High Performance Highway Structures - RIBAProductSelector.com

High Performance Highway Structures
Product Datasheets and Safety Datasheets
can be accessed via: www.international-pc.com

Over recent years the Highways Agency has moved towards the use of two pack epoxy and polyurethane coatings
for the protection of steel bridges in preference to more conventional single pack paints.
These coatings offer improved corrosion protection and durability, savings in application and
traffic management costs, and compliance with Environmental Legislation.
Coating systems for new highway structures are detailed in Highways Agency’s Specification for
Highways Work Series 1900 and can be summarised as follows.
Type 1 - Ready Access
Surface Preparation:
Blast clean with chilled iron grit or aluminium oxide grit to Sa3, medium profile.
Coating System:
1st Coat: Item 111, Intercure 324, Zinc Phosphate HB/QD Epoxy Blast Primer (2 Pack)
2nd Coat: Item 112, Intercure 384, MIO HB/QD Epoxy Undercoat (2 Pack)
3rd Coat: Item 168, Interthane 870, Polyurethane (2 Pack) Finish to 50 μm mdft
Minimum Total Dry Film Thickness: 300 microns
Type II - Difficult Access
Surface Preparation:
Blast clean with chilled iron grit or aluminium oxide grit to Sa3, medium profile.
Metal Coating: Aluminium Metal Spray to 100 μm mdft
1st Coat: Item 159, Intergard 214, Aluminium Epoxy Sealer (2 Pack)
Apply at 12-20 m²/litre
2nd Coat: Item 111, Intercure 324, Zinc Phosphate HB/QD Epoxy Blast Primer (2 Pack)
3rd Coat: Item 112, Intercure 384, MIO HB/QD Epoxy Undercoat (2 Pack)
4th Coat: Item 168, Interthane 870, Polyurethane (2 Pack) Finish to 50 μm mdft
Minimum Total Dry Film Thickness of the Paint System: 300 microns
Type III - Interior of Box Girders
Surface Preparation:
Blast clean with metallic abrasive to Sa2½, medium profile
Coating System:
1st Coat: Item 111, Intercure 324, Zinc Phosphate HB/QD Epoxy Blast Primer (2 Pack)
2nd Coat: Item 112, Intercure 384, MIO HB/QD Epoxy Undercoat (2 Pack) to 100 μm mdft
Minimum Total Dry Film Thickness: 200 microns
1

Type IV - Galvanised Parapets
Metal Coating:
Hot Dip Galvanising
Coating System:
1st Coat: Item 155, Interprime 160, ‘T’ Wash
2nd Coat: Item 110, Intergard 307, Zinc Phosphate Epoxy Blast Primer (2 Pack)
3rd Coat: Item 111, Intercure 324, Zinc Phosphate HB/QD Epoxy Blast Primer (2 Pack)
4th Coat: Item 168, Interthane 870, Polyurethane (2 Pack) Finish to 50 μm mdft
Minimum Total Dry Film Thickness of the Paint System: 175 microns
For the maintenance of steel highway bridges the Type I system would be applied to structures where all of
the existing coatings are to be removed by combined wet/dry abrasive blast cleaning to Sa2½ standard.
Under circumstances where total removal of the existing paint system is not seen as necessary or where
blast cleaning is not practical the use of surface tolerant epoxy primers and barrier coats is recommended
and a typical system utilising these coatings would be:-
Surface Preparation:
Prepare all areas of corrosion by abrasive blast cleaning or power tool cleaning to clean steel, removing all
loose coatings to a firm edge. Clean down overall and present a clean, dry surface for painting.
Coating System:
Patch Prime: Item 115, Interplus 256, HB Epoxy Aluminium Primer (2 Pack) to 100 μm mdft
1st Overall Coat: Item 116, Interseal 670 HS*, HB Epoxy Undercoat (2 Pack) to 75 μm mdft
2nd Overall Coat: Item 116, Interseal 670 HS*, HB Epoxy Undercoat (2 Pack) to
75 μm mdft
3rd Overall Coat: Item 168, Interthane 870, Polyurethane (2 Pack) Finish to
50 μm mdft
Minimum Total Dry Film Thickness: 300 microns
*For overcoating existing chlorinated rubber or acrylated rubber paints the use of Item 116, Interplus 770, is preferred.
2

While the above protective systems are those most commonly specified for Highways Agency contracts, many DBFO
Contractors and Local Authorities have preferred to employ other proprietary products and systems which can extend
the life between maintenance periods such as glass flake epoxy barrier coats and acrylic polysiloxane finish coats.
Interzone 505 glass flake epoxy can be applied up to 500 μm d.f.t. in a single spray application and can eliminate
the need for aluminium metal spray on new structures thus reducing costs and improving production without
compromising the corrosion protection.
Interfine 979 acrylic polysiloxane has been adopted by many Local Authorities as their favoured choice of top coat.
The product’s barrier protection can be compared to an epoxy intermediate allowing a reduction in the paint system
while its long term gloss and colour retention make it a clear choice for high profile structures such as bridges.
Recommended systems to offer a life to first major maintenance of 25 years+ are:-
1. Surface Preparation:
Blast clean with chilled iron grit or aluminium oxide grit to Sa2½ medium profile.
Coating System:
1st Coat: Intergard 307 Zinc Phosphate Epoxy Blast Primer (2 Pack) to 25 μm mdft
2nd Coat: Interzone 505 HB Glass Flake Epoxy (2 Pack) to 400 μm mdft
3rd Coat: Interfine 979 Acrylic Polysiloxane (2 Pack) Finish to 100 μm mdft
2. Surface Preparation:
Blast clean with chilled iron grit or aluminium oxide grit to Sa2½ medium profile.
Coating System:
1st Coat: Interzinc 52 HS Epoxy Zinc Rich Primer (2 Pack) to 75 μm mdft
2nd Coat: Intercure 384 MIO HB/QD Epoxy Undercoat (2 Pack) to 125 μm mdft
3rd Coat: Interfine 979 Acrylic Polysiloxane (2 Pack) Finish to 100 μm mdft
Both systems eliminate the necessity for aluminium metal spray and therefore can show cost savings
when compared to other systems.
3

Track Record
Interzone glass flake epoxy has an established track in the severe environmental conditions of the
Offshore Oil Industry and was introduced into the Onshore Bridges Sector in 1993. Since then it
has been adopted by many authorities for both new steel and maintenance projects including:-
Brafferton Bridge
M25 Gantry
Frome Footbridge
New Hall Footbridge
Middleton Bridge
Woodhall Footbridge
River Air Footbridge
Scalpay Bridge
Croydon Tramlink
Chain Bridge
Helmsley Road Bridge
Tyne Millennium Bridge
Wye Bridge
White Bridge
Doncaster Viaduct
Parkway Bridge
Southampton Underpass
A1 Willowburn Bridge
St Marys Bridge
Centenary Way Viaduct
North Yorkshire CC
Highways Agency
Gloucestershire CC
Sheffield City Council
Northumberland CC
North Yorkshire CC
North Yorkshire CC
Western Isles Council
Gibbs Ltd
Monmouth CC
Derbyshire CC
Gateshead MBC
Monmouth CC
Hampshire CC
Doncaster MBC
Hampshire CC
Hampshire CC
Highways Agency
Doncaster MBC
Rotherham MBC
4

Track Record (Cont’d)
While a recent introduction into the bridges sector, Interfine 979 acrylic polysiloxane has been
specified by many Local Authorities for both its durability and environmental benefits and
Highways Agency has now allocated item number 185 to this product type. Projects include:-
Wynyard Bridge
Trent Bridge
Wearmouth Bridge
Myton on Swale Bridge
Various Footbridges
Thorngate Bridge
River Tawe Bridges
Bristol Bridge
Morfa Stadium Bridge
Paddington Basin Bridge
Phoenix Bridge
Cox Green Bridge
Lumley Bridge
New Hamilton Bridge
North Lodge Bridge
Queen Alexandra Bridge
Tyne Swing Bridge
Nevilles Cross Bridge
Brandycarr Bridge
Holme Forge Bridge
Woodpecker Flyover
Durham CC
Nottingham City Council
Sunderland City Council
North Yorkshire CC
Caerphilly Council
Durham CC
City of Swansea
Bristol City Council
Swansea City Council
Atelier One
WhitbyBird/Coventry City Council
Sunderland City Council
Durham County Council
N Lanarkshire Council
Durham County Council
Sunderland City Council
Newcastle City Council
Durham City Council
West Yorkshire County Council
N Lanarkshire Council
Leeds City Council
Protective systems for rail structures are detailed in the Railtrack RT98 Specification and
International Coatings have approvals for a comprehensive range of systems for both new
and maintenance projects.
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