Tag: crevice corrosion

$3M International Bridge Painting Project

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$3M International Bridge Painting Project Begins

MONDAY, JULY 18, 2022

Last week, a painting project to coat the Canadian side of the Sault Ste. Marie International Bridge began, using a one-coat paint system.

The steel truss arch bridge spans the St. Mary’s River between Sault Ste. Marie, Michigan, and Sault Ste. Marie, Ontario, and is the only vehicular crossing between those locations within a 300-mile distance. The structure is also the largest trade crossing in Northwestern Ontario, playing a “vital role” for both Soo communities, according to the bridge’s website.

Latest Coating Work

The $3 million painting project will coat the curb and service walk railing on the Canadian half of the bridge. Work is being completed by prime contractor source: https://www.paintsquare.com/news/view/?25293

For the coatings, the contractor will use a high-ratio calcium sulfonate alkyd (HRCSA) one-coat paint system.

“This innovative product and process offers many benefits,” said Bridge Engineer Karl Hansen. “We anticipate cost savings, enhanced corrosion resistance, quicker completion time, and minimized disturbance to the environment and our customers.”

US Army Corps of Engineers, Richard McDonald, public domain, via Wikimedia Commons
Last week, a painting project to coat the Canadian side of the Sault Ste. Marie International Bridge began, using a one-coat paint system.
Sault Ste. Marie International Bridge

According to the release, painting operations will be conducted at various locations around the Canadian side using moveable scaffolding. One lane of alternating traffic will be maintained during the painting.

“The International Bridge Administration (IBA) advises motorists to expect delays, remain alert for workers, and use caution when traveling through the work zone,” writes the IBA.

The project is fully funded through the Federal Bridge Corp. Limited with the help of a capital budget allocation approved by the Government of Canada. Work is expected to be completed by Nov. 1.

Previous Bridge Work

(Post-Interview video with contractor Matt Glavin, http://www.glavin.net, regarding his personal experience of working with HRCSA on the Canadian side of the Sault Ste. Marie bridge arch.)

https://forms.office.com/Pages/ResponsePage.aspx?id=CdD64KqRQEudBeOYb0H7GgcCPFyhnbNKsSiMIZ0_yKRUN0E4QVdWWVVYV1Y2WDAxQ0ZPRlYyRUZQSy4u

HRCSA is Chemically Active

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When the word “Coating” is used, most people think of a paint that forms into a solid barrier film.

The HRCSA Self-Priming Topcoat is an unconventional coating system which is both chemically active and elastomeric.

Traditional barrier or sacrificial barriers cure across the steel micro voids leaving areas of exposed steel between the coating and the substrate – these micro void areas are vulnerable to rapid undercutting once the barrier is breached.

Typical causes of newly applied coating breaches: Workers walking on fresh coating during construction and take-down. Mechanical damage (tools being dropped), stone chips, debris, etc.

HRCSA is a reacted calcium sulfonate, calcium carbonate based complex that fully wets the surface as it neutralizes acids, displaces moisture and scavenges oxygen leaving no micro voids unfilled.

The high ratio of active calcium sulfonate thoroughly wets the micro voids creating a mono-molecular layer of cations which ensure chemical neutrality and no undercutting if the coating is breached. ( The HRCSA reacted formulation’s uniqueness is what gives it this performance advantage.) <Link to Specifications>

The role and function of HRCSA calcite platelets.

Once applied, the formulation’s artificially grown calcite crystals line up like fish scales to form a strengthened film with extended pathways for moisture and oxygen.

When acidic moisture (acid rain) passes through these crystals, a minute amount of the calcite dissolves to create a neutral base liquid void of acidity at the steel substrate.

Summarily, it neutralizes acids, displaces moisture, and scavenges oxygen.

HRCSA Penetrant/Sealer + HRCSA Self Priming Topcoat = Meld

When the word “Penetrant” is used, most people think of a low molecular weight epoxy or moisture cured urethane penetrants which were primarily designed to bind up existing rust on steel surfaces and a tiecoat.

Low molecular weight penetrants applied into active corroded connections do not chemically neutralize the active corrosion. Because they are epoxies or MCUs, they harden and then crack whenever movement occurs.
This explains why rust bleeding from connections can usually be seen < 2 years after application – the corrosion was never stopped.

HRCSA meld coat is both chemically active AND flexible.

Crevice corroded and pack-rusted joints and connections that are properly prepared (flushed, salt mitigated and dried) then pressure filled to refusal with HRCSA Penetrant-Sealer, Meld-coated with HRCSA self-priming topcoat and overcoated with same (wet on wet), creates a chemically active, flexible seal that actively stops corrosion inside the connection for years (even decades) to come.

Because the chemistry stays active in the connection allowing the structure to move without damaging the film.

HRCSA can applied by spray, brush or roller to anything Fe – including: steel of any type, as well as overcoating tightly adhered, contaminant-free existing coatings.

Pressure-Applying HRCSA Penetrant into flushed out, blown dried, cleaned corroded crevices before application of the HRCSA meld-coat.

Pack-rusted connections saturated with HRCSA Penetrant.

Application of HRCSA meld coat (thick layer of HRCSA self-priming topcoat overtop HRCSA Penetrant).

Same pack-rusted connection filled with HRCSA self-priming topcoat over top of HRCSA Penetrant filled connection.

HRCSA Penetrant inside tubes or enclosed areas.

HRCSA Penetrant can be fogged, or mist applied inside tubes.

Visualization of how the HRCSA Penetrant/Sealer fills the inside of steel tubes when applied with a sprayer fitted with a flexible rust proofing wand with a star tip.

Bearings, Pin Connectors, Interfaced steel

Once all connections are treated properly, the entire steel structure is overcoated with HRCSA self-priming topcoat. Single component, single coat application makes for shortest coating application times in the industry.

HRCSA applied between the bolted in reinforcement plates keep corrosion activity from taking place between the two.
Steel Corrosion Mitigation: 80/20 Rule
Case Studies
Performance Warranty

HRCSA is a Maintenance Coating

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In the following bridge preservation project, the HRCSA maintenance coating was applied to a minimally prepared steel substrate (WJ4 || WA1 ) inside a highly condensed period of time (2 weeks of rail line shut-down).

The steel bridge as it WAS before WJ4 || SA1 surface preparation and HRCSA application.

One Year After the Bridge Overcoating Initiative.

Coating Systems: Beautification or Corrosion Mitigation Initiative?

The US Federal Highway Administration strongly promotes maintaining existing infrastructure in a “Good State of Repair”. This has lead to a great emphasis on “doing more with less” by focusing on bridge preservation practices designed around extending the service life of the existing structures. Mitigating corrosion is a big part of this formula.

The British structure featured in today’s discussion reveals how structures can be preserved cost effectively and with minimal preparation – regardless of tight time schedule pressures.

What the sections which were applied to specification look after 7 years. (No undercuttin).

  1. Most areas were prepared and corrosion mitigated to specification.
  2. Some areas were missed during the works (Time constraints, access limitations).
  3. ALL ACTIVE CORROSION HOTSPOTS CAN BE VERY QUICKLY AND EASILY REPAIRED WITH POWER AND HAND TOOL CLEANING.

The two circled areas of concern in this photograph are active corrosion hotspots which showed up after the application of chemically active HRCSA materials that triggered the delaminating of tightly adhered black oxide patches. HRCSA chemistries cause heavily contaminated black oxide spots to detach. (See repair procedure bottom of page).

The browned areas reveal bridge immersion from brackish Ouse River water during two separate floodings.

In the circled area, rust bleeding is coming from where previously salt contaminated delaminating coating was missed during surface preparation before the application of the HRCSA self-priming topcoat. A complete repair of this active corrosion hotspot can be achieved in very short order using a right angle sander, solvent wipe and brushed on application of single component, single coat HRCSA self-priming topcoat.

This photo demonstrates the excellent surface wetting and polar bonding of the HRCSA system on heavily pitted and previously heavily corroding substrate (Pressure washed then coated). Salts had been very effectively mitigated during surface preparation else it would have shown through the applied coating material. The coating profile shows no signs of deterioration and is working properly to protect the substrate from the elements.

Another fine example of excellent surface wetting and polar bonding of the HRCSA system to heavily pitted and corroded steel substrate. The coating shows no signs of deterioration and is working properly. Pitted areas (black oxide delaminations) can be quickly and easily repaired using the attached repair procedure below.

Further evidence of discoloration caused by the brackish flood waters as they rose up the side of the girder. Although the coating may be have been discolored there is no corrosion or damage triggered by the brackish floodwaters.

There can be many reasons why hard to reach areas get overlooked during busy works and stressful time constraints. These can include machine failures, weather constraints and so forth. Fortunately, HRCSA repairs can be quick and easy using the repair procedure defined below. [Note: Less than 1% of the surface area was affected.]

In the following examples, inadequate surface preparation and salt removal causing premature coating failures on the sections highlighted below.

  • Selby 11a
  • Selby 10a
  • Selby 9a
  • Selby 8a
  • Selby 7a
  • Selby 6a

Preservation Repair Procedures.

HRCSA-Spot-Repair-Procedure

LED Bridges and HRCSA

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Can LED beautification lighting projects lead to premature galvanic corrosion?

The corrosion of structural steel is an electrochemical process that requires the simultaneous presence of moisture and oxygen. Essentially, the iron in the steel is oxidized to produce rust, which occupies approximately six to ten times the volume of the original material. The rate at which the corrosion process progresses depends on a number of factors:

Micro-climate: In the photo above, this bridge is exposed to heavy de-icing salts during the winter. Due to multiple seasonal freezes, thaw cycles there is allot of moisture present which can migrate into the crevices. Result (electrolyte).

To avoid long term damage from crevice corrosion, these are the corrosion risks that could exist in LED lighting installed on steel bridges.

Examples of lighting fixtures applied to bridges.

From a corrosion mitigation point of view, these are the following corrosion risks that we see could exist in LED lighting installed on steel bridges.

LED lights fixture on a galvanized steel plate bolted directly to a carbon steel bridge frame.

Galvanic corrosion (also called bimetallic corrosion or dissimilar metal corrosion) is an electrochemical process in which one metal corrodes preferentially when it is in electrical contact with another, in the presence of an electrolyte. 

The aluminum plate interfaced to the copper plate and bolted with a carbon steel nut shows why you need electrical isolation.
Dissimilar metals braced together without insulation lead to corrosion.

Grounding example (dissimilar metals). Do lighting configurations operate on independent floating grounds?

How HRCSA Characteristics help manage LED light installation corrosion:

HRCSA is Non-conductive up to 100KV. Where HRCSA is applied as an electrical insulator between metals, HRCSA can impede the electrochemical process from taking place.

HRCSA Chemistry can insulate connections, so Corrosion has no place to start: The photo below represents BEST PRACTICE for fastening dissimilar metals together. HRCSA Penetrant/Sealer applied under pressure into gaps around the fastener shaft areas followed by a brush applied application of HRCSA self-priming topcoat both between the dissimilar plates as well as overtop the fasteners can help you achieve the same protection.

Repairs are fast & easy: Where existing installations show signs of dissimilar metal corrosion, HRCSA user-friendliness can put affordable and long lasting corrosion mitigation repairs within reach.

Applying HRCSA at the time of installation can be done with little effort.

Conclusion: When attaching dissimilar metals together, HRCSA is a user friendly cost effective alternative for preventing corrosion..

Wet Abrasive Blasting

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Although the vast majority of HRCSA project Surface Preparation is done with High Pressure Water Cleaning and/or hand tool cleaning.

It does happen, on occasion, where abrasive blasting is required (engineer specified, heavy black oxide removal, etc.). Because HRCSA is not profile dependent, the following WAB (Wet Abrasive Blast) configuration using crushed glass has proven quite popular.

Most contractors who work with HRCSA already own 7,000 psi, 6gpm, hot water high pressure water cleaners. They maximize their profits by avoiding the cost of negative air containment [1,000 gallons of fuel / day]. When specifications ask for RECOATING, wet abrasive blasting can be achieved by combining their washers with blasters. Environmentally friendly abrasion can be found with crush glass media.

The magic lies in the quality and design of the injection nozzle used.

Example of WAB (Wet abrasive blasting) using crushed glass media with pressure washer and media injection pot as per above configuration.

Field Application

Field Uses:

  • Sectional coating removal [To remove lead paint in preparation for welding.]
  • Can facilitate the removal of thick black oxides.

Photo: It is critical for black oxides to be removed and to mitigate the heavy concentrations of salts at the exposed steel substrate.

NOTE: Hand tools are also used to remove surface black oxides.

Be sure to remove black oxides at all interfaces.

Pack-rusted Joints: Do not blast.

Do not introduce media injection to the corrosion build between plates. High pressure water clean with salt remover only before drying and treating with HRCSA corrosion mitigation chemistry.

NOTE: The corrosion inside a pack-rusted connections to only be high pressure water cleaned with salt remover (then blown dried with clean, dry, 100 psi air pressure). DO NOT introduce abrasives into the pack rust otherwise you will clog the capillary channels. These must remain open.

Structure Critical Corrosion Safety.

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“In 1990, the federal government gave the I-35W bridge a rating of “structurally deficient”, citing significant corrosion in its bearings.“

“The inspection carried out June 15, 2006 found problems of cracking and fatigue.”

I-35W Mississippi River bridge – Wikipedia

It’s Tough Being a Bridge.

Society tends to take it’s infrastructure for granted. We rarely give the structures we depend on for our livelihood little notice (other than perhaps cursing the potholes that mess up our suspensions and alignments).

Nonetheless, those unseen structure critical connections that hold the bridge together are, well, critical. When leaking expansion joints, faulty drainage or nearby pollution emitting plants introduce non-visible contaminants to the steel, insidious damage slowly introduces it’s self in the form of corrosion-frozen moving parts such bearings, pin connectors, wire rope all of which can have a very negative impact on the superstructure’s integrity.

When bearings seize, the superstructure becomes restricted in it’s ability to flex and move with contractions, expansions, traffic load changes and even high winds in some areas.

Additionally, when movements are restricted, imagine the pressures that take place at the connection plates and on the fasteners? In the very least, the coating that’s protecting the connection is sure to crack and let corrosion causing contaminants and water in. Once corrosion sets in inside the connection, the steel at the connection converts into corrosion by-product – which can be 10 times as voluminous as the steel from whence it came – resulting in both thinner steel at the connection AND even more pressure on the fastening plates and fasteners.

Compound this effect with heavy traffic loads, and, well, history has it’s story stories to tell.

Field Proven HRCSA is unique in it’s ability to chemically stop active corrosion INSIDE CORRODING CONNECTIONS (for 15-20 years) and also inside pin connectors, and corrosion frozen bearings.

When it comes to bearings and pin connectors look no further. HRCSA not only stops the corrosion between the plates by displacing moisture, scavenging oxygen and neutralizing acids, but it also causes black oxides to detach from the steel interface (thereby unrestricting it’s movements) while also adding lubricity to the plates and a coating that stretching with microcracking.

How’s that for functional elegance?

HRCSA Coating Life Expectancy

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Coating life expectancy.

Japanese and American lab tests predict that the HRCSA coating system (250 microns recoat) will last 40+ years in the field.

Field erosion tests measured losses at a rate of 25 microns every 5,6 years.

Unfortunately, none of these performance predictions mean anything if the structure they are being applied to is being torn apart by structure critical corrosion.

Primary Reasons For Collapses.

Bent plates, loss of fasteners, loss of section, weakened girders, Ongoing section loss due to corrosion can negatively impact load ratings over time.

Corrosion frozen moving parts induce great stress to the superstructure and may induce microcracking, bending and misalignment of critical components.

Corrosion within the strands can affect structural integrity and load carrying capabilities. [PS: HRCSA offers OUTSTANDING wire rope coating solutions! Enquire below.]

Leaking expansion joints affect piers, bearings, bends, superstructure and substructure elements.

“Threats to Coating Service life.”

Damage / Abrasion / Impact / undercutting

Ph environment, de-icing salts, atmospheric pollution.

Preservation’s primary objective is to extend the service life and utility of existing assets.

  • Cost effective and easily deployed with least amount of delay to the users.
  • HRCSA is 30 year field proven to help solve the specific corrosion issues identified above.

Ask Your Supplier:

  • Does the coating system you propose solve the potential or actual structure critical corrosion problems that are present on my asset?
  • Does the proposed coating system demonstrate the proven ability to chemically stop crevice corrosion, pack rust, free corrosion frozen bearings, on structures with complex geometries and inaccessible areas to stop section loss and compromises to structural integrity?
  • How does your proposed coating systems’ chemistry deal with crevice corrosion, pack rust, corrosion frozen bearings, and complex geometries?
  • What testing, field experience, and case histories can you provide to confirm your system’s demonstrated ability to mitigate the above-mentioned corrosion issues?
  • How is your system cost effective and rapidly deployed to minimize user delays?
  • Do you have peer reviewed publications to back your claims?
  • What type of performance warranty has your solution offering been tied to and can you provide a written example?

Do you have a project in mind? Schedule a meeting.

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Mitigating Crevice Corrosion and Pack Rust

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There are no words to describe how seeing this a year after abrasive blasting and applying 3 coats makes the owner feel… <disappointed>, <resigned>, <frustrated>, <deceived>

HRCSA: Preserving Steel

When dealing with aged, in-place, corroded structures, traditional film-form coatings do not have the right chemistry needed to stop pack-rust growth.

When bearings freeze due to corrosion, pressure is introduced to the bridge superstructure.

When corrosion build between plates expands and out of plane bending occurs, the integrity of the structure is put at risk, the rating is affected, and fasteners are weakened.

Structure Critical Corrosion Can Shave Years of Service Life off Your Structure.

For years it was believed that “There is nothing you could do about rust bleed leaking from connections.” until as recently as 30 years ago when HRCSA formulations were created specifically to chemically step active corrosion inside connections. Although the HRCSA Self-priming topcoat is applied stand-alone on exposed steel substrate, there is one specific area where it it is provided a boost: inside pack-rusted joints and connections and other steel openings.

Four Simple Steps for Extending the Service Life of Your Steel Assets.

Step 1: High pressure water clean with salt remover to produce a clean, tightly adhered substrate and flushed joints and connections.

Step 2: Apply high pressure air to remove water and humidity from surfaces and inside connections

Step 3: Apply HRCSA Penetrant under pressure to fill capillary channels inside connections.

Step 4: Apply HRCSA Self-Priming Topcoat to Penetrant treated connections, rivet heads and sharp angles using a brush. Overcoat the entire structure.

The photo at the bottom is that of an HRCSA treated pack-rusted connection after 17 years in service.

The HRCSA melding process is achieved by first saturating, flushing, and blowing out connections and then flooding the inside of the connections with low viscosity HRCSA Penetrant/Sealer under pressure. This material chemically treats corrosion causing acids inside the crevice corroded or pack rusted joints or connections. Once applied, this material will remain chemically active inside the connection for as long as it is sealed in by the HRCSA Self-Priming Topcoat. Together, they form a mid-layer of chemistry we call the “meld zone”. This meld-zone serves as a chemical reserve that is a continuous source of corrosion-fighting chemistry as HRCSA continually wicks it way deeper and deeper into the crevice during structural movement (expansion and contraction). When this process is applied to bearing plates, the HRCSA chemistry applies lubricity as it frees up corrosion frozen bearings.

Why not stop all corrosion – including crevice corrosion?

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Overcoating Steel Structures

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Different Technologies, Different Outcomes.

Traditional cross-linking overcoating systems adhere by chemical-mechanical reaction which means that THEY shrink more and more over time stressing the existing overcoated substrate paint systems whereas HRCSA does not shrink meaning that HRCSA overcoated substrate paints will not lift away from the steel as time passes on.

HRCSA overcoat systems adhere through polar bonding and are not reliant on chemical nor mechanical reactions for adhesion producing a low surface energy bond without risk of existing coating delamination.

HRCSA Self-priming topcoat.

Because HRCSA is a chemically active, surface tolerant system, it can be applied to any existing tightly adhered cleaned, salt and black oxide free substrate (avoid applying over rubber or uncured tar). In addition, HRCSA can overcoat tightly adhered, contaminant-free existing coating systems.

Due to HRCSA’s low surface energy, the risk of delamination caused by shrinkage from traditional overcoat systems is very low.

During open forum discussions about structure critical corrosion with chief structural engineers at the Federal Highway and with state bridge authorities, the engineers were disapproving of how ineffective painting structures with traditional barrier coating systems is. Especially with regard to particularly stopping rust bleeding at the crevice corroded connections and corrosion-frozen moving parts and long term reliability.

The low surface energy HRCSA self-priming topcoat does not ‘tug and pull’ (long term) existing substrate coatings – a characteristic that is especially important in cold weather conditions.

The chemically active aspect for the HRCSA self-priming topcoat’s cousin (HRCSA active Penetrant) is field proven to stop structure critical corrosion inside complex joints and connections, moving parts and wire rope.

Overcoating Steel StructuresDownload

To discuss a specific project you are considering, please register and the manufacturing licensee in your territory will be notified. Thank you.

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Rapid Deployment Corrosion Mitigation

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With the HRCSA corrosion mitigation system, Bridge Owners are rapidly mitigating corrosion on beam ends and bearings with minimal traffic disruptions.

With the environmentally clean HRCSA process and chemistry, containment is not an issue when high-pressure water cleaned (with salt remover) steel substrates are force air dried and treated with HRCSA chemistry quickly, effectively and without delays.

Specifications for projects (above).

WJ 4 Spec completedDownload

A 22 meter long, 9 girder wide bridge superstructure corrosion mitigated inside a week.

This 22 meter long bridge with nine 1.5 meter wide girders was surface prepared and corrosion mitigation treated with HRCSA inside a week.

Surface Preparation – High Pressure Water Cleaning.
(Rotating tip and salt remover additive)

Beginning at one end, the steel substrate was high pressure water cleaned with 4.8 Mpa hot water, rotating tip with salt remover additive. Black oxides were hand tool cleaned before washing. Surface preparation on the full length of all 9 girders was completed inside 3 days.

Surface preparation was done heading in 1 direction. The single coat, single component HRCSA self-priming topcoat was airless spray applied during the return trip – all inside one business day.

The work included chemical treatment of all joints, connections and bridge bearings. Worth mentioning that a train was scheduled to pass twice a day so scaffolding was designed to accommodate this traffic.

Train man confirming tracks were clear. 2 trains passed per day.

To Schedule a Discussion Regarding a Steel Corrosion Project, Schedule here.

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Thank you for your interest in Single Coat HRCSA corrosion mitigation system.