with the current 3-coat systems were exposed in outdoor conditions for up to 2 years and in salt-fog exposure for up to 14,600 hours.
The performance of a Chemically Bonded Phosphate Ceramic (CBPC) coating was investigated for marine bridge application. Assessment of possible coating degradation and corrosion development was made by physical and electrochemical techniques. Passive-like conditions developed in the chloride-free solutions and formation of oxide product occurred in the chloride solutions. A large degree of oxide product formation throughout the non-scribed coating exposure surface area, consistent with the large, measured corrosion current, was indicative that the ceramic coating had poor barrier coating properties.
The bulk characteristics of Chemically Bonded Phosphate Ceramic (CBPC) coating was investigated for marine bridge application in alternate wet and dry exposure. Assessment of possible bulk coating degradation was made by physical testing, Mercury Intrusion Porosimetry (MIP) and electrochemical techniques. The bulk coating material was observed to become chalky and in some cases form cracks when exposed to alternate wet and dry conditions. Cohesive strength appeared to degrade.