Development of an Intrinsically Conductive Polymer-Based Low-Cost, Heavy-Duty, and Environmentally-Friendly Coating System for Corrosion Protection of Structural Steels

This project will develop and demonstrate the application of a polymer-based, low-cost and environmentally-friendly coating system for the corrosion protection of structural steels in highway structures. Work in Stage 1 will focus on laboratory development and evaluation of the coating system based on intrinsically conducting polymers (ICP). Promising ð-conjugated polymers will be produced and doped into ICPs using chemical treatment. Using scanning Kelvin probe force microscopy and electrochemical impedance spectroscopy, anti-corrosion capabilities of the polymers will be evaluated when coated on steel samples as the primer layer. The electrical potential of the substrate surface will be measured to evaluate the steel-ennobling capability of the primer. The electronic and ionic conductivities of the primer in the substrate electrolyte system will be determined to evaluate respectively the oxygen smearing-out capability (for reducing coating delamination) and the smart corrosion-healing capability of the primer. Three ASTM standard tests: B117 (Salt Spray Test), D5894 (Cyclic Weathering Exposure Test), and D4541 (Pull-Off Strength Test) will be conducted to evaluate the overall corrosion durability under different corrosive conditions (B117 and D5894) and the tensile adhesion to substrate surface (D4541) of the coating system. Work in Stage 2 will focus on field evaluation and technology transfer of ICP-based coating system. Working in collaboration with the Maryland State Highway Administration (SHA), two field sites will be chosen for evaluating the in-service durability of the developed ICP-based coating system. The blistering, rusting, undercutting, and pull-off strength of the coated steel panels will be evaluated following similar procedures and criteria as the ASTM standards B117, D5894 and D4541. Based on test performance results, necessary modifications and improvements will be made to the formulation, doping techniques, and coating-application procedures of the prototype coating system. Finally, technology transfer efforts will also be initiated in collaboration with Maryland SHA by demonstrating the application of the coating system in field conditions. The coating system will be further evaluated in the North East Protective Coating Committee (NEPCOAT) states and, if successful, plans for nationwide implementation will be developed.


  • English


  • Status: Active
  • Funding: $107458.00
  • Contract Numbers:

    Project 20-30, IDEA

  • Sponsor Organizations:

    Federal Highway Administration

    1200 New Jersey Avenue, SE
    Washington, DC  United States  20590

    American Association of State Highway & Transportation Officials (AASHTO)

    444 North Capitol Street, NW, Suite 225
    Washington, DC  United States  20001

    National Cooperative Highway Research Program (NCHRP) Innovations Deserving Exploratory Analysis (IDEA)

    500 Fifth Street, NW
    Washington, DC  United States  20001
  • Project Managers:

    Jawed, Inam

  • Performing Organizations:

    Illinois Institute of Technology, Chicago

    10 West 35th Street
    Chicago, IL  United States  60616
  • Principal Investigators:

    Pan, Tongyan

  • Start Date: 20141209
  • Expected Completion Date: 0
  • Actual Completion Date: 0
  • Source Data: RiP Project 38189

Subject/Index Terms

Filing Info

  • Accession Number: 01547494
  • Record Type: Research project
  • Source Agency: Transportation Research Board
  • Contract Numbers: Project 20-30, IDEA
  • Files: TRB, RIP
  • Created Date: Dec 10 2014 1:02AM