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INITIAL REPORT STOPPING CORROSION On a bridge in By High Pressure (5,000 psi) and Overcoating With the Termarust High Ratio Co-Polymerized Calcium Sulfonate Coating System
For Cleaning & Coating by Corrosion Protection, Inc.; Coating Materials from Termarust Technologies, Project Painting Date: July and
August, 2006 INITIAL REPORT
By: Craig A. Ballinger, P.E. Termarust Technologies Phone: 888-279-5497 [then
press 4] Email:
cballinger@termarust.com OVERVIEW This report provides some
background information and information and pictures on the cleaning and
painting portion of work that was done on this bridge, in July and August 2006,
for the Summit County Ohio, Department of Public Works. As may be seen in the
following pictures, the bridge, the fluted (concrete filled) steel pipe
columns, and the sheet piling faced abutments had severe corrosion, rust
scaling, and crevice corrosion and pack rust in the connections, and some loss
in steel thickness. In addition, the
reinforced concrete deck had deteriorated to the point that it was becoming
structurally deficient. Initial assessment
indicated that it was probably not cost effective to restore the bridge. However, after learning about the Termarust
coating system (and how it chemically stops corrosion), it was decided
to: (1) remove and replace the deck and (2) clean and paint the steel members
with the Termarust coating system.
Although most of the cleaning was done with a 5,000 psi pressure washer,
heavy scale rust was removed with hand power tools. The project involved: ·
Removal
of the reinforced concrete deck, by County personnel ·
Installation
of heavy-gage galvanized steel panels, for the structural portion of the new
deck, by County personnel. ·
Cleaning
of the structural steel; with a 5,000 psi pressure washer and hand power tools,
by Corrosion Control, Inc. ·
Application
of the Termarust coating systems Penetrant and the Self Priming Topcoat ·
Paving
the deck with an asphaltic concrete, under another County contract. It is
important to note: 1.
The
contract required a 5-year warranty against coating system failure 2.
Containment
of corrosion debris and paint chips was not required, because the existing
paint did not contain lead. Shown below are references and procedures for
cleaning and painting, and pictures of cleaning and painting of the bridge. REFERENCES Contact Person: Sam Ross Construction Engineer Phone:
330-643-2850 Painting Contractor Corrosion Protection, Inc. Contact Person: Aaron Long or Mark Preusser CLEANING AND APPLICATION PROCEDURES The following Termarust
standard procedures were specified and followed: 1. Pressure wash clean the bridge with a
5,000 psi pressure washer (at a 6 standoff distance) with clean water with an
additive of Chlor*Rid to remove non-visible salts; e.g. chlorides. (For
more information on Chlor*Rid see www.chlor-rid.com) 2. Remove heavy scale rust with hand power
tools, and then pressure wash those areas (with Chlor*Rid in the water) to
remove salts that are contributing to the active corrosion under the scale rust. 3. With dry compressed air blow dry all
connections between steel members. 4. Apply Termarust TR2200 Penetrant into
all open connections; especially where there is crevice corrosion and pack
rust; including the connections in the sheet piling. 5. Apply a caulk (or stripe) coat of
Termarust TR2100 Topcoat into open connections; where there is crevice
corrosion and pack rust minimum 10 mils dry film thickness (DFT). 6. Spot prime areas of bare steel and
tightly adhered (contaminant free) rust with 5 mils DFT of Termarust TR2100
Topcoat 7. Overcoat the entire area with another 5
mils DFT of TR2100 Topcoat. It is important to note
that steps 4 through 7 may be done immediately after each other; i.e.
wet-on-wet; which is why the Termarust system is considered to be a One Coat
system. The final result was: ·
5
mils DFT on tight paint, ·
10
mils DFT on bare steel and tight rust, and ·
20
mils DFT over connections. PICTORIAL OVERVIEW The following pictures provide a pictorial overview
of the project.
Photo 1 The surface of the bridge and the approach
roadways
Photo 2 Underside of the bridge showing severe
corrosion on all steel members
Photo 3 One end of the bridge, the support columns
and the sheet piling facing of the abutments.
Photo 4 Close-up view of the condition of the
bridge.
Photo 5 Side view of corroded steel beams
Photo 6 Underside of steel deck panels and support
beam. (The deck was replaced)
Photo 7 Corrosion at the end of the bridge on the
beams and steel columns.
Photo 8 Corrosion of fluted columns and the sheet
piling abutment facing.
Photo 9 Cleaning equipment a pressure washer and
an air compressor.
Photo 10 Close-up of pressure washer.
Photo 11 Pressure wash cleaning of beams after
removal of the deck.
Photo 12 Pressure washing of the beams.
Photo 13 Beams after initial pressure washing
scale rust must still be removed.
Photo 14 After pressure washing and hand tool
cleaning to remove scale rust.
Photo 15 New structural steel deck panels have been
installed
Photo 16 Using an air chisel to remove pack rust
from connections of sheet piling.
Photo 17 Columns and sheet piling have been cleaned
and are ready for coating.
Photo 18 Beams have been cleaned and are ready for
coating.
Photo 19 Bridge, columns and sheet piling have been
cleaned and painted with Termarust coating
Photo 20 After cleaning and painting (Ref. see
Photo 7)
Photo 21 After cleaning and painting (Ref see Photo
4)
Photo 22 Sheet piling cleaned and painted (Ref. See
Photo 8) |
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