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The combination of an anionic primer layer with a cationic topcoat consist an ion barrier provides corrosion protection without using conventional anticorrosion pigments. The primer inhibits the anodic dissolution of the metals, and the topcoat rejects the aggressive anions from the environment entering the coating-metal interface.
A five-year coatings research project was initiated by the Pennsylvania Department of Transportation in 1986 to evaluate the performance of an organic zinc rich coating system. The coating system consisted of a moisture cured urethane zinc rich primer, an epoxy intermediate, and an aliphatic polyester urethane finish coat. The system was applied to the Windgap Bridge located in McKees Rocks, Pennsylvania (near the City of Pittsburgh) in 1986 and 1987.
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Third-party paint inspection contracts provided an immediate, tangible benefit in supplying a qualified, certified coating inspector full-time to a painting project. Inspectors could be rapidly deployed and provided someone to the project with broad experience in painting projects; however, simply providing a third-party contract paint inspector to a project did not always ensure the project was completed properly.
Details of a new protocol for evaluating the effectiveness of coatings to reduce corrosion of steel structures is presented in this paper. Basic concepts of accelerated testing specified in American Society for Testing Materials (ASTM) standards and recent research investigations were used to develop a procedure that can provide conclusive results within 2400 hours of exposure as compared to more than 5000 hours in current practices.