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Demonstration and Validation of Two Coat High Performance Coating System for Steel Structures in Corrosive Environments

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Technical Report

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U.S. Army Engineer Research and Development Center Champaign United States

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Department of Defense DoD installations have many steel structures in the base infrastructure that encounter problems with atmospheric corrosion. Maintenance and repair costs due to the damage from corrosion are costly to the DoD. Paint systems are the firstline of defense for protecting structures from the effects of corrosion. These structures are typically painted with the high-performance coating systems that include epoxies and polyurethanes. This demonstration utilized a two-coat high-performance system to achieve performance standards similar to the conventional high-performance three-coat system using zinc primer, while also comparing cost effectiveness. The two-coat high-performance paint system consisted of an epoxy barrier coating and a fluoropolyurethane topcoat. These coatings were applied to selected diesel fuel storage tanks and static lift cranes at Fort Bragg, NC. The demonstrated two-coat system performed very well over 12 months, and proved to be effective, faster to apply, and more environmentally friendly than the three-coat control system. The project return on investment was calculated to be 7.03. The demonstrated system is recommended for incorporation into applicable DoD guidance for coating steel structures and equipment in atmospheric exposure.

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