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51317--9593-Update on Corrosion Performance of CBPC Coatings in Aggressive Bridge Environment

Chemically Bonded Phosphate Ceramic coating was investigated in various environments such as inland, beach and salt-fog exposure. After 8-month outdoor testing, the coating was evaluated by visual inspection, coating thickness, adhesion measurement and X-ray diffraction. Long term testing ensued, up to 24 months.

 

Product Number: 51317--9593-SG
ISBN: 9593 2017 CP
Author: Md Ahsan Sabbir
Publication Date: 2017
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Coatings are widely used to mitigate corrosion of structural steel in aggressive humid environments. However the service life is often diminished in aggressive environments. Repair of coatings can be costly due to materials labor and environmental controls. Novel coating systems are commercially available for steel bridge aplication. As a part of research to assess novel coatings Chemically Bonded Phosphate Ceramic (CBPC) coating was investigated. Research in progress on CBPC coating considered various exposure environments such as inland beach and salt-fog exposure. Long term testing included up to 24 months in outdoor environments and up to 14600 hours in salt-fog exposure. To assess the corrosion damage due to exposure the coating was evaluated by visual inspection coating thickness and adhesion measurement as well as electrochemical testing of corrosion behavior and coating quality. Preliminary results after short term outdoor testing was inconclusive and salt-fog exposure could not capture coating performance exposed in actual exposure conditions. However extended salt-fog exposure may provide indication of corrosion behavior after advanced coating degradation. Presence of under coating oxide products were sometime observed and were thought to provide some corrosion mitigation. Results from the long term testing reported here provide further assessment of undercoating degradation including material analysis of any protective oxides. The assessment also provides important information of CBPC coating degradation mechanism in marine environment.

Key words: Chemically Bonded Phosphate Ceramic, Coating, Steel, Bridge, Exposure, Corrosion

Coatings are widely used to mitigate corrosion of structural steel in aggressive humid environments. However the service life is often diminished in aggressive environments. Repair of coatings can be costly due to materials labor and environmental controls. Novel coating systems are commercially available for steel bridge aplication. As a part of research to assess novel coatings Chemically Bonded Phosphate Ceramic (CBPC) coating was investigated. Research in progress on CBPC coating considered various exposure environments such as inland beach and salt-fog exposure. Long term testing included up to 24 months in outdoor environments and up to 14600 hours in salt-fog exposure. To assess the corrosion damage due to exposure the coating was evaluated by visual inspection coating thickness and adhesion measurement as well as electrochemical testing of corrosion behavior and coating quality. Preliminary results after short term outdoor testing was inconclusive and salt-fog exposure could not capture coating performance exposed in actual exposure conditions. However extended salt-fog exposure may provide indication of corrosion behavior after advanced coating degradation. Presence of under coating oxide products were sometime observed and were thought to provide some corrosion mitigation. Results from the long term testing reported here provide further assessment of undercoating degradation including material analysis of any protective oxides. The assessment also provides important information of CBPC coating degradation mechanism in marine environment.

Key words: Chemically Bonded Phosphate Ceramic, Coating, Steel, Bridge, Exposure, Corrosion

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