TURNER-FAIRBANK HIGHWAY RESEARCH CENTER TURNER-FAIRBANK HIGHWAY RESEARCH CENTER One-Coat Systems Applicable to Steel Bridge Structures Coatings & Corrosion Laboratory Office of Infrastructure R & D Turner-Fairbank Highway Research Center Federal Highway Administration McLean, VA 22101 TRB 2009 One-Coat Systems Applicable to Steel Bridge Structures Coatings & Corrosion Laboratory Office of Infrastructure R & D Turner-Fairbank Highway Research Center Federal Highway Administration McLean, VA 22101 TRB 2009
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TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
One-Coat Systems Applicable to Steel Bridge Structures
Coatings & Corrosion LaboratoryOffice of Infrastructure R & D
Turner-Fairbank Highway Research CenterFederal Highway Administration
McLean, VA 22101
TRB 2009
One-Coat Systems Applicable to Steel Bridge Structures
Coatings & Corrosion LaboratoryOffice of Infrastructure R & D
Turner-Fairbank Highway Research CenterFederal Highway Administration
McLean, VA 22101
TRB 2009
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
3-Coat System (Control)3-Coat System (Control)
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
CSACSA
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
GFPGFP
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
EMEM
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
WBEPWBEP
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
UMUM
0 2,160 4,320 6,840
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
Findings Findings
1. Two control coating systems (3-coat and 2-coat) had a dry film thickness (DFT) of approximately 13 mils and a pencil scratch hardness of HB.
2. The 3-coat demonstrated very good performance in almost all aspects and slightly better than the 2-coat.
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
Findings - Continued Findings - Continued 3. With regard to initial DFT, pencil scratch hardness, and
adhesion properties, the eight one-coat systems varied significantly compared to those of the controls.
4. Four one-coat systems (ASP, WBEP, SLX, and UM) had either higher adhesion strength or thicker DFT compared to the controls, but their performance in terms of defect development, rust creepage, and rate of physical deterioration was far inferior to the rest.
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
Findings - Continued Findings - Continued 5. The fifth one-coat system, HBAC, had a DFT of 10.4
mils with a very soft pencil scratch hardness (6B) and showed mixed results with a relatively low number of coating defects, moderate rust creepage resistance, and good physical appearance.
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
Findings - Continued Findings - Continued 6. To date, CSA has been the best performer despite its
softness and very weak adhesion strength. 7. GFP is also an excellent coating system and is the 2nd
best in the overall performance rating. These two one-coat systems outperformed the controls.
8. Performance of EM was comparable to those of the control systems.
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
100-Year Life Coating Systems
Coatings & Corrosion LaboratoryOffice of Infrastructure R & D
Turner-Fairbank Highway Research CenterFederal Highway Administration
McLean, VA 22101
TRB 2009
100-Year Life Coating Systems
Coatings & Corrosion LaboratoryOffice of Infrastructure R & D
Turner-Fairbank Highway Research CenterFederal Highway Administration
McLean, VA 22101
TRB 2009
TURNER-FAIRBANK HIGHWAY RESEARCH CENTERTURNER-FAIRBANK HIGHWAY RESEARCH CENTER
BackgroundBackground1. This is a Congress mandated study under the HPS
program.2. Main objective is to identify and evaluate coating
materials that can provide 100 years of maintenance-free service life for steel bridge structures.
3. This study started in November 2008 and will be carried out for 36 months.
4. Some types of weathering steel will be also tested.
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Coating Systems SelectedCoating Systems SelectedSystem
Number Category Generic Coating Name
1 Control - Conventional 3-coat Shop System IOZ / Epoxy / Aliphatic Polyurethane
2 Control -3-coat OZ Shop System Zn-rich Epoxy / Epoxy / Aliphatic Polyurethane
3 3-coat Fluoro-Topcoat System MCU Zn / Epoxy / Fluorourethane
4 2-coat Fast Dry Coating Zn-rich Epoxy / Aliphatic Polyurethane