Jotun Paints

Jotun AS, P.O. Box 2021, N-3235 Sandefjord, Norway

tel:+47 33 45 70 00 fax:+47 33 46 50 95
www.jotun.com

Designed and produced by The Richard Milner Partnership Ltd., Hull, England 0500/3000/0538054

MEETING THE CHALLENGES

OF PROTECTING
BRIDGES

Jotun Paints

JOTUN PAINTS
A WORLDWIDE PAINT
COMPANY DELIVERING
EFFECTIVE ECONOMICAL
SOLUTIONS TO
THE PROTECTION
OF BRIDGES

MEETING THE
SPECIFIC CHALLENGES OF
PROTECTING BRIDGES

CASE HISTORY NORWAY

In the fight against corrosion, infrastructure projects, such as bridges, viaducts and other structures in concrete or steel, challenge todays advanced
coatings technology.
The effects of attack from extremes of weather and the aggressive content
of the atmosphere can wreak havoc if the protective system applied has
Jotun Paints is recognised as one of the worlds
leading

manufacturers

and

suppliers

of

sophisticated paints and cathodic protection

the slightest weakness. It is essential that a corrosion protection system is

selected with care to ensure it meets three specific demands resistance
to the penetration of corrosive substances extremely good adhesion and
resistance to chemical, mechanical and thermal stress. For submerged

systems. It is part of the worldwide Jotun

structures, coatings in combination with a cathodic protection system is

Group with factories and offices in more than

recognised to be the most effective method of prevention of corrosion.

50 countries. Jotun is active in every area of

coatings technology providing products, which
protect infrastructure projects, industry, buildings,

CASE HISTORY DENMARK

The protective system should never be chosen on the basis of cost alone.
Any savings in the initial cost will, in virtually every case, be more than
offset by the cost of expensive maintenance, shut-down, or worse, should

worst that nature or man can offer.

the structure present a safety hazard.

and concrete projects, is an area of particular

THAILAND
One of six flyover bridges protected
with Penguard Special/Penguard Stayer/
Penguard Topcoat

Life Cycle Cost

offshore and marine against attack from the

The protection of the infrastructure, both steel

This railway bridge in Drammen, Norway, is protected with metallizing,

Penguard Tie Coat 100, Jotamastic 87 and Hardtop HB. In a tough
environment (C3 to C4 according to ISO 12944) the bridge will be well
protected for years to come.

Choosing a protective coating system should be based on minimising the

cost of maintenance over the design lifetime of the structure. The direct
costs of material and labour for preparation and application at initial

expertise for Jotun, combining investment, proven

installation and at each maintenance period, combined with downtime or

technology and innovative solutions with a

other indirect costs, should be evaluated. Known as Life Cycle Cost, and

wealth of practical knowledge earned in the

long advocated by Jotun, this analysis enables different protective systems

successful protection of structures located

to be evaluated and the most effective and economical solution specified.

throughout the world.

Life Cycle Cost analysis can be applied to both new and existing

Kolding, Denmark. One of the first rail bridges in Europe to be constructed

from composite material, the bolts and bearings being the only exceptions.
The bridge is protected with Hardtop HB, a flexible two pack polyurethane.

SOUTH KOREA
Steel box girder bridge. Protected with
Prosil ZSP/Pioner Primer/Pioner Topcoat

CASE HISTORY AUSTRALIA

installations.
Service combined with economical, effective and
quality products are key words in Jotuns aim
to satisfy its customers needs and to work with
them to provide the optimum in protection.

Expert advice and assistance

Highly qualified technical inspectors are available at your local Jotun
office to provide coating design advice, site surveys, written specifications
and plan the actual coating work. Technical service will be provided by
Jotun personnel who are certified to FROSIO or NACE standard. You are
assured the surface preparation and application of the coating system will
be to the standards which secure lasting corrosion protection with minimum maintenance.

One of 16 concrete bridges in Melbourne, Australia with protective

systems ranging from 3 to 37 years in age. The railway overpass shown
above is protected with the equivalent of Jotuns Jotacote 5, and was
found to be in perfect condition.

NORWAY
Gvarv railway bridge. Protected by
Jotamastic 87 Aluminium/Jotamastic 87/
Hardtop HB

CORROSION
PROTECTION
WITH PAINT

and which will handle the environment

where the construction is situated. The
cost of paint will often be only 23% of
the total project cost.
It is sometimes difficult to draw a
The reasons for using paint can basically
definite line between what is protection
be placed in two categories protection
and what is cosmetic. Very often
(Safety and Economy) and cosmetic.
there is a close connection between
Firstly, industry wishes to preserve its
appearance and protection. Bridges
investments and avoid accidents. The
play a major role in society and the
safety aspect is partly governed by
aesthetics of the construction will be of
legislative authorities and partly taken
great importance.
care of by the industrys own safety
This means that we all have to realise
standards and procedures.
that the paint in the tin is by no means
Secondly, protection is undertaken in
a complete product. The
order to save money.
end product, with all its
To allow constructions
95% OF ALL
strengths and
to corrode and then
COATING FAILURES
weaknesses, is the paint
RESULT FROM
simply build new ones
POOR SURFACE
applied on the structure.
when the safety limit
PREPARATION
If the end product is
was passed, could have
POOR APPLICATION
to comply with the
been a solution. The fact
85% OF ALL
expectations regarding
is, by proper corrosion
COATING
FAILURES
lifetime of the coating,
protection, society will
APPEAR AFTER
protection of a structure
save a lot of money. The
12 YEARS
must be looked upon
question is therefore not
as a chain of quality
if the structure should
influencing processes, where the end
be protected but rather to find the most
result is determined by the weakest
cost effective method of protection. In
link of the chain. To achieve a
many cases it is found that the optional
good result, with no reduction in
method is to use paint as protection
quality, requires good workmanship
against rust.
and adequate quality control and/or
Painting can cost a great deal of money
inspection at each stage of the
and can require considerable work.
job. Coating technology is improving,
However, adequate pre-treatment of the
however, the improvements actually
substrate before the paint is applied
lead to greater variations with respect
often costs many times more than
to pre-treatment methods, application
the paint itself. And the pre-treatment
and coating systems to be used.
method and the quality of the work done
Knowledge, education and experience
have a great influence on the final result.
from the personnel involved in coating
It is of major importance to select
technology are more important
a paint system with properties that
than ever.
are compatible with the pre-treatment

JOTUN PAINTS
CASE HISTORY
BASCULEBRUG
OVER DE NOORD
THE NETHERLANDS

Wirebrush cleaning to St 3 where it is difficult to carry out blast

cleaning.

Stripe coating before each sprayed coat.

Stripe coating with a brush is vital for proper results.

Airless spray application.

The result after stripe coating and spraying.

A mirror will show whether or not the coating work is well done.

Control of film thickness after each coat.

The final inspection after the last sprayed coat.

Bridge structures represent challenges for

optimal coating work.

Details represent challenges for both

pre-treatment and coating work.

Inspection and control of blast cleaning

according to the specification (Sa 21/2).

RESIST 86
A quick curing zinc ethyl silicate
based coating with a high
content of zinc. It can be used
as a single coat or as the first coat in a paint
system designed for long lasting corrosion
protection.

The mastics range

SELECTION OF A PAINT SYSTEM

Many factors influence the choice
of coatings for the protection of
a structure or part of a structure.
Selection of a coating system may be
based on an owners own experience,
standard specifications or on
recommendations from the applicator
or the coating manufacturer. There
will be a mix of the legislative
requirements, cost, usage and coating
properties. Authorities will also
influence the selection of coatings
through legislation and by such
recommended practices as safety,
health, environment and technical
recommendations.
TYPICAL COATINGS FOR BRIDGES
The important foundation
of a paint system
Hot spray metallizing with pure
metals such as aluminium and zinc
and zinc-rich primers can provide
cathodic protection of steel structures.
Combined with other coatings
this will give added value to the
protective system, reducing the risk of
undercutting corrosion. Proper
pre-treatment to Sa 21/2 or Sa 3
is necessary. Jotun zinc primers
are Barrier, WaterFine Barrier,
WaterFine Zn Primer, Jotacote 5,
Resist 86 and Resist 78.
BARRIER
A zinc rich epoxy primer for use
on blast cleaned steel.
For use in combination with
most advanced coating systems to further
improve protection against corrosion.

are in the range of products to be used

in bridge protection. Jotun products
are Vinyguard Silvergrey, Conseal
Primer, Conseal Topcoat, Conseal
Touch-up, Correx, Mammut Primer,
Mammut Topcoat, Pioner Primer,
Pioner Topcoat and Pilot II.

JOTAMASTIC 87

Epoxies

A modified epoxy coating with

82% volume solids (aluminium
version 87%).
It has exceptional penetration and superior
adhesion properties. It is suitable for all
kinds of structures and surfaces such as steel
and concrete. It can be used for new and
blast cleaned areas and for maintenance
where water jetting and/or wire brushing is
the alternative treatment. The wintergrade
quality cures down to -5C.
Jotamastic 87 is applied to 40 million square
meters a year!

Traditional epoxy systems normally

contain active corrosion protective
pigments. Jotun products are
Penguard Tie Coat 100, Penguard
Primer, Penguard HB, Penguard
Special, Penguard Stayer and
Penguard Topcoat. Jotaspeed products
are for use as an intermediate or

Jotuns mastic coatings provide

within a short time thus saving time

surface tolerance, superior wetting

and money.

properties, excellent penetration and

Designed for extreme exposure

that equips the coatings with

exceptional mechanical strength.
POLYMASTIC 2000
A modified solvent free epoxy
coating. It can be applied in high
film thickness as an anticorrosive
coating for steel structures and where blast
cleaning is not possible. For use alone or overcoated with a variety of topcoats including
water-borne acrylic topcoat. Such a system
will have a very low solvent emission (low
VOC). Polymastic 2000 can also be used for
immersed structures.

A range of water-borne products

that are almost free from organic
solvents. The WaterFine range
represents a new generation of water-borne
coatings. They are suitable for internal and
external use. Compared to traditional coatings
they have less impact on health, safety and
the environment VOC emissions into the
atmosphere are minimal and there is no
compromise on protection. Two and three
coat systems have passed the criteria of
independent test institutes for use on water
jetted and blast cleaned steel.

act as barrier coatings, but can also

undercoat and can be overcoated

superior adhesion a combination

WATERFINE PRODUCTS

BALTOFLAKE MULTI
A glassflake reinforced high build
polyester coating that gives a
hard, abrasion resistant surface
providing the very strongest protection against
chemical, mechanical and environmental
attack.

from zinc rich primers to long lasting

glossy topcoats, is available.
The Jotun range of products includes
Jotacote 5, WaterFine Acrylic Primer,

LIFE CYCLE
COST
ANALYSIS

polyester coatings are mechanically

very strong and are used in specially
exposed areas. They are all high build

High film thicknesses provide

coatings and the polyester coatings

excellent resistance to abrasion,

are quick curing thus reducing

mechanical damage, stress and

downtime. The Jotun products are

eposure to the elements. These all

Jotamastic 87 GF (epoxy mastic),

round coatings can be applied to

Marathon (epoxy), Baltoflake Multi

surfaces pre-treated to St 2, or water

and styrene free Baltoflake Multi E

jetted surfaces with flash rust. All

(polyester).

are available in colours. Jotamastic

87, Primastic and Primastic Universal

The Green Line

are available in wintergrade versions

Todays water-borne coatings offer

which cure at temperatures down

corrosion protection as good as, or

to -5C.

even better than the traditional

The one component range

systems for bridges and other steel

Many different one component

structures. They have reduced impact

products have been used for years

on safety, health and environment.

and there are reasons why they still

A complete range of Jotun products,

quality system, suitable for the environment, the corrosion rate and the
costs can be reduced dramatically.
In practice the use of a high quality
coating system has demonstrated a
reduction in maintenance costs of
2540% after implementing systematic surveys.

Jotun has conducted life cycle cost

COATING MATERIAL
OFTEN REPRESENTS
LESS THAN 10% OF TOTAL
MAINTENANCE EXPENSES

analyses for over 25 years. An analysis

of such exercises revealed that the coating represented less than 10% of total

WaterFine Primer, WaterFine Barrier,

LIFE CYCLE COST OVER 25 YEARS

WaterFine Zn Primer, WaterFine

Special and WaterFine Topcoat.
JOTATHANE
An aliphatic high solids
polyurethane topcoat with a
low VOC content. It can be
applied over epoxy, epoxy mastic or WaterFine
Special to provide a very low VOC system.
Excellent colour and gloss retention. Very
good resistance to weather, chemicals and
abrasion. It can be applied at 5080 microns
dry film thickness to give a lasting high gloss
finish. Cures down to 0C.

Net present value (cost index)

100
80
60
40
20
0

Oxidative or
physically drying

The final touch

Glassflake reinforced epoxy and

maintenance costs. By choosing a high

PRE-PLANNING
TO ACHIEVE
OPTIMUM VALUE

appeal of colour and finish with

120

exposure to the sun and the most

extreme climatic conditions.

110

The Jotun range includes topcoats

100

with different types of binders

90

Hardtop AS and Hardtop HB.

HARDTOP PRODUCTS
Hardtop AS and Hardtop HB are
polyurethane topcoats for use
as a topcoat in epoxy systems
where the gloss retention required is not
achieved with an epoxy topcoat. They cure
down to 0C. Gloss and colour retention are
very good. Hardtop AS has a high gloss finish,
Hardtop HB has a semigloss finish and can be
applied up to 100 m DFT.

Baltoflake Multi/
Baltoflake Multi E

protection against the effects of long

Correx, Pioner Topcoat, Jotathane,

Jotamastic 87
system

EXPECTED COST DEVELOPMENT

FOR TYPICAL MAINTENANCE SYSTEMS

Topcoats must combine the cosmetic

Maintenance cost (unit m2)

JOTUN PAINTS
COATINGS AND SYSTEMS
PROVEN IN USE
ON BRIDGES THROUGHOUT
THE WORLD

80
70
60
50
40
30
20
10
0
0

15
10
Years in operation
1000 microns Baltoflake Multi/Baltoflake Multi E
340 microns Jotamastic 87 system
Oxidative and physically drying

20