United States Department of Transportation
i
Performance Evaluation of One-Coat Systems on New Steel Bridges: [techbrief]
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2011-05-01
[PDF-99.36 KB]
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Abstract:This document is a technical summary of the Federal Highway Administration report, "Performance Evaluation of One-Coat Systems on New Steel Bridges" (FHWA-HRT-11-046). The current state of practice in bridge coating usually involves multilayer coating typically consisting of a zinc-rich primer over an abrasive blast-cleaned surface and two additional coating layers on top of the primer. Although this current coating technology provides a comprehensive solution for better corrosion protection of steel bridges, the overall cost involved is relatively higher than its lead-based predecessors. The purpose of this study was to evaluate the performance characteristics of various commercially available high-performance coating materials that can be applied as one-coat systems to steel bridge in shop application. Eight one-coat systems and two controls, a three-coat system and a two-coat system, were chosen, and their performance was evaluated using accelerated laboratory testing and outdoor exposure conditions. Performance of these coating materials was evaluated on the basis of variations in color and gloss, changes in adhesion strength, changes in pencil scratch hardness, and the development of surface defects and rust creepage. Regression analysis was used to identify correlations among the various performance parameters, and a comprehensive system was developed to rank the coating systems based on overall performance. This TechBrief summarizes the laboratory approach, the test results and conclusions.
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