Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts,...

28
Selecting and Sourcing Coatings for Waterfronts, Locks, and Dams A JPCL eBook

Transcript of Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts,...

Page 1: Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts, locks, and dams, followed by JPCL Buying Guide material on coating systems for these

Selecting and Sourcing Coatings for Waterfronts,Locks, and Dams

A JPCL eBook

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Selecting and Sourcing Coatings for Waterfronts, Locks, and Dams

A JPCL eBook

Copyright 2011 byTechnology Publishing Company2100 Wharton Street, Suite 310

Pittsburgh, PA 15203

All Rights Reserved

This eBook may not be copied or redistributed without the written permission of the publisher.

i

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Contents

iiContents

1

7

17

Introduction iii

Coating Sheet Pile Structures: An Overview 1by Tim Race

Coating Systems Guide for Waterfronts, 7

Locks, and Dams

Coatings Company Profiles 17

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Introduction

Introduction

This eBook consists of a recent JPCL article on selecting and using

coatings for protecting waterfronts, locks, and dams, followed by JPCL

Buying Guide material on coating systems for these structures.

The Buying Guide is organized, first, by exposure type, such as

“Onshore Atmospheric Exposure Weathering, UV, & Airborne Salt,” then

by substrate type, first steel, then concrete. Then, coating manufacturers

are listed in alphabetical order and their preferred system is named in

both proprietary and generic terms. Finally, contact details are given for

all the companies.

This collection is designed to provide general guidance on selecting

and specifying coatings for waterfronts, locks, and dams, and then to

give sources for acquiring the appropriate systems.

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heet piling is commonly used in construction. Piles are commercially available in a vari-ety of shapes, sizes, and materials. Common piling materials include steel, aluminum, con-crete, FRP-composite, and vinyl. Steel is by far the dominant material, although the use ofcorrosion-resistant composite and vinyl piling is increasing. Because of their inherent cor-rosion resistance, composite and vinyl piles are not painted. In theory, these materials canbe advantageous in a corrosive marine environment. In practice, however, their use is lim-

ited to light and medium duty applications, such as marine and freshwater bulkheads and smaller re-taining walls. This article gives an overview of steel piling and its uses; reasons for coating it; shopcoating of new steel piling; and ways to access, inspect, and perform maintenance coating of installedsteel piling.

Steel Piling and Its Uses

Steel piling is available in a variety of shapes, lengths, thicknesses, and alloys. Several ASTM stan-dards describe some of the salient characteristics of steel pilings: ASTM A857/A857M-07, StandardSpecification for Steel Sheet Piling, Cold Formed, Light Gage; ASTM A328/A328M-07, StandardSpecification for Steel Sheet Piling; and ASTM A6/A6M-08a, Standard Specification for GeneralRequirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling.1

Steel piling comes in many shapes, including H, U, Z, and flat sections. Combinations of shapes canbe used to fulfill specific engineering and aesthetic requirements. Piles typically have integral inter-locks that allow the piles to be connected as they are installed in the field. Optional interlock bars and

corners facilitate the installation of virtually any con-figuration, but interlocks have a small degree of playand are not watertight. Sealants and seal welding areused for applications that require the structure to bewater-impermeable. Performed after field installation,seal welding creates a simple continuous weld thatprovides a watertight seal. Alternatively, flexible or-ganic sealants are applied to piling structures prior tofield installation, which also facilitates future mainte-nance painting. Piling is used for many structures, both temporary

and permanent. Examples include retaining walls,quay walls, bridge abutments, seawalls, bulkheads,cofferdams, basements, underground parking garages,in-ground hazmat containment barriers, load bearingfoundations (e.g., water tanks), groin walls for beacherosion, and wing walls for bridges and culverts. Sheetpiling has even been installed as a barrier along sec-tions of the shared border between the U.S. and Mexico.

WaterfrontsLocks and

Dams

S

1

By Tim Race,

Kaked LLC

Editor’s note: This article appearedin JPCL in April 2009.

Coating Sheet Pile Structures:An Overview

Uncoated sheet pileCourtesy of the U.S. Army Corps of Engineers

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To Coat or Not to Coat

Pilings used for temporary structures are not typically coated. In fact, the vast majority of piling forboth temporary and permanent structures is installed without a coating system or any other meansof corrosion protection. Paints are sometimes used for visibility and aesthetics, such as on the pile walls of basements and

underground parking garages, land-sited retaining walls, and water storage tank foundations. In gen-eral, atmospheric exposed sheet piling is coated to improve appearance. For pilings installed in corrosive environments, piling manufacturers suggest that protective coat-

ings, thicker steel, or higher yield strength steel be used to ensure that the design life of the structureis met. Higher yield strength steel compensates for loss of section caused by corrosion but does notprevent corrosion itself. For piling installed in corrosive environments, often only a relatively smallarea is exposed to highly corrosive elements. For example, consider a marine bulkhead constructedof 50-foot-long piles. If the combined depth of the low water, tidal, and splash zones (the most cor-rosive areas) is a modest 5 feet, then only 5% of the total area of the piles will be subject to high ratesof corrosion. Coating, sometimes supplemented with cathodic protection, can be a more cost-effec-tive approach than over-engineering the structure in part or as a whole. Alternatively, thicker piles overall or piles reinforced with additional sectional thickness in the zone

of greatest corrosion can also be used. (A pile can be reinforced by welding plates or another sectionof piling onto the main piling to add thickness just to the area where the corrosion rate is highest. Reinforcement eliminates the need to use a thicker pile over the entire length [height] of the piles.)Selecting a higher yield strength steel can effectively increase section thickness. For example, a

higher yield strength steel that increases section thickness by 30% may only modestly increase thecost by approximately 2%. In some cases, the zones of greatest corrosion may not match the areasthat are most highly stressed. Piles have bending forces from side loads, but the loads are not equal.So the bending forces in piles are not like those caused by grabbing a stick at both ends and bendingit. In the latter case, the maximum load is at the center, right where you expect the stick to break. The

static and dynamic loads on a pile will vary with height based onhow deep the pile is driven, whether it has tiebacks and wherethey are, the relative depth of the water, tidal height changes, andwave action. So the maximum bending force that will collapse thewall is not necessarily at the center of the pile. The area with thehighest corrosion rates may or may not coincide with the locationof highest loading.Designers are encouraged to use cost engineering to aid in the

decision process. Major suppliers of sheet piling have compiledgeneral information and tools to assist the designer in selecting themost cost-effective approach to achieve the desired durability. The general order of environmental corrosiveness is: saltwater

> freshwater > soil > atmospheric. This rank order is a broad gen-eralization, and, within these categories, the severity can be fur-ther subdivided, yielding overlaps and disorder within thegeneralized ranking. Sheet pile installed in undisturbed natural soils does not need

to be coated. In practice, pilings used to construct seawalls, bulk-heads, and retaining walls will be backfilled on the soil side, whichmay increase the corrosion rate and require protective coatingsor design compensation. (Corrosion rates are higher for backfilledareas due to soil aeration, affecting about the first 10 feet belowsoil grade.) Some soils, such as aggressive natural soils and fills,may be as corrosive as or more corrosive than seawater and willalso warrant the use of protective coatings or corrosion compen-

Driving piles coated with CTECourtesy of the U.S. Army Corps of Engineers

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sation through design. In its guide specification for engineering in tropical regions, the U.S. Navy hasspecific guidelines for protecting sheet pile in tropical marine environments, with special considera-tion given to pile driven in coralline soils with low resistivity.2 In this case, coatings are used to pro-tect the soil side of pile structures.Sheet pile continuously immersed in seawater has a low enough corrosion rate that painting is not

required. However, mill scale on sheet piling may facilitate pitting of bare steel in seawater immer-sion. Therefore, piling to be immersed in seawater is usually painted for corrosion protection andsometimes supplemented by application of either impressed current or sacrificial cathodic protection.If the piling is to be coated for immersion service, the mill scale is first removed as part of surfacepreparation.The marine tidal zone and, especially, the low water level, are quite aggressive, so piling in these

areas is usually coated for protection and may again be supplemented by cathodic protection. The ma-rine splash zone is also very aggressive, and piling in the splash zone is usually painted; however, ca-thodic protection is not applicable. Exposed pile above the splash zone is typically treated the sameas the splash zone.

Coating of New Sheet Piling

If a new sheet pile structure is to be coated, application almost always occurs within a shop facility.Surface preparation and shop coating offer tremendous cost savings over field coating. Piles are typ-ically cleaned using centrifugal blast machines to achieve either an SSPC-SP 6, Commercial BlastCleaning, or SSPC-SP 10, Near-White Blast Cleaning. Shop-applied coating systems are usually two- or three-coat systems. The types of products used

are variable, but generally they are the same types used for any similar industrial application. Epoxyprimers and intermediate coats are typical, with polyurethane topcoats used for preservation of ap-pearance. Coating suppliers and end users have not conferred royal status to any single coating ma-terial or system. Most systems offered and specified for immersion and soil applications have filmbuilds of 12 mils and up. The only U.S.-based standard for coating sheet pile is ASTM A950/A950M-99 (2007), Standard

Specification for Fusion-Bonded Epoxy-Coated Structural Steel H-Piles and SheetPiling.1 The powdered coating is electrostatically applied and heat cured. Fusion-bonded epoxy (FBE) coatings have good edge retention and few pinholes in the fin-ished product. Like other epoxy coatings, FBE is tough and well-suited to the rigorsof shipping and field installation. FBE has only fair resistance to cathodic disbond-ment and is not the best choice for use with cathodic protection. The traditional workhorse coating for protecting sheet piling is coal tar epoxy

(CTE), covered under the standard SSPC-Paint 16. CTE is well-suited to buried soil,freshwater and marine immersion, and tidal and splash zone exposures. CTE doesnot perform well in direct sunlight and is available only in black and dark reds; itis not used for its aesthetic properties. CTE is more flexible and impact-resistantthan many epoxy coatings, and it retains these properties even at low tempera-tures. Coating flexibility and impact resistance help reduce coating damage beforeand during piling installation. The U.S. Army Corps of Engineers (USACE) andother owners specify CTE for use on permanent sheet pile structures. USACE alsospecifies an epoxy zinc-rich primer for marine applications. The nominal two-coatthickness of CTE is 18 mils. USACE also allows the use of two- and three-coatepoxy polyamide systems on sheet pile. Polyamide systems may also be enhancedby application over an epoxy zinc-rich primer.3

Other coating materials have been shown to be well-suited to protect sheet pil-ing. One study showed that the long-term performance of flame-sprayed aluminumwith a topcoat sealer gave the best protection in a cold water marine environment,and a polyester glass flake coating gave the best protection in a warm water ma-rine exposure. CTE with a zinc-rich primer performed well at both of the locations.4

Caribbean resort bulkhead repainted in the dry to just below low waterline. Dewatering was accomplished by damming canal inlet and lowering water level using pumps.Courtesy of the author

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A research program sponsored by the American Association of State Highway and Transporta-tion Officials in cooperation with the Federal Highway Administration produced a report that pro-vides recommendations for metallizing systems to use on sheet piling and provides a standardpractice.5 USACE recommends aluminum thermal spray coatings for piling exposed to seawater.6

In addition to metallized coatings, hot-dip metal coated pilings, including zinc, zinc/aluminum alloy,and aluminum are commercially available. Hot-dip metal coatings on sheet piling offer the sameeconomies as for other applications. Interested specifiers should refer to literature available fromthe American Galvanizers Association.7 The designer should consider the size of piling that will beused on a project because there are practical limits on the overall length of a sheet that can be dippedinto the galvanizing bath. The designer should also consider whether the added cost of providingcorrosion protection to both soil and water sides is warranted.The world’s largest steel producer recommends CTE at a nominal 18-mil thickness or glass-filled

epoxy for seawater immersion.8 For freshwater immersion, the company recommends a 12-mil-thicksystem of epoxy polyamine primer and epoxy polyamide topcoat. For aesthetic purposes, the sys-tem can be supplemented with an aliphatic polyurethane topcoat. The company also recommendsepoxy/polyurethane systems for atmospherically exposed piling.

Inspection and Maintenance

of Coated Sheet Piling

All coatings eventually reach the end of their service life when they no longer protect the underly-ing surface. Maintenance schedules and repair options are evaluated by means of inspection.

Access and Inspection of Sheet PileInspection of coated sheet pile is challenging because direct access to the coated surface is generallylimited. In practice, inspection is often performed by trained divers, but devices have been devel-oped for remote inspection, including robotic crawlers and manually positioned instruments. Diversand remote instruments can conduct visual observations as well as perform physical measurements,including pit depth, ultrasonic steel thickness, film thickness, and electrochemical processes. Soil side inspection is generally not possible; however, the soil side is usually the area of least con-

cern because of the generally low rate of steel corrosion in most soils (except as noted earlier). Insome cases, soil resistivity is measured as a means of assessing the relative severity of the soil sideexposure. Direct inspection may be conducted if the structure can be dewatered. Direct access allows eval-

uation by qualified non-diving inspectors in a dry environment. With few exceptions, dewatering ofa structure is seldom a practical alternative. Portable limpet dams (essentially miniature portable

cofferdams) have been developed to facilitate inspection as wellas maintenance of sheet piling in the dry. The width and depthof access are limited by practical considerations. Installationand movement of the device is straightforward and fairly rapid.The limpet dam must be customized to match the specific shapeand profile of the piling. When the limpet dam is configuredwith straight sidewalls and a bottom with a toothed designmatching the piling profile, the dam can be securely attached tothe pile wall, and the contained area is dewatered by pumpingit dry.The results of the inspection can be used to determine the

necessary course of action. Sometimes the pile structure maywarrant structural repair, rather than just maintenance paint-ing. In such a case, structural repair may be accomplished bywelding additional steel plate to the affected piles to increasesectional thickness and strength. Sometimes, a new sheet pile

Corroded pile revealed during levee inspection.Courtesy of the U.S. Army Corps of Engineers

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wall must be installed, typically by driving new piles in front of the existing piles. The new and oldwalls can be connected with tie rods to take advantage of the existing anchorage of the old pilingstructure.

Access and Maintenance PaintingAccess for maintenance painting has the same limitations as for inspection. Dewatering may be ac-complished with a limpet dam or other damming devices that allow the water elevation to be low-ered to the extent necessary to perform maintenance operations in the dry. Earthen, rock, pile, andinflatable dams may be suitable for blocking inlets or isolating sections of canals. Dewatering is ac-complished by pumping out water. From a practical standpoint, the water does not need to be re-moved all of the way to the mud line. In fact, complete dewatering may compromise the integrity ofthe piling walls and may harm the local animal and plant life. Most repairs will be performed in thezones of highest corrosion, which is near the waterline in freshwater and from the low waterlinethrough the splash zone in seawater. The dewatering of open water structures such as seawalls and other waterfront structures may

require the construction of a cofferdam. This practice can be quite expensive and may negatively im-pact commerce or security. Where dewatering cannot be accomplished, it may be necessary to uti-lize divers to perform surface preparation and coating application underwater. While many types of coatings are suitable for use on new sheet piling, the same is not true for the

maintenance of sheet pile structures. If dewatering is a practical alternative, and if dry conditions canremain long enough, then most of the coatings mentioned for shop application on new piles may beused. Coating selection is limited however, when productivity is paramount and coated surfaces must

be returned rapidly to wet service. Suitable systems are those that either cure very rapidly or cureunderwater. Such products may include 100% solids epoxy, polysulfide-modified epoxy, andpolyurea applied by plural-component spray. If it is not sealed, metallizing may be used to returnpiling to service immediately. If sealed with a fast-cure product, metallized piling may be returned toservice rapidly.Products specifically formulated for underwater application are not widely available. There are per-

haps six to eight manufacturers of such products. Applying coatings underwater is both difficultand slow because of the surface preparation quality required; poor initial adhesion; and potential ap-plication defects, including floating, lifting, and sagging.Underwater surface preparation may include hand cleaning, grinding, and water and abrasive

blasting with zero-thrust equipment. Removal of all loose coating and loose rust as well as all marineorganisms is generally specified. Underwater coatings are applied by roller, brush, or trowel. Older products, referred to as splash

zone putties, were mixed and applied with a gloved hand. The putty-like coatings worked but werevery slow to apply. Newer products are applied using pressure-fed rollers and brushes. Productsavailable for underwater application are 100% solids, including epoxy polyamine and polysulfide-modified epoxy coatings. The addition of fiber reinforcement to these products reportedly improvesapplication properties by reducing floating.9

Summary

Permanent sheet pile structures are either designed with a corrosion allowance or coated to achievethe required design life. Surface preparation and coating are best accomplished in the fabricationshop. Techniques are available to inspect sheet pile structures installed in seawater and freshwater.If maintenance coating is necessary, operations should be performed in the dry, but if dewatering isimpractical, underwater-applied coatings may be used.

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References

1. ASTM International, West Conshohocken, PA.2. U.S. Navy, UFC 3-440-05N Tropical Engineering.3. U.S. Army Corps of Engineers, UFGS-09965 Painting: Hydraulic Structures.4. A. Kumar, V. L. Van Blaricum, and A. Beitelman, “Twenty Year Field Study of The Performance of Coatings in Seawater,” U.S. Army Construction Engineering Research Laboratories, IL, and Boy, J.H., Oak Ridge Institute for Science and Education and U.S. Army Construction Engineering Research Laboratories, IL.

5. James A. Ellor, Walter T. Young, and John Repp, “Thermally Sprayed Metal Coatings to Protect Steel Pilings: Final Report and Guide.”

6. U.S. Army Corps of Engineers, UFGS-09971 Metallizing: Hydraulic Structures.7. www.galvanizeit.org.8. ArcelorMittal, Piling Handbook, 8th Edition, www.arcelormittal.com.9. Jeff Longmore, “The Development and Evolution of Underwater Coatings,” CoatingsPro November2006.

Tim Race, now retired, was the founder and owner of Kaked, a coatingsconsulting firm in Elmhurst, IL. Previously, he worked for the ArmyCorps of Engineers and CCC&L. Mr. Race has been an active memberof SSPC since 1986. He serves on the Standards Review Committee aswell as several others. Race is also a member of the Federation of Societies for Coatings Technology, NACE International, and the AmericanChemical Society. He has written for JPCL and other journals.

JPCL

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� �

Systems are alphabetized by company name.

�%�(*) ��*#!'���%).��*(+�)3Endura-Zinc 768/Mult-E-Prime 500/Multi-ThaneOrganic Zinc/Epoxy/Urethane

�/�*).��*1 !,��*�.%)#-Alesta AR Powder CoatingsEpoxy (1-2 Coats)/Fluoropolymer

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Coating System Guidefor Waterfront, Lock,& Dam Industry

Onshore Atmospheric ExposureWeathering, UV, & Airborne SaltSteel

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Page 13: Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts, locks, and dams, followed by JPCL Buying Guide material on coating systems for these

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9

Page 14: Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts, locks, and dams, followed by JPCL Buying Guide material on coating systems for these

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�����')$�."��ZRC Zero-VOC Galvanizing CompoundZinc-Rich, Inorganic

Same superior product. Brand new name.

Now there’s a permanent name for portable power: Doosan. Formerly

a division of Ingersoll Rand, we’re the product that construction and

mining companies worldwide have relied upon for 140 years. Known

for innovative solutions and extraordinary service, we’re the same

superior product as always. The only change is the name.

DoosanPortablePower.com(800) 633-5206 ©2011 Doosan Infracore Portable Power Find Us on

Waterfront, Lock, & Dam IndustryClick our Reader e-Card at paintsquare.com

/ric

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10Click our Reader e-Card at paintsquare.com

/ric

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Page 16: Selecting and Sourcing Coatings for Waterfronts, Locks ... · coatings for protecting waterfronts, locks, and dams, followed by JPCL Buying Guide material on coating systems for these

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15

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