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This synthesis will be of interest to state department of transportation (DOT) bridge maintenance engineers, coating specialists, chemists, and researchers. Manufacturers and suppliers of corrosion protection products and systems for exposed structural steel on existing bridges will also find it of interest. This synthesis describes current practice regarding maintenance and protection strategies for exposed structural steel on existing bridges. NCHRP Synthesis 251, Lead-Based Paint Removal for Steel Highway Bridges ( 1997), provides a complementary and more in-depth treatment of maintenance issues involving lead-based paint removal. This report of the Transportation Research Board defines the maintenance management systems and decision making criteria used by transportation agencies for maintaining exposed bridge steel. Material selection criteria, surface preparation and application practices, quality control and quality assurance programs, and funding mechanisms are discussed in detail. The impact of recent and proposed environmental and worker protection regulations on current practice is reported. Information for the synthesis was collected by surveying state transportation agencies and by conducting a literature search. Responses to the survey, Appendix C to this document, are published on the Internet as NCHRP Web Document 11.
A current state-of-the-art survey is presented with regard to painting of highway structural steel. A thorough literature review was conducted and an inspection and evaluation made of more than 4,000 paint exposure tests. Paint film thickness measurement studies were made. Specific recommendations are given for selecting typical paint systems on the basis of six environmental zones, which represent the range of severity of environment in which highway steel structures are located in the United States. Model specifications are suggested for surface preparation, application, material procurement, and paint system.
The purpose of this project was to identify efficient and cost-effective methodologies for maintenance painting of steel bridges for MnDOT bridge crews to extend the service life of the coating system by at least five years before complete coating rehabilitation would be warranted. Five generic coating systems, chosen for their compatibility with existing MnDOT coating systems and minimal requirements for surface preparation and application, were applied over minimally prepared surfaces on two St. Paul bridges. Coating performance was evaluated annually over a three-year period through visual field observation following the MnDOT Steel Bridge Coating Condition Assessment Photographic Field Guide and MnDOT Bridge and Structure Inspection Program Manual. Adhesion testing was performed in accordance with ASTM D3359 in conjunction with the third-year evaluation. The results were photographed and documented in a matrix, identifying key performance characteristics. The predominant failure affecting two of the coating systems was delamination due to application over an anti-graffiti finish coat. Otherwise, each system performed to a standard aligning with the pre-established project goal for expanded serviceability of five years. Because developing a Bridge Maintenance Coating Program requires critical timing in the inspection process to identify existing coating condition, a Bridge Coating Repair Reference Table was developed to assist MnDOT crews with determining the appropriate preventive maintenance painting strategy based on condition and existing coating system. This work also determined that surface conditions demonstrating pitting with rusting, or surfaces with an anti-graffiti coating should not be addressed through maintenance painting but instead should be considered for coating removal and replacement.
The recently promulgated environmental regulations concerning volatile organic compounds (VOC) and certain hazardous heavy metals have had a great impact on the bridge painting industry. As a response to these regulations, many of the major coating manufacturers now offer "environmentally acceptable" alternative coating systems to replace those traditionally used on bridge structures. The Federal Highway Administration sponsored a 7-year study to determine the relative corrosion control performance of these newly available coating systems. The most promising coating systems were selected for long-term field evaluation based on accelerated test performance. The long-term exposure testing was conducted for 5 years in three marine locations. Panels were exposed on two bridges, one in New Jersey and one in southern Louisiana. The third long-term exposure location was in Sea Isle City, New Jersey. Thirteen coating systems were included for long-term exposure testing.
The Federal Highway Administration 100-Year Coating Study was initiated in August 2009 to identify coating systems that can provide 100 years of virtually maintenance-free service life at comparable costs to the existing coating systems, even in adverse environments. This book focuses on the study and discusses the performance evaluation of one-coat systems for new steel bridges.
This report presents findings of a survey and laboratory evaluation of materials and techniques for cleaning and painting chloride-contaminated weathering steel bridges. Laboratory techniques suitable for field usage were developed for assessing the conductivity and chloride level of prepared surfaces. The following cleaning techniques were evaluated for their effectiveness in removing chloride from corroded and pitted plates: air abrasive wet blasting, dry blasting (including alternative abrasives), dry blast and rinse sequences, pressurized water jetting, power tool cleaning, hand tool cleaning, and chemical strippers. Eight coating systems, including organic and inorganic zinc, high-solids epoxies, thermal spray zinc, oil/alkyd, and petroleum wax were selected for laboratory evaluations. They were applied over laboratory and bridge specimens of weathering steel having various levels of chloride contamination using four preparation techniques: wet and dry blasting, power tool and hand tool cleaning. The coatings were exposed to salt spray, immersion in deionized water, and a composite test incorporating ultraviolet radiation, condensation, and freeze-thaw conditions. Based on these tests, and other considerations, the four surface preparation techniques and the following eight systems were selected for multisite 5-year bridge and test fence evaluation: epoxy zinc-rich, urethane zinc-rich, epoxy mastic, thermal spray zinc, three inorganic zincs (conventional and low-VOC ethyl silicate, and water-borne alkali silicate) and oil-alkyd control. Preliminary guidelines were developed for weathering steel maintenance options of no painting, painting corroded areas only, and painting entire structure.
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The Federal Highway Administration 100-Year Coating Study was initiated in August 2009 to identify coating systems that can provide 100 years of virtually maintenance-free service life at comparable costs to the existing coating systems, even in adverse environments. This book focuses on the study and discusses the performance evaluation of one-coat systems for new steel bridges.