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Pull-off adhesion behaviors of 15 coating systems in three groups were studied utilizing test method ASTM D4541. Three groups of coating systems included coating systems with organic or inorganic zinc-rich primers, polymeric polyurea coatings, and overcoating systems applied on an existing coating system.
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Traditional zinc rich primers are the primer of choice during new construction of assets placed offshore for oil & gas production. However, during maintenance, zinc rich primers are not used because of difficulties of having good surface preparation and controlling applied dft to prevent cracking. This paper will examine the performance of new, activated zinc rich epoxy primers compared to conventional zinc rich epoxy primers on steel prepared to different surface profiles using standard techniques of today.
This paper will examine the formulation and performance of new, activated zinc epoxy primers compared to conventional zinc-rich epoxy primers. We will demonstrate comparable corrosion resistance at reduced zinc levels in the dried film (Level 3 ≥65%) and show that zinc metal levels can be reduced to as low as 31% by weight without compromising galvanic corrosion protection while improving adhesion and mechanical properties of the dry film.
Corrosion is a durability concern for any unprotected structural steel from its exposure environment and coatings are widely used for corrosion protection. Zinc-rich primer-based three-coat (ZRP) systems are the most widely used for structural steel, since 1980’s. However, these coating systems often require regular maintenance. So, there is always interest to develop durable novel coating systems to reduce the maintenance cost.
Over the past 40 years, three-coat systems consisting of zinc-rich primer, epoxy intermediate and polyurethane topcoat (ZEU) have been the preferred coating system for steel bridge structures in highly corrosive environments due to their proven performance and cost effectiveness.1-6 Each layer serves a different function: galvanic protection is supplied by the zinc-rich primer, while the epoxy intermediate coat provides barrier to water and salts, and the polyurethane topcoat resists against ultraviolet degradation, abrasion, and chemicals.
The seismic retrofitting of the County of Placer/Foresthill Road Bridge included replacing the gusset plates at the bolted connection points on the structure. Newly fabricated connection plates were prepared in the steel fabrication shop by abrasive blast cleaning and applying an inorganic zinc-rich primer. Existing connection plates were removed and the surfaces beneath abrasive blast cleaned and primed on-site with an organic (epoxy) zinc-rich primer. The connections were slip-critical.
On July 28, 1986 a tornado struck an area outside of Sioux City, IA, destroying one of the four power generation plants at Port Neal. The tornado registered an F4 on the Fujita scale, indicating that “devastating damage” had taken place on the ground. Although there were no major injuries to the employees at the plant, severe damage took place on the equipment.
Traditional sacrificial protection afforded by zinc rich primer technology relies on the zinc metal acting as its own metallic pathway to transfer electrons to the steel substrate. Understanding this mechanism of corrosion protection versus an enhanced method of electron transfer using a self-assembling nanoscale carbon quantum network will demonstrate to the reader how this new approach to galvanic corrosion protection is more effective, sustainable, and greener for the environment.
This paper summarizes the problems encountered by manufacturers and end-users relying on the available standards for materials and performance tests for zinc-rich coatings in today’s industry and presents some suggestions for improving them. The reasons and the need for developing new and only performance based specifications are also explained.
Various types of zinc-rich coatings are available for corrosion protection. The challenges associated with the proper specification and application of zinc-rich coatings are briefly discussed. The paper then focuses on data from various studies, which quantify the corrosion protection benefits of various types of zinc-rich coatings.