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This paper covers 45 years of personal experience in the development of corrosion-resistant protective coatings for steel and concrete and experience in industry practices in corrosion prevention since World War II. The performance of traditional coatings for the protection of steel is outlined, followed by a comparison with various high-performance coatings based on vinyl, epoxy, and ethyl silicate binders. The effect of surface preparation on coating performance is described, together with an indication of the formulation of coatings of superior performance in chemical environments on rusty steel when abrasive blasting is impossible under plant conditions. The paper concludes with a plea for thorough, statistically designed long-term testing of experimental formulations, so as to ensure adequate correlations between laboratory results and plant exposures.
steel protection history, protective coatings, inorganic zinc silicate, ethyl silicate, postcured primers, self-curing primers, long-term testing
Chairman of the Board/Chief Executive Officer, Carboline Co., St. Louis, MO