Issues Impacting Bridge Painting: an Overview
FHWA/RD/94/098 –August 1995

Prepared by Thomas F. Bernecki, George M. Nichols, David Prine, Gary Shubinsky and Alan Zdunek

BIRL Industrial Research Laboratory,
Northwestern University
1801 Maple Avenue, Evanston, IL 60201-3135

U.S. Department of Transportation
Federal Highway Administration
Research and Development
Turner Fairbank Highway Research Center
6300 Georgetown Pike, McLean, VA 22101-2296

FHWA contract #DTFH61-92-C-00033

Abstract | Table of Contents | Executive Summary | Chapter 1 | Chapter 2 | Chapter 3 | Chapter 4 | Chapter 5 | Chapter 6 | Chapter 7 | Appendix A | References | List of Figures | List of Tables

Table of Contents

Abstract
Executive Summary
Chapter 1 . Introduction
Chapter 2. Task A - Economic Evaluation

• Introduction
• Background
• Model Development
  • Life-Cycle Cost Model Development
  • LCC Model Applications
  • Expanded Spreadsheet Model
• Summary and Conclusions

Chapter 3. Task B - Worker Protection/Paint Removal

• Introduction
• Discussion
  • Paint-Removal Methods
• IDOT Paint-Removal Demonstration - Testing Protocol
  • Initial Tests
  • Tests Conducted During the Paint Removal
  • Tests Conducted After Paint Removal
  • Analysis of Paint and Steel for Lead by X-Ray Fluorescence
  • Water-Jet Cleaning Results
  • Air-Sampling Tests for VOC's Generated During Grit Blasting Within Confinement
  • Airborne Grit-Blast Debris Particulate Sampling and Analysis
  • Effectiveness of Paint-Removal Procedures
• Julien Dubuque Bridge at Dubuque, Iowa

Chapter 4. Task C - Evaluation of Procedures for Analysis and Disposal of Lead-Based Paint-Removal Debris

• Introduction
• Discussion
  • Waste Analysis Methods
    • Analysis of the Existing Paint
  • Samples of Existing Paint From I-55
  • Existing Paint Analysis by Energy-Dispersive X-Ray Analysis
  • TCLP Analysis of the Paint Debris
  • Waste Treatment
  • Iron Stabilization of Lead-Based Paint Debris
  • TCLP and Optical Analysis of Paint Debris Samples
• Conclusions and Suggestions

Chapter 5. Task D - Advanced Coatings

• Introduction
• Background
• Dilemmas Facing Fabrication Shops
  • Increased Shop Painting
  • Containment For Maintenance Painting
  • Fabrication Shop Problems
  • Regulation of Fabrication Shops
• Overcoating
  • Factors Affecting Performance and Durability of Overcoating Systems
  • Adhesion/cohesion
  • Surface Contamination
• Thermal Spray Technology
  • Introduction
  • Thermal Spray Coatings
  • Thermal Spray Materials
    • Zinc
    • Aluminum
    • Zinc/Aluminum
    • Sealers
• Infrastructural Applications of Thermal Spray Technology
• Thermal Spraying of Steel Bridges: A Short History
• Test Panel Preparation
• Conclusions and Recommendations

Chapter 6. Task E - Accelerated Testing

• Background
  • Types of Coating Failure
  • Coating Properties
  • Coating Evaluation
• Objectives and Approach
• Materials and Procedures
  • Test-Panel Preparation
  • Coating Type and Application
  • Electrolyte Preparation
  • Accelerated Test Procedure Identification and Modification
    • Immersion Experiment
    • Immersion Test Procedure
    • Cyclic Test I
    • Cyclic Test I Procedure
    • Cyclic Test II
    • Cyclic Test II Procedure
• Results and Discussion
  • Immersion Experiments
  • Thermally Sprayed Coatings
    • Pb/Alkyd and VOC-Compliant Coatings
    • Cyclic Accelerated Tests
    • Non-flat Panel Results
  • Flat Panel Results
    • Visual Rating
    • EIS Analysis
• Conclusions and Recommendations

Chapter 7. Task F - Productivity Improvement

• Introduction
• Degree of Surface Rusting
• Evaluation of Blast-Cleaned Surface
• Quantitative Measurement of Damaged Area
• Infrared Thermography
  • Introduction
• Disbondment of Existing Paint Systems
• Conclusion and Recommendations

Appendix A. Description of Electrochemical Techniques

• Electrochemical Impedance Spectroscopy
  • Linear Polarization
  • Potentiodynamic Polarization

References

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