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Modeling the Service Life of Corrosion Protection Coatings

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The life of corrosion protection coating systems very often will not meet the design life of the steel structures they are supposed to protect. Decisions about corrosion protection coating selection are usually focusing on the costs for the initial application, ignoring the certain future maintenance costs. However, repeated maintenance operations, and resulting downtime, can add significantly to the total cost of ownership.

Product Number: 51323-19068-SG
Author: M. Gagné
Publication Date: 2023
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Life-cycle cost modeling can be used to compare expected performance of corrosion protection systems over the entire life of a steel structure. Life-cycle models consider not only initial application costs, but also future maintenance costs. Critical, however, to the value and validity of the model are the assumptions used for the longevity of various corrosion protection systems and the timing for maintenance interventions. Coating durability guidelines for corrosion protection coatings estimates the time to first maintenance and also provides a schedule for subsequent maintenance actions. Fortunately, many steel structures exist with various corrosion protection coating systems so that cost models can be verified against real-world performance. While guidelines for liquid applied organic coatings compare well with observed real-world performance, estimates for the durability of duplex zinc coatings significantly underestimate the life of the coating, thereby overestimating the life-cycle cost. Real-world performance of organic coatings and duplex zinc coatings will be compared to illustrate the validity and limitations of coating durability guidelines used for life cycle cost modeling.

Life-cycle cost modeling can be used to compare expected performance of corrosion protection systems over the entire life of a steel structure. Life-cycle models consider not only initial application costs, but also future maintenance costs. Critical, however, to the value and validity of the model are the assumptions used for the longevity of various corrosion protection systems and the timing for maintenance interventions. Coating durability guidelines for corrosion protection coatings estimates the time to first maintenance and also provides a schedule for subsequent maintenance actions. Fortunately, many steel structures exist with various corrosion protection coating systems so that cost models can be verified against real-world performance. While guidelines for liquid applied organic coatings compare well with observed real-world performance, estimates for the durability of duplex zinc coatings significantly underestimate the life of the coating, thereby overestimating the life-cycle cost. Real-world performance of organic coatings and duplex zinc coatings will be compared to illustrate the validity and limitations of coating durability guidelines used for life cycle cost modeling.

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Implementation of classification and certification programs for durable industrial and infrastructure maintenance coating systems is hindered by a lack of test protocols to reliably accelerate the aging process and estimate service lifetime. This gap in the industry also hurts development efforts to
reformulate or add new color choices to existing product lines. The first problem can be addressed by performing long-term weathering testing at outdoor exposure sites in places like south Florida and Arizona, but the need to wait 5 or 10 years or longer to confirm a classification or certify a product makes such schemes difficult to implement and ultimately reduces their value.
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