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Protecting Steel Structures From Corrosion With Thermal Sprayed Zinc Duplex Coatings

Picture for Protecting Steel Structures From Corrosion With Thermal Sprayed Zinc Duplex Coatings
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Product Number: 51321-16512-SG
Author: M. Gagné/ Ole Knudsen
Publication Date: 2021
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$20.00
$20.00

In order for steel structures to meet a 100 year design life, protective coatings with very long durability are needed to reduce maintenance costs. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) have used TSZ duplex coatings for protection of steel bridges since 1965. Many steel bridges in Norway cross rivers or fjords along the sea coast and are exposed to a corrosive marine environment. In addition, many of the inland bridges are exposed seasonally to road de-icing salts. The results of coating performance evaluation on coastal and inland bridges show that very long lifetimes can be achieved with TSZ duplex coatings. There are examples of 50 year-old bridges with the zinc duplex coatings in good condition. There is no corrosion evident, and the bridges may realize their full design life without maintenance. Even in very corrosive environments, bridges with more than 40 year-old coatings are still in good condition. While the coating evaluation found a few bridges where the coating has failed after only about 20 years, the typical coating failure mechanisms are application errors, low paint film thickness and saponification of the paint.

Key words: Thermal sprayed zinc, duplex coatings, corrosion

In order for steel structures to meet a 100 year design life, protective coatings with very long durability are needed to reduce maintenance costs. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) have used TSZ duplex coatings for protection of steel bridges since 1965. Many steel bridges in Norway cross rivers or fjords along the sea coast and are exposed to a corrosive marine environment. In addition, many of the inland bridges are exposed seasonally to road de-icing salts. The results of coating performance evaluation on coastal and inland bridges show that very long lifetimes can be achieved with TSZ duplex coatings. There are examples of 50 year-old bridges with the zinc duplex coatings in good condition. There is no corrosion evident, and the bridges may realize their full design life without maintenance. Even in very corrosive environments, bridges with more than 40 year-old coatings are still in good condition. While the coating evaluation found a few bridges where the coating has failed after only about 20 years, the typical coating failure mechanisms are application errors, low paint film thickness and saponification of the paint.

Key words: Thermal sprayed zinc, duplex coatings, corrosion

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