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Cost-Effective Alternative Methods for Steel Bridge Paint System Maintenance Federal Highway Administration Contract No. DTFH61-97-C-00026 Robert Kogler - FHWA Christopher Farschon - Corrpro Brad Shaw - Corrpro Introduction

  1. “Cost-Effective Alternative Methods for Steel Bridge Paint System Maintenance” Federal Highway Administration Contract No. DTFH61-97-C-00026 Robert Kogler - FHWA Christopher Farschon - Corrpro Brad Shaw - Corrpro

  2. Introduction • Objective • Program Overview • Achievements • Conclusions • Future Visits

  3. Objective • To identify methodologies and technologies that will reduce the cost of bridge maintenance painting for steel bridge owners. • Compare these technologies and associated costs to the current “state of the art” in bridge painting.

  4. Program Overview Practical Observations Site Visits Productivity 9 Reports Cost Model Observations Objective Data Pricing Data Productivity and Cost Data

  5. Achievements • Investigated 9 technologies at over 25 job sites – gathered cost data – productivity data – made comparisons • Produced a separate report for each technology • Developed Cost Model Spreadsheet and User’s Guide

  6. Reports • ElectroStrip • Lead Stabilizers (abrasive additive and pre-applied • Abrasive Injected Water coating) Blasting • Water Jetting • Rapid Deployment • Metallizing • Recyclable Steel Grit • Adhesive Foil • Torbo™ System

  7. ElectroStrip • Applicable to “small” areas • No dust • Needs high-ampere DC electric source • Relatively slow production • Supplement with hand tool cleaning

  8. Abrasive Injected Water Blasting • Imparts profile unlike water blasting • No dust • Must contain water

  9. Rapid Deployment • No peak time traffic disruptions • All work cycles in one shift • Substantial coordination required

  10. Recyclable Steel Grit • Less dust than disposable abrasives • Larger equipment costs • Less waste generated

  11. Torbo™ System • Low dusting • Operator control of “mixture” • Must rinse surfaces after preparation • Collection of slurry

  12. Lead Stabilizers (abrasive additive and pre-applied coating) • Lower disposal costs • Possible extra application • Greater material costs

  13. Water Jetting • Higher Equipment costs • Water disposal required • Low dusting • No profile generation

  14. Metallizing • Higher Equipment Costs • Superior coating durability • Higher material costs

  15. Adhesive Foil • Relatively slow application rates • Requires primer coating • Higher material costs • Good “rust through” performance over SP-2 surfaces

  16. Cost Model • A Cost Comparison Tool – Designed to provide activity-based cost estimates – Allows comparisons of alternative technologies by initial cost – Validated through field observations – Fully adjustable cost factors (e.g. for regional labor differences) – Default data based on this study

  17. Summary • Cost Oriented Project • Nine Technologies • Cost Model Developed • This Project Does Not Address Life Cycle Economics or Durability of Painting Options

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