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The University of Kentucky’s Kentucky Transportation Center (KTC) is working with the Kentucky Transportation Cabinet (KYTC) and the structural steel coating industry to develop a revolutionary tool to aid in the inspection of protective coatings applied to steel structures.
The University of Kentucky’s Kentucky Transportation Center (KTC) is working with the Kentucky Transportation Cabinet (KYTC) and the structural steel coating industry to develop a revolutionary tool to aid in the inspection of protective coatings applied to steel structures. It has been long recognized that the service lives of protective coatings on steel structures are closely related to the quality of coatings application. Two very important elements of successful bridge painting projects are linked – inspection and the quality of coatings application. To support that linkage, KTC identified the use of coatings containing Optically Activated Pigments (i.e., OAP coatings) being used by the Department of Defense as a potential inspection tool to assist in the evaluation of application quality. A research study, KYSPR 09-377 “Fluorescing Coatings for Improved Inspection during Bridge Maintenance Painting”, was initiated with the primary objectives of developing laboratory methods for evaluating the effectiveness of OAP coatings and, upon obtaining positive laboratory results, working with the KYTC to conduct a field trial using those coatings. The laboratory work was comprised of two primary elements, constructing mock bridge beams to be coated with OAP coatings for evaluation of inspection effectiveness and accelerated weathering testing to determine OAP coatings performance. Mock-up bridge beams were coated with a variety of systems using OAP coatings. Designed flaws in the applications were cataloged and experienced coating inspectors performed timed inspection assessing the coatings using both normal white light and fluorescing light (to activate the OAPs). Inspection using the fluorescing light increased the flaw detection by 15%. Accelerated weathering (ASTM D 5894) was completed with OAP coatings performing well. Based on the laboratory results, the KYTC used OAP coatings on a maintenance bridge painting project. Results of the field trial revealed some issues with the coatings but also verified that there is potential for beneficial use of this inspection tool. Further field trials are planned to “fine tune” the coatings chemical makeup, handling, application, and inspection procedures.
Zinc-rich coatings have long been known to provide excellent corrosion resistance in highly corrosive environments, in general,inorganic zincs for new construction and organic zincs for maintenance. A recent trend has been toward zinc-rich coatings with reduced levels of zinc dust. An SSPC committee formed to revise SSPC Paint 29, Zinc Dust Sacrificial Primer, Performance Based, to reference performance only, removing reference to minimum zinc dust level.
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A two-year Federal Highway Administration (FHWA) in-house study was launched in November 2006 to evaluate various coating materials that may be applied as one-coat systems to steel bridges. A total of eight test materials plus two control systems, a 3-coat and a 2-coat, were applied over near-white steel test panels (SSPC-SP10). Their performance has been evaluated for 20 months using electrochemical impedance spectroscopy, surface failure characterizations, rust creepage at scribe, pull-off adhesion, and changes of color and gloss.
There are several thousand bridges that are scheduled for maintenance painting both in the State of Tennessee and Missouri. The Caruthersville Bridge (I-155 Mississippi River Bridge) is an on-going project, which is the northern-most bridge over the Lower Mississippi River, with the combined flow of the Upper Mississippi and the Ohio River.