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Publication Number: FHWA-HRT-12-044
Date: November 2012

 

Federal Highway Administration 100-Year Coating Study

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FOREWORD

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. Eight coating systems were selected for the study—three three-coat systems consisting of organic, inorganic, and moisture-cured zinc-based primers; four two-coat systems with various combinations of zinc-based primers and organic top coats; and a single-coat system of calcium sulfonate alkyd. One design innovation feature was the employment of 18- by 18-inch large test panels that contained welding joints and angle attachments using bolts and nuts to closely simulate realistic conditions that are encountered in bridges in the field. All coating systems were evaluated under accelerated laboratory testing and three outdoor exposure conditions, namely natural weathering and natural weathering with salt spray in McLean, VA, and outdoor testing at the Golden Gate Bridge in San Francisco, CA. This report presents results of the performance evaluation of the eight coating systems.

Jorge E. Pagán-Ortiz
Director, Office of Infrastructure
Research and Development

Notice

This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document.

The U.S. Government does not endorse products or manufacturers. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of the document.

Quality Assurance Statement

The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement.

 

Technical Report Documentation Page

1. Report No.

FHWA-HRT-12-044

2. Government Accession No. 3 Recipient's Catalog No.
4. Title and Subtitle

Federal Highway Administration 100-Year Coating Study

5. Report Date

November 2012

6. Performing Organization Code
7. Author(s)

Pradeep Kodumuri (SES Group and Associates) and Seung-Kyoung Lee (Center for Advanced Infrastructure and Transportation)

8. Performing Organization Report No.

 

9. Performing Organization Name and Address

SES Group and Associates
614 Biddle City
Chesapeake City, MD 21915
(Formerly manager of FHWA Coatings and Corrosion Laboratory) Center for Advanced Infrastructure and Transportation Rutgers, the State University of New Jersey
100 Brett Road
Piscataway, NJ 08854

10. Work Unit No. (TRAIS)

11. Contract or Grant No.
12. Sponsoring Agency Name and Address

Office of Infrastructure Research and Development
Federal Highway Administration
6300 Georgetown Pike
McLean, VA 22101-2296

13. Type of Report and Period Covered

Final Report

14. Sponsoring Agency Code

 

15. Supplementary Notes

The Federal Highway Administration project managers were Seung-Kyoung Lee (Rutgers) and Y.P.Virmani, HRDI-60.

16. Abstract

The Federal Highway Administration 100-Year Coating Study was initiated in August 2009 to search for durable coating systems at a reasonable cost. The objective of the study was to identify and evaluate coating materials that can provide 100 years of virtually maintenance-free service life for steel bridges. Selected coating systems included three three-coat systems, four two-coat systems, and a single-coat system of high-ratio calcium sulfonate alkyd. All coating systems were evaluated under accelerated laboratory testing and three outdoor exposure conditions, namely natural weathering and natural weathering with salt spray in McLean, VA, and outdoor testing at the Golden Gate Bridge in San Francisco, CA. One design innovation was the employment of 18- by 18-inch large test panels that contained welding joints and angle attachments using bolts and nuts to closely simulate realistic conditions that are encountered in bridges in the field. This report presents results of performance evaluation of the eight coating systems.

17. Key Words

One-coat, Two-coat, Three-coat, Steel bridge coatings, Corrosion protection, Accelerated laboratory testing, Outdoor exposure, Coating performance evaluation

18. Distribution Statement

No restrictions. This document is available to the public through the National Technical Information Service, Springfield, VA 22161

19. Security Classification
(of this report)

Unclassified

20. Security Classification
(of this page)

Unclassified

21. No. of Pages

58

22. Price
Form DOT F 1700.7 Reproduction of completed page authorized

SI* (Modern Metric) Conversion Factors

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

 

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