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FHWA 100-Year Coating Study and Come Preliminary Test Results

The FHWA 100-year coating study was initiated in August 2009. The objective of this study is to identify and evaluate coating materials that can provide 100 years of maintenance-free service life for steel bridges. 

Product Number: 41211-623-SG
Author: Pradeep Kodumuri, Seung-Kyoung Lee
Publication Date: 2011
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The FHWA 100-year coating study was initiated in August 2009. The objective of this study is to identify and evaluate coating materials that can provide 100 years of maintenance-free service life for steel bridges. Selected coating systems included three 3-coat systems consisting of organic, in-organic, and moisture curing zinc-based primers, four 2-coat systems with various combinations of zinc based primers and organic top coats, and a single coat HRCSA (High Ratio Calcium Sulfonate Alkyd). One design innovation was employment of 18 in. x 18 in. large size test panels which contained welding joints and angle attachments to closely simulate realistic conditions that are encountered in the field bridges. All coating systems will be evaluated under accelerated lab testing and outdoor exposures including Golden Gate Bridge in California. This paper presents overview of the work plan and the first data sets collected through six 360-hr accelerated test cycles and one 6-month outdoor exposure test cycle.

The FHWA 100-year coating study was initiated in August 2009. The objective of this study is to identify and evaluate coating materials that can provide 100 years of maintenance-free service life for steel bridges. Selected coating systems included three 3-coat systems consisting of organic, in-organic, and moisture curing zinc-based primers, four 2-coat systems with various combinations of zinc based primers and organic top coats, and a single coat HRCSA (High Ratio Calcium Sulfonate Alkyd). One design innovation was employment of 18 in. x 18 in. large size test panels which contained welding joints and angle attachments to closely simulate realistic conditions that are encountered in the field bridges. All coating systems will be evaluated under accelerated lab testing and outdoor exposures including Golden Gate Bridge in California. This paper presents overview of the work plan and the first data sets collected through six 360-hr accelerated test cycles and one 6-month outdoor exposure test cycle.

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