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Arc Sprayed Coatings for Steel Bridges

Metalizing offers long term protection for steel bridges. The ability of thermal sprayed zinc, aluminum, and zinc/aluminum coatings to provide effective long term protection for steel exposed to a variety of environments has been documented in several studies.

In one report, metalized steel samples exposed to a marine environment for 44 years exhibited 0% base-metal rust1. Recent developments in high deposition twin wire electric arc spray systems have reduced application costs for metalized coatings on steel. Projected over a 50 year period it has been estimated that metalizing steel bridges could reduce coating costs by 50%5.

The Washington Crossing Bridge is a steel truss structure that spans the Delaware River connecting Pennsylvania to New Jersey. Interstate Coatings of Seattle, WA completed the spraying of nearly 48,000 square feet of steel with zinc in 1994. The Washington Crossing Bridge was the first steel bridge to be arc sprayed with 3/16" zinc.

The Rainbow Bridge connects Niagara Falls New York, USA to Niagara Falls, Ontario, Canada.  This 450,000 sq foot project called for 8-12 mils of 85/15 zinc/aluminum.

This coating will provide years of maintenance free corrosion protection.

References and Additional Sources of Information:

  1. "Appearance of Thermal Sprayed Metallic Coatings After 44 Year's Marine Atmospheric Exposure at Kure Beach, North Carolina", 44 Year Corrosion Report, (November 1996), 1 
  2. Dave Wixson, "Arc-Spray - A Real World Solution for Infrastructure Corrosion Control", Spraytime (Second Quarter 1999), 12 
  3. Robert A. Sulit, "AWS Guide for the Protection of Steel with Thermal Spray Coatings of Aluminum and Zinc and Their Alloys and Composits", Paper submitted for the National Thermal Spray Conference, Anaheim CA (June 1993) 
  4. "Corrosion Tests of Flame-Sprayed Coated Steel 19 Year Report, " (American Welding Society, 1974), C2/14-74 
  5. Joesph T Butler, "Is Painting Structural Steel More Expensive Than Metallizing?" Corrosion 99 (NACE, 1999), Paper No. 299 
  6. Robert A. Kogler, Jr., et al, "Recent FHWA Experience In Testing and Implementing Metallized Coatings for Steel Bridges", Corrosion 98 (NACE, 1998) Paper 499 
  7. Bob Irving, "Thermal-Sprayed Zinc Coatings Defend Steel and Concrete Bridges", Welding Journal (September 1993), 69 
  8. Professor Herbert Herman, Guest Commentary, Journal of Thermal Spray Technology (September 1992), 195 
  9. Metallinze, (September. 1994), The Platt Bros. & Co. 
TMS Metalizing Systems is "The Right Choice"TM  in Thermal Spray Equipment!