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Protecting Steel Structures From Corrosion With Thermal Sprayed Zinc Duplex Coatings

Picture for Protecting Steel Structures From Corrosion With Thermal Sprayed Zinc Duplex Coatings
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Product Number: 51321-16512-SG
Author: M. Gagné/ Ole Knudsen
Publication Date: 2021
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$20.00
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In order for steel structures to meet a 100 year design life, protective coatings with very long durability are needed to reduce maintenance costs. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) have used TSZ duplex coatings for protection of steel bridges since 1965. Many steel bridges in Norway cross rivers or fjords along the sea coast and are exposed to a corrosive marine environment. In addition, many of the inland bridges are exposed seasonally to road de-icing salts. The results of coating performance evaluation on coastal and inland bridges show that very long lifetimes can be achieved with TSZ duplex coatings. There are examples of 50 year-old bridges with the zinc duplex coatings in good condition. There is no corrosion evident, and the bridges may realize their full design life without maintenance. Even in very corrosive environments, bridges with more than 40 year-old coatings are still in good condition. While the coating evaluation found a few bridges where the coating has failed after only about 20 years, the typical coating failure mechanisms are application errors, low paint film thickness and saponification of the paint.

Key words: Thermal sprayed zinc, duplex coatings, corrosion

In order for steel structures to meet a 100 year design life, protective coatings with very long durability are needed to reduce maintenance costs. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) have used TSZ duplex coatings for protection of steel bridges since 1965. Many steel bridges in Norway cross rivers or fjords along the sea coast and are exposed to a corrosive marine environment. In addition, many of the inland bridges are exposed seasonally to road de-icing salts. The results of coating performance evaluation on coastal and inland bridges show that very long lifetimes can be achieved with TSZ duplex coatings. There are examples of 50 year-old bridges with the zinc duplex coatings in good condition. There is no corrosion evident, and the bridges may realize their full design life without maintenance. Even in very corrosive environments, bridges with more than 40 year-old coatings are still in good condition. While the coating evaluation found a few bridges where the coating has failed after only about 20 years, the typical coating failure mechanisms are application errors, low paint film thickness and saponification of the paint.

Key words: Thermal sprayed zinc, duplex coatings, corrosion

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Picture for Life Cycle Costs For Thermal Spray Zinc Duplex Coatings On Long Lifetime Steel Constructions
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Life Cycle Costs For Thermal Spray Zinc Duplex Coatings On Long Lifetime Steel Constructions

Product Number: 51322-17803-SG
Author: M. Gagné, O.Ø. Knudsen, K. O. Dahle
Publication Date: 2022
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Very often the life of a corrosion protection paint coating system will not meet the design life of the steel structure it is supposed to protect. Decisions about coating selection are usually focusing on the costs for the initial construction, ignoring the certain future maintenance costs. The total cost of ownership includes the initial cost plus the maintenance, operating and finance costs over the life of a structure. Repeated maintenance operations, and resulting downtime, can add significantly to the total cost of ownership.
51322-18207-SG
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Combining Thermal Spray Zinc And Hot-Dip Galvanizing To Achieve An All Metallic Zinc Coating System

Product Number: 51322-18207-SG
Author: Bernardo Duran
Publication Date: 2022
$20.00

Corrosion protection of infrastructure and assets is an area of increasing focus due to increasing financial and safety concerns. On a global scale, corrosion has an annual cost of $2.5 trillion (USD).1 To combat the deleterious effects of this natural phenomenon, specifiers and owners have many choices in terms of materials and protective coatings. Consideration of both initial and life cycle costs has become more important in the age of increased competition and shrinking maintenance budgets.  
Picture for 04022 Experiences on Thermal Spray Aluminum
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04022 Experiences on Thermal Spray Aluminum (TSA) Coating for Offshore Structures

Product Number: 51300-04022-SG
ISBN: 04022 2004 CP
Author: Desmond K.K. Tiong, Shell International; Halimah Pit, Sarawak Shell Berhad
Publication Date: 2004
$20.00

Since 1982, there has been a move to Thermal Sprayed Aluminum (TSA) coating in the “splash zone” of offshore structures.  Our experience indicates that an experience applicator, good surface preparation and quality of wire combined to achieve required thickness and apply the sealer to seal the entire surface.

 
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