Development of Accelerated Weathering and Corrosion Tests to Identify High-Performance Coatings for Structural Steels

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General Information
Solicitation Number: 1473
Status: Solicitation withdrawn
Date Posted: Apr 11, 2018
Last Updated: Sep 18, 2019
Solicitation Expires: Apr 30, 2019
Partners: IL, MO, TX
Lead Organization: Kentucky Transportation Cabinet
Financial Summary
Commitment Start Year: 2019
Commitment End Year: 2021
100% SP&R Approval: Approved
Commitments Required: $1,100,000.00
Commitments Received: $225,000.00
Contact Information
Lead Study Contact(s): Jarrod Stanley
jarrod.stanley@ky.gov
Study Champion(s): Jarrod Stanley
jarrod.stanley@ky.gov
Phone: 502- 782-4090
Organization Year Commitments Technical Contact Name Funding Contact Name Contact Number Email Address
Illinois Department of Transportation 2019 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Illinois Department of Transportation 2020 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Illinois Department of Transportation 2021 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Missouri Department of Transportation 2019 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Missouri Department of Transportation 2020 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Missouri Department of Transportation 2021 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Texas Department of Transportation 2019 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2020 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2021 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov

Background

Currently, protective coatings applied to new steel bridges have anticipated service lives of approximately 30 years; for maintenance coatings, this figure is 20 years. With state highway agencies seeing their maintenance funding stretched thin to maintain infrastructure, it is critical to extend the service lives of coatings for as long as possible. Coatings manufacturers possess the knowledge and technologies required to produce new coatings which significantly outperform what they currently provide to public agencies, however, they their isn't much of a market for those items absent empirical testing. The current market environment for structural coatings is commodity-based and often emphasizes low up front cost over coating performance / longevity. The additional upfront cost of a high-performance coating system is could be more than offset by a significant reduction in life cycle costs over the life of the coatings project. If coating project specifiers had stratified lists of approved materials which recognized the cost differentials for better performing materials, longer service lives of protective coating systems could be achieved at advantageous life cycle costs.

Test methods currently used to evaluate protective coatings — typically, ASTM D5894 for structural steel coatings — do not stress the coatings sufficiently to differentiate between acceptable and high-performance coatings materials within a reasonable timeframe. Current test protocols call for 5,000 hours of accelerated weathering/corrosion and approximately 40 weeks to complete. After 5,000 hours of weathering/corrosion, poor performing coatings can be identified, but it is not possible to reliably differentiate better performing coatings from ones that are merely acceptable. It is impractical to conduct coatings performance tests that last for a longer period than those currently used.

Objectives

This project will develop accelerated performance testing protocols, including evaluation methods, for high-performance coatings for structural steel. It will also develop equipment to execute the new testing protocols and undertake comparison testing of the current and new performance testing protocols.

Commitment level is $25,000/yr. for 3 years.

Scope of Work

Phase 1: Assess the current state of the practice and expertise. Recommend new test protocols to address the objective of accelerated weathering/corrosion of steel coatings.

Phase 2: Develop modified or new test protocols and equipment.

Phase 3: Proof of concept testing and reporting.

Subjects: Bridges, Other Structures, and Hydraulics and Hydrology Maintenance Materials and Construction

Documents Attached
Title File/Link Type Privacy Download
Approval of SPR-B Waiver Approval of SPR-B Waiver Pooled Fund Solicitation #147.pdf Memorandum Public

Development of Accelerated Weathering and Corrosion Tests to Identify High-Performance Coatings for Structural Steels

General Information
Solicitation Number: 1473
Status: Solicitation withdrawn
Date Posted: Apr 11, 2018
Last Updated: Sep 18, 2019
Solicitation Expires: Apr 30, 2019
Partners: IL, MO, TX
Lead Organization: Kentucky Transportation Cabinet
Financial Summary
Commitment Start Year: 2019
Commitment End Year: 2021
100% SP&R Approval: Approved
Commitments Required: $1,100,000.00
Commitments Received: $225,000.00
Contact Information
Lead Study Contact(s): Jarrod Stanley
jarrod.stanley@ky.gov
Commitments by Organizations
Agency Year Commitments Technical Contact Name Funding Contact Name Contact Number Email Address
Illinois Department of Transportation 2019 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Illinois Department of Transportation 2020 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Illinois Department of Transportation 2021 $25,000.00 Kelly Morse Megan Swanson 217-782-3547 Megan.Swanson@illinois.gov
Missouri Department of Transportation 2019 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Missouri Department of Transportation 2020 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Missouri Department of Transportation 2021 $25,000.00 Todd Bennett Jennifer Harper 573-526-3636 Jennifer.Harper@modot.mo.gov
Texas Department of Transportation 2019 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2020 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov
Texas Department of Transportation 2021 $25,000.00 Johnnie Miller Ned Mattila 512-416-4727 ned.mattila@txdot.gov

Background

Currently, protective coatings applied to new steel bridges have anticipated service lives of approximately 30 years; for maintenance coatings, this figure is 20 years. With state highway agencies seeing their maintenance funding stretched thin to maintain infrastructure, it is critical to extend the service lives of coatings for as long as possible. Coatings manufacturers possess the knowledge and technologies required to produce new coatings which significantly outperform what they currently provide to public agencies, however, they their isn't much of a market for those items absent empirical testing. The current market environment for structural coatings is commodity-based and often emphasizes low up front cost over coating performance / longevity. The additional upfront cost of a high-performance coating system is could be more than offset by a significant reduction in life cycle costs over the life of the coatings project. If coating project specifiers had stratified lists of approved materials which recognized the cost differentials for better performing materials, longer service lives of protective coating systems could be achieved at advantageous life cycle costs.

Test methods currently used to evaluate protective coatings — typically, ASTM D5894 for structural steel coatings — do not stress the coatings sufficiently to differentiate between acceptable and high-performance coatings materials within a reasonable timeframe. Current test protocols call for 5,000 hours of accelerated weathering/corrosion and approximately 40 weeks to complete. After 5,000 hours of weathering/corrosion, poor performing coatings can be identified, but it is not possible to reliably differentiate better performing coatings from ones that are merely acceptable. It is impractical to conduct coatings performance tests that last for a longer period than those currently used.

Objectives

This project will develop accelerated performance testing protocols, including evaluation methods, for high-performance coatings for structural steel. It will also develop equipment to execute the new testing protocols and undertake comparison testing of the current and new performance testing protocols.

Commitment level is $25,000/yr. for 3 years.

Scope of Work

Phase 1: Assess the current state of the practice and expertise. Recommend new test protocols to address the objective of accelerated weathering/corrosion of steel coatings.

Phase 2: Develop modified or new test protocols and equipment.

Phase 3: Proof of concept testing and reporting.

Subjects: Bridges, Other Structures, and Hydraulics and Hydrology Maintenance Materials and Construction

Title Type Private
Approval of SPR-B Waiver Memorandum N

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