Climate change poses new challenges in protecting steel infrastructure from corrosion, particularly in coastal regions experiencing record temperatures, humidity levels and rainfall.1 These extreme environmental forces, in the presence of salts and pollution, can accelerate corrosion of critical steel structures such as bridges, electrical utilities and telecommunications, increasing the likelihood of catastrophic failure.2 Conventional anti-corrosion coating systems are vulnerable to degradation under these same extreme environmental conditions and require costly maintenance programs, multiple time-consuming re-coats and in severe cases of neglect, early failure. This paper explores a novel multi-layer coating solution consisting of a topcoat formulated with an aqueous polyvinylidene fluoride (PVDF)-acrylic dispersion that has demonstrated decades of exceptional coastal durability in architectural applications. Combined with an innovative cathodic primer layer and mid-coat, this system demonstrates benefits in ultraviolet radiation durability and corrosion resistance when compared to conventional anti-corrosion coating systems.
Corrosion's destructive effects on critical steel infrastructure have costly economic and security implications for the United States. According to a NACE International report from 2001, the annual corrosion costs in the United States industrial sector were $47.9 billion per year, with the largest portion stemming from the maintenance of critical utilities such as gas, water, electric, and telecommunications.3 Catastrophic failure due to corrosion jeopardizes the resilience of critical utilities, risking the interruption of service to millions and creates weak-points the nation's homeland security.4 Estimates for the service lifetimes of steel infrastructure are 50-100 years when well maintained.5 This longevity is possible by employing a combination of protective coating strategies, one that creates a barrier between the steel and corrosive elements.6 The other, introduces sacrificial elements that redirects the corrosion process away from the steel asset.6 Corrosive effects are intensified in coastal marine environments and regions where salt-based de-icers are frequently utilized, creating additional challenges in protecting vital infrastructure.7
