Background

The majority of the steel bridges in the interstate highway system were constructed between 1950 and 1980. Until the mid to late 1970's, virtually all steel bridges were protected from corrosion by three to five thin coats of lead and chromate containing alkyd paints applied directly over millscale adherent to the formed steel. These baseline conditions present major materials performance and environmental compliance challenges when maintaining steel bridge structures.

The natural aging of steel bridge structures coupled with harsh environments and exposure to roadway deicing chemicals (salts) has created a growing corrosion control maintenance burden on the nation's bridges. The presence of potentially hazardous materials in existing bridge paint has complicated maintenance processes and created dramatic cost increases for major and routine level bridge paint maintenance.

For the past several years, FHWA, Turner-Fairbank Highway Research Center (TFHRC) has administered research programs aimed at defining the most cost effective means of protecting steel bridge structures with coatings. Particular focus was given to this issue in 1987 with the establishment of a High Priority National Research Area (HPNRA) for bridge coatings. This program has targeted the key issues of coating material performance, surface preparation requirements, definition of the corrosivity of various environments, environmental compliance and impact, and containment and disposal of waste generated during typical bridge repainting projects.

Meet the Bridge Coatings Team

Contract Research Studies

Epoxy Mastic Bridge Coatings

FHWA Field Manual for Bridge Painting Inspection (FHWA-RD-98-084)

Metallizing: The Illinois Experience

Metallized Steel Bridge Coatings

Model Site-Specific Worker Training/Orientation Program: Bridge Lead Removal and General Site Safety (FHWA-RD-98-179)

Overcoating (Maintenance Painting)

Personnel Protection During Bridge Paint Removal

Safety and Health on Bridge Repair, Renovation, and Demolition Projects (FHWA-RD-98-180)

Zinc-Rich Bridge Coatings