Coating Systems for Painting Old and New Structural Steel National Academy of Sciences Monthly P

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GEORGIA INSTITUTE OF TECHNOLOGY
OFFICE OF CONTRACT ADMINISTRATION
SPONSORED PROJECT INITIATION
January 24, 1978
Date:
Project Title: Coating Systems for Painting Old and New Structural Steel
Project No: A-2092
Project Director: D. J. O'Neil
(cid:9)
National Academy of Sciences
Sponsor:
Agreement Period: From (cid:9) 1/1/78 (cid:9) Until -3/31/80
Type Agreement: Contract No. 4 14
-
Amount: $149,231
(cid:9) Monthly Progress Schedule; Quarterly Narrative; Final Technical.
Reports Required:
Sponsor Contact Person (s):
Technical Matters Contractual Matters
(thru OCA)
Nt. Ronald R. Wiley
National Academy of Sciences
2101 Constitution Ave., N.W.
Washington, D.C. 20418
[phone]
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(cid:9)
GEORGIA INSTITUTE OF TECHNOLOGY OFFICE OF CONTRACT ADMINI:;TRATION
SPONSORED PROJECT TERMINATION SHEET
, (cid:9) Date (cid:9) 6/4/82
Project Title: Coating Systems for Painting Old and New Structural Steel
Project No: (cid:9) A-2092
Project Director: Dr. C. J. Ray
Sponsor: National Academy of Sciences
Effective Termination Date: 12/31/81
Clearance of Accounting Charges: (cid:9)
Grant/Contract Closeout Actions Remaining:
)1_ Final Invoice and Closing Documents
q Final Fiscal Report
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FORM OCA 10:781
-14 COPY NO.
COATING SYSTEMS FOR PAINTING OLD AND NEW
STRUCTURAL STEEL
Preliminary Draft
FINAL REPORT
Prepared for
NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM
TRANSPORTATION RESEARCH BOARD
NATIONAL RESEARCH COUNCIL
By
Frank A. Rideout, Charles J. Ray, and Leslie E. Henton
GEORGIA INSTITUTE OF TECHNOLOGY
A Unit of the University System of Georgia
Engineering Experiment Station
Atlanta, Georgia 30332
1982
Acknowledgment
This work was sponsored by the American Association
of State Highway and Transportation Officials, in co-
operation with the Federal Highway Administration, and
was conducted inthe National Cooperative Highway
research Program which is administered by the Trans-
portation Research Board of the National research
Council.
Disclaimer
This copy is an uncorrected draft as submitted
by the research agency. A decision concerning ac-
ceptance by the Transportation Research Board and
publication in the regular NCHRP series will not
be made until a complete technical review has been
made and discussed with the researchers. The opin-
ions and conclusions expressed or implied in the
report are those of the research agency. They are
not necessarily those of the Transportation Research
Board, the National Academy of Sciences, the Federal
Highway Administration, the American Association of
State Highway and Transportation Officials, or of
the individual states participating in the National
Cooperative Highway Research Program.
TABLE OF CONTENTS
Page
LIST OF FIGURES (cid:9) iv
LIST OF TABLES (cid:9)
ACKNOWLEDGEMENTS (cid:9) viii
ix
ABSTRACT (cid:9)
1
SUMMARY OF FINDINGS (cid:9)
CHAPTER ONE (cid:9) INTRODUCTION AND RESEARCH APPROACH . (cid:127) (cid:127) (cid:9) 3
Problem Statement
Research Objective
Research Approach
8
CHAPTER TWO FINDINGS (cid:9)
DOT Survey
Literature Survey
Experimental Program
PACE - Review and Conclusions
58
CHAPTER THREE (cid:9) INTERPRETATION (cid:9)
Tentative Guidelines
68
CHAPTER FOUR (cid:9) SUGGESTED RESEARCH (cid:9)
Design of Field Evaluation Program
Additional Research
APPENDIX A State-of-the-Art DOT Survey Tables
APPENDIX B Annotated Bibliography
APPENDIX C Experimental Evaluation of Recently
Developed Coating Systems
LIST OF FIGURES
Page
Figure C-1. (cid:9) Weatherometer - 60° Gloss Ratings (cid:9) C-7
Figure C-2. (cid:9) Weatherometer - 60° Gloss Ratings (cid:9) C-8
Figure C-3. (cid:9) Weatherometer - 60° Gloss Ratings (cid:9) C-9
Figure C-4. (cid:9) Weatherometer - 60° Gloss Ratings (cid:9) C-10
Figure C-5. (cid:9) Weatherometer - Color Differences for Various
Candidate Topcoats (cid:9) C-12
iv.
LIST OF TABLES
Page
TABLE 1. (cid:9) Questions Submitted to States to Establish (cid:9) 9
Current Practice
TABLE 2. (cid:9) Zones Used by States for Painting Specifica- (cid:9) 11
tions in 1978-1979
TABLE 3. (cid:9) Comparison of Unit Costs for Surface Prepara- (cid:9) 35
tion
TABLE 4. (cid:9) Comparison of Unit Costs for Primer Paints (cid:9) 35
TABLE 5. (cid:9) Comparison of Unit Costs for Topcoat Paints (cid:9) 35
TABLE 6. (cid:9) Overview of Paint Systems Tested on New Steel (cid:9) 37
TABLE 7. (cid:9) Test Matrix for Paint Systems on New Steel (cid:9) 39
TABLE 8. (cid:9) Ranking of Paint Systems Based on Time to (cid:9) 41
Failure in a Salt Fog Cabinet
TABLE 9. (cid:9) Comparison of Paint Systems Over New Steel (cid:9) 43
(Marine Exposure)
(cid:9)
TABLE 10. (cid:9) Paint Systems Applied Over Old, Intact Paint 45
(cid:9)
(cid:9)
TABLE 11. Paint Systems Applied Over Hard Rust (Brush 46
Blast Abrasive Cleaning)
(cid:9) (cid:9)
TABLE 12. Comparison of New Topcoats Over Old, Intact 49
Paint
(cid:9) (cid:9)
TABLE 13. System Thickness and Performance Data for 50
Coatings Over Hard Rust (Urban Test Site)
(cid:9)
TABLE C-1. Overview of Paint Systems Tested on New Steel (cid:9) C-18
TABLE C-2. (cid:9) Paint Systems on New, Near-White Blast
Cleaned Steel (cid:9) C-19
TABLE C-3. (cid:9) Test Matrix for Paint Systems on New Steel (cid:9) C-22
TABLE C-4. (cid:9) Thickness of Coatings on Weatherometer Panels (cid:9) C-23
TABLE C-5. (cid:9) Pencil Hardness and Tape Adhesion of Base
Systems to Steel (cid:9) C-24
v.
LIST OF TABLES (Con't)
Page
TABLE C-6. (cid:9) Gloss Readings During Accelerated Weathering
Exposure (cid:9) C-25
TABLE C-7. (cid:9) Tristmulus Valves Y, X, and Z for Paint
Systems During Weatherometer Exposure (cid:9) C-26
TABLE C-8. (cid:9) Total Color Difference E for Coatings
Exposed in Weatherometer (cid:9) C-28
TABLE C-9. (cid:9) Dry Film Thickness for Coatings Tested in
Salt Fog (cid:9) C-29
TABLE C-10. (cid:9) Corrosion and Blister Ratings for Salt Fog
Exposure of Systems on New Steel (cid:9) C-30
TABLE C-11. (cid:9) Comparison of Rust Ratings by ASTM D 610 and
ASTM D 1654 (cid:9) C-37
TABLE C-12. (cid:9) Thickness of Coatings on Initial Set of KTA
Panels Exposed at Brunswick, Georgia (cid:9) C-38
TABLE C-13. (cid:9) Thickness of Coatings on Second Set of KTA
Panels Exposed at Brunswick, Georgia (cid:9) C-43
TABLE C-14. (cid:9) Thickness of Coatings on New Steel Panels Ex-
posed at Brunswick, Georgia (cid:9) C-47
TABLE C-15. (cid:9) Rust Ratings for First Set of KTA Panels
Placed on Marine Exposure (cid:9) C-50
TABLE C-16. (cid:9) Rust Ratings for Second Set of KTA Panels
Placed on Marine Exposure (cid:9) C-53
TABLE C-17. (cid:9) Rust and Chalk Ratings for Flat, Steel
Panels Exposed in the Marine Environment (cid:9) C-55
TABLE C-18. (cid:9) Paint Systems Applied Over Old, Intact Paint (cid:9) C-57
TABLE C-19. (cid:9) Paint. Systems Applied Over Hard Rust (Brush
Blast Abrasive Cleaning) (cid:9) C-58
TABLE C-20. (cid:9) Coating Thickness Data for Systems Applied
Over Old, Intact Paint (cid:9) C-67
TABLE C-21. (cid:9) Performance Data for New Topcoats Over Old,
Intact Paint Exposed at Marine Testing Site (cid:9) C-68
vi.
LIST OF TABLES (Con't)
Page
TABLE C-22. System Thickness and Performance Data for
(cid:9)
Coatings Over Hard Rust (Urban Test Site) C-69
TABLE C-23. Ranking of Paint Systems Based on Time to
(cid:9)
Failure in a Salt Fog Cabinet C-71
TABLE C-24. Comparison of Paint Systems Over New Steel
(cid:9)
Marine Exposure) C-72
TABLE C-25. Comparison of Test Coatings with Control
(cid:9)
Coating Using Student's t C-73
TABLE C-26. Comparison of New Topcoats Over Old, Intact
Paint (cid:9) C-74
TABLE C-27. ANOVA Table for Coatings Over Old, Intact Paint (cid:9) C-75
vii.
ACKNOWLEDGEMENTS
The research reported herein was performed under NCHRP Project 4-14
by the Energy and Materials Sciences Laboratory of the Engineering Experi-
ment Station, Georgia Institute of Technology.
The invaluable assistance of the Georgia Department of Transportation
and its staff is gratefully acknowledged. In particular, the counsel, the
many old, coated steel panels cut from replaced bridge girders and the use
of the exposure test racks at Brunswick, Georgia provided by Vernon Smith
are appreciated.
The contributions of raw materials and paints by several suppliers
are gratefully acknowledged as well as their suggestions of starting com-
positions and procedures. The many suggestions of John Keane and Joseph
Bruno of the Steel Structures Painting Council and the early review of
their work with replacement pigments for lead and chromate ones were
especially helpful.
viii.