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Coating Solution Forum Presentation V6


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Our highways, bridges, and overpasses are aging and deteriorating, but corrosion can be controlled with protective coatings.

Published in: Engineering
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Coating Solution Forum Presentation V6

  1. 1. The Coating Solution Forum presents: The Importance of Corrosion Prevention — Presented by: REINFORCING OUR NATION’S INFRASTRUCTURE.
  3. 3. How Stark is the Reality? 610,749 1Total number of U.S. bridges 50 Years 2Average designed bridge lifespan 43 Years 3Current average age of bridges 65 Years 4Average age of “structurally deficient”* bridges 1,500 Miles… that’s how far the structurally deficient bridges in America would run if lined up, end to end!5 * Structurally deficient means there are elements of the bridge that are considered a “significant defect”, requiring monitoring and/or repair. 03
  4. 4. Estimated cost to replace “structurally deficient” bridges Estimated cost to recoat How Great is the Cost? $500 Million 7 $3.79 Billion 6 04
  5. 5. How Attainable is a Qualified Solution? The solution is within reach via… Pragmatic dialogue and qualified expertise. Without a map, any road will get you there.. 05
  7. 7. What is Corrosion? The physical properties of metal are constantly in flux. This “disintegration” occurs through unintentional or electrochemical activity that starts on the metal’s surface, as part of its natural behavior. 07
  8. 8. Causes of Corrosion Water / moisture (humidity) Acids Bases Salts Oils Within these bridge, highway and overpass applications, the metallic form will continually corrode due to a variety of factors: 8
  9. 9. 9 Assessment Selection and Engineering
  10. 10. Corrosion Prevention Some of the common coatings used on bridges: Ultra-High Solids (Plural Component) Coatings, High Performance Alkyds, Alkyd Esters and Acrylics, Epoxy Esters, Pre-Catalyzed Epoxies, Moisture Cured Urethanes, VOC Compliant Coatings, Powder Coatings, Metalizing, Vinyls, Radiation Cured Coatings, Sacrificial Coatings. Technological advancements in the formulation of coatings, the expertise necessary to choose the appropriate coating solution for each infrastructure asset, the proper inspection by certified coatings inspectors and the proper surface preparation and application by certified coatings applicators, has increased the professionalism of the industry and elongated the expected performance life-cycles. 10
  12. 12. It is an age-old problem… too great the number of initiatives, too few the funding resources. However, if we only focus on the short-term economics, we may lose sight of the ”long-view” savings. The Cost of Public Safety 12
  13. 13. A Deeper Look at the Numbers A leveraged bridge, overpass and highway infrastructure has a direct, negative effect on the U.S. economy of more than $500 billion per year… that’s about $1,500 per citizen! 8 13
  14. 14. Funding Snapshot Of that total commitment, $13.4 billion (42.2%) was dedicated towards items such as road reconstruction / resurfacing, bridge replacement and bridge repairs. 10 Prior to the Highway Bill of 2011, $31.8 billion in federal dollars was committed for new projects – approximately 126,000 miles of highway and over 4,500 bridges. 9 The Department of Transportation currently estimates highways and bridges face a “backlog” of investment needs to the tune of $808.2 billion, including $479.1 billion in critical repair work. 11 14
  16. 16. Stringent Training Program enacted in 2004. Training Modules: Environmental Safety and Health; Process Control; Materials; Surface Preparation; and Coating Application. What is the “NACE 13/SSPC ACS-1 Standard?” 16
  17. 17. The CIP and PCS Programs The Protective Coatings Specialist Program (PCS) - introduction to coatings and linings used to control corrosion… defines and examines common coatings, addressing when, how and why they should be used. NACE Coating Inspector Program (CIP) - for over 30 years, the “gold standard” for inspections in the protective coatings industry. 17
  18. 18. US Navy’s Naval Facilities department (NAVFAC) did a cost-benefit analysis regarding the use of certified or non- certified contractors on coatings projects. The results showed that utilizing certified contractors and trained personnel has proven an overwhelming “cost-benefit” success.12 Independent Cost-Benefit Analysis 18 Location Contractor Certification Contract Award Final Contract Cost Material $/Sq Foot NFESC Support Total Time San Diego, CA YES $ 320 K $ 320 K $ 30 K $ 17.50 $ 40 K $ 390 K 2 months Pensacola, FL None $ 320 K $ 600 K $ 30 K $ 31.50 $ 240 K $ 870 K 5 months
  19. 19. The NACE 13/SSPC ACS-1 Standard was firmly in place to execute the massive Capitol Dome Restoration Project. Case Study 19
  20. 20. American workforce, well versed in the up-to-date techniques and equipment to truly make a difference in fighting corrosion. The Coating Application Specialist 20
  21. 21. TAKEAWAYS 21
  22. 22. Preservation Through Mitigation We can expand expected lifetimes of these structures up to13 100 Years! 22
  23. 23. Responsible Economics 30% Through proper mitigation, costs can be reduced by as much as14 23
  24. 24. Harnessing the expertise of those trained to handle these types of projects brings about the culmination of The Coating Solution. Certified Personnel 24
  25. 25. 25 Proper Assessment & Selection + Qualified Applicators & Contractors + Certified Inspectors The Coating Solution Quality Job=
  26. 26. The Coating Solution Forum presents: The Importance of Corrosion Prevention — Presented by: REINFORCING OUR NATION’S INFRASTRUCTURE.
  27. 27. THANK YOU 27
  28. 28. APPENDIX 28
  29. 29. 29 1 NACE® International 2 Transportation for America 3 Transportation for America 4 Transportation for America 5 Transportation for America 6 The United States Corrosion Study / NACE® International 7 The United States Corrosion Study / NACE® International 8 NACE® International 9 NACE® International 10 NACE® International 11 NACE® International 12 NAVFAC (Naval Facilities Engineering Command) 13 NACE® International 14 NACE® International Appendix