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 (202) 389-6908 Defense Priority Rating: Technology & Development Laboratory Assigned to: (School/Laboratory) COPIES TO: Project Director Library, Technical Reports Section Division Chief (EES) EES Information Office School/Laboratory Director EES Reports & Procedures Dean/Director—EES Project File COCA) Accounting Office Project Code (GTRI) Procurement Office Other (cid:9) Security Coordinator (OCA) Reports Coordinator COCA) It (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 Final Report of Inventions Govt. Property Inventory & Related Certificate Classified Material Certificate El Other (cid:9) Assigned to: (cid:9) EMSL (sot/Laboratory) COPIES TO: 441(/ AdtvtiRistrative-Geeeditwiter. Research Security Services EES Public Relations (2) Research Property Management ..-Reports---euordinster-(OCA) Computer Input Accounting Legal Services (OCA) Project File Procurement/EES Supply Services Library Other (cid:9) 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.