Objective:

To protect against corrosion, all surfaces of steel waterfront structures initially receive either three coats of solvent-based epoxy-polyamide (System 1) or two coats of coal tar pitch epoxy-polyamide (System 2) as recommended in Unified Facilities Guide Specification (UFGS) - 09967N. In System 1, each coat contains 300 grams per liter (g/l) of volatile organic compounds (VOC), methyl isobutyl ketone (MIK), and xylene (a hazardous air pollutant, HAP), as well as the pigment chromium oxide. In System 2, each coat contains 30% by weight coal tar pitch (regulated by the Occupational Safety & Health Administration [OSHA] as a known human carcinogen, National Toxicology Program), 192 g/l of VOCs, and xylene. The objective of this project is to demonstrate and validate two innovative Low VOC, Coal Tar Free Splash Zone Coatings (SZC) to protect in-service steel located in the "Splash Zone." The "Splash Zone" is defined as the area between the years' lowest tidal mark and up to ten feet above the years' highest tidal mark, whereby corrosion rates have been documented to exceed 30 mils per year on unprotected steel. Systems 1 and 2 display approximately 5 years service before complete removal and reapplication is required.

Technology Description:

The technology to be demonstrated and validated was developed in response to the Small Business Innovative Research (SBIR) Program's Solicitation 02.1, "N02-006: Polysulfide Modified Epoxy Novolac Cladding for Steel Immersion/Splash Zone Service." The two SBIR contractors, PolySpec L.P. of Texas and Polymeright Inc. of California, successfully developed novel resin formulations based on proprietary blends of polysulfide combined with barrier pigments and epoxy novolac resin (hereinafter SZC). Each formulation met the solicitation's performance requirements and fulfilled ease of installations employing commercial-off-the-shelf (COTS) spray equipment. In this project, the demonstration will consist of installing the two SZCs in a side-by-side comparison to 5,000 square feet (10,000 square feet total) of properly prepared in-service sheet pile bulkhead and monitoring field performance over no less than 4 years. The SZC are very low in VOCs (less than 68 g/l), toxic metal-free, HAP-free, and contain no coal tar pitch.

Expected Benefits:

The U.S. Navy owns about 816 million square feet of waterfront bulkheads. If 0.1% of these bulkheads annually are replaced with new sheet piles coated with the SZC or receive the SZC as an in-service maintenance coating, VOCs would be reduced by 9,749 pounds per year (lbs/year), 34,560 lbs/year of coal tar pitch eliminated, and a one-time maintenance cycle cost of up to $18.7M avoided. Additional SZC infrastructure applications may include tainter gates, pipe piles, H-piles, cranes, ships (i.e., ballast tanks), bridges, water and wastewater structures, industrial facilities, mooring structures, and marine equipment. (Anticipated Project Completion - 2007)

Principal Investigator:
Mr. David Gaughen
Naval Facilities Engineering Service Center
1100 23rd Avenue, Code 63
Port Hueneme, CA 93043-4370
Telephone: (805) 982-6776
Fax: (805) 982-1074
E-mail: david.gaughen@navy.mil