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Detection and Remediation of Soluble Salt Contamination Prior to Coating Steel Highway Structures

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Detection and Remediation of Soluble Salt Contamination Prior to Coating Steel Highway Structures NCHRP Project 10-97 Final Report Detection and Remediation of Soluble Salt Contamination Prior to Coating Steel Highway Structures Volume 2 – Technical Report Submitted by: Elzly Technology Corporation October 31, 2018 Contents Table of Figures ............................................................................................................................................. 4 Table of Tables .............................................................................................................................................. 7 Executive Summary ....................................................................................................................................... 9 Background ................................................................................................................................................. 11 Soluble Salt Effects on Coating Performance.......................................................................................... 11 Salting Methods ...................................................................................................................................... 13 Anti-icing ............................................................................................................................................. 13 Deicing ................................................................................................................................................. 13 Pre-wetting ......................................................................................................................................... 13 Salting Materials ..................................................................................................................................... 13 Impacts of Deicers on Steel Corrosion Rate ............................................................................................ 14 Salt Detection Methods .......................................................................................................................... 15 Soluble Salt Extraction Methods ......................................................................................................... 15 Analysis Methods ................................................................................................................................ 16 Soluble Salt Remediation ........................................................................................................................ 18 Bridge Cleaning with Water ................................................................................................................ 18 Bridge Cleaning with Additives ........................................................................................................... 20 Surface Preparation for Painting ......................................................................................................... 21 Industry Surveys .......................................................................................................................................... 25 DOT Survey of Bridge Painting Practices................................................................................................. 25 Survey of User Experience with Detection and Remediation Methods ................................................. 26 Survey of Soluble Salt Impact and Industry Needs ................................................................................. 28 Experimental Approach .............................................................................................................................. 32 Laboratory Evaluation of Detection Techniques .................................................................................... 32 Multi-Step Conductivity Measurement Techniques ........................................................................... 33 Fully Automated Conductivity Measurement Technique ................................................................... 35 Multi-Step Ion-Specific Methods ........................................................................................................ 36 Laboratory Test Conditions for Detection Methods ........................................................................... 36 Remediation ............................................................................................................................................ 41 Phase I Evaluation of Nine Remediation Methods on Complex Test Panels ...................................... 41 Phase II Evaluation of Combinations of Pressure Washing and Abrasive Blasting on Flat Panels...... 48 1 Phase III Evaluation of Combinations of Pressure Washing and Power Tool Cleaning on Flat Panels49 Coating Performance Over Remediated Surfaces .................................................................................. 50 Coating Application ............................................................................................................................. 51 Corrosion Testing ................................................................................................................................ 52 Field Observations .................................................................................................................................. 54 Results and Discussion ................................................................................................................................ 56 Detection ................................................................................................................................................. 56 Test Conditions 1 and 9 – Direct Injection of Known Solutions .......................................................... 56 Test Conditions 2 and 7 – Measurement of Clean Test Panels ........................................................... 69 Test Conditions 3 through 6 – Controlled Contamination Scenarios ................................................. 71 Test Condition 8 – Simulated Field Contaminated Surface ................................................................ 78 Remediation Effectiveness ...................................................................................................................... 81 Phase I Evaluation of Nine Remediation Methods on Complex Test Panels ...................................... 82 Phase II Evaluation of Combinations of Pressure Washing and Abrasive Blasting on Flat Panels...... 87 Phase III Evaluation of Combinations of Pressure Washing and Power Tool Cleaning on Flat Panels89 Coating Performance Over Remediated Surfaces .................................................................................. 91 Accelerated Corrosion Testing ............................................................................................................ 91 Natural Exposure Testing .................................................................................................................... 96 Field Observations ................................................................................................................................ 105 Winter Salt buildup on New Jersey Highway Overpass .................................................................... 105 Washing of the Verrazano Narrows Bridge ...................................................................................... 113 Robert F. Kennedy Bridge (New York City) ....................................................................................... 116 Marine Parkway-Gil Hodges Memorial Bridge.................................................................................. 126 Throgs Neck Bridge (New York City) ................................................................................................. 131 Discussion of Field Paint Project Data ............................................................................................... 135 Conclusions ............................................................................................................................................... 139 Soluble Salt Detection ........................................................................................................................... 139 Soluble Salt Remediation ....................................................................................................................... 140 General Issues ....................................................................................................................................... 140 Recommendations .................................................................................................................................... 141 Soluble Salt Detection ........................................................................................................................... 141 Soluble Salt Remediation ....................................................................................................................... 141 Summary of Practical Guidance from Volume 1 ........................................................................................ 142 2 Soluble Salt Detection ........................................................................................................................... 142 Soluble Salt Remediation ....................................................................................................................... 142 General Issues ......................................................................................................................................
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