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Performance Evaluation of One-Coat Systems on New Steel Bridges - Final Results

In an effort to address cost issue associated with shop application of conventional 3-coat systems, FHWA completed a study to investigate the performance of eight one-coat systems and two control coatings for corrosion protection of highway bridges. Based on prior performance, a three coat system and a two coat system were selected as the control coating systems. 

Product Number: 41211-622-SG
Author: Pradeep Kodumuri, Yuan Yao, Seung-Kyoung Lee
Publication Date: 2011
Industry: Coatings
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In an effort to address cost issue associated with shop application of conventional 3-coat systems, FHWA completed a study to investigate the performance of eight one-coat systems and two control coatings for corrosion protection of highway bridges. Based on prior performance, a three coat system and a two coat system were selected as the control coating systems. The performance of all coating systems was evaluated under accelerated lab and outdoor exposure conditions. Accelerated testing was performed in the lab for 6840 hrs. Natural weathering exposure was performed in the outdoor environment for 18 months and at a marine exposure site for 24 months. CSA coating system was found to perform equally in comparison with 3-coat. Regression analysis helped identify a correlation between color and gloss, adhesion strength and coating defects for the one-coat systems.

In an effort to address cost issue associated with shop application of conventional 3-coat systems, FHWA completed a study to investigate the performance of eight one-coat systems and two control coatings for corrosion protection of highway bridges. Based on prior performance, a three coat system and a two coat system were selected as the control coating systems. The performance of all coating systems was evaluated under accelerated lab and outdoor exposure conditions. Accelerated testing was performed in the lab for 6840 hrs. Natural weathering exposure was performed in the outdoor environment for 18 months and at a marine exposure site for 24 months. CSA coating system was found to perform equally in comparison with 3-coat. Regression analysis helped identify a correlation between color and gloss, adhesion strength and coating defects for the one-coat systems.

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