Technical Findings from NCHRP Scan 15-03 on Successful Preservation Practices for Steel Bridge Coating Preservation
Steel bridge coating systems play an important role in protecting bridges from corrosion and extending their service life, yet preservation strategies vary widely across agencies. To better understand effective approaches, the National Cooperative Highway Research Program (NCHRP) conducted “Scan 1503: Successful Preservation Practices for Steel Bridge Coatings” as part of the U.S. Domestic Scan Program. The scan was chaired by GPI branch manager Paul Vinik and brought together public sector and industry practitioners to evaluate current practices used by transportation agencies to extend coating service life.
Approach and Execution
The scan was executed as a Type 3 desk scan supplemented by a practitioner workshop, involving representatives from 11 state departments of transportation (DOT) and two non-DOT organizations. The scan team focused on identifying practices that have demonstrated effectiveness in slowing corrosion, extending service life, and managing lifecycle costs for steel highway bridges. Information was shared through presentations, roundtable discussions, and technical webinars, allowing agencies to compare methodologies and performance outcomes and learn from one another’s experiences.
Focus Areas of the Scan
The scan examined steel bridge coating preservation through multiple technical lenses, including:
- Evaluating existing coatings before recoating, with emphasis on determining when overcoating is appropriate versus when full removal and replacement are necessary
- Surface preparation methods, including decision criteria based on coating condition, exposed steel, and expected service life
- Selecting the right coating systems, considering agency standards, system compatibility, and long-term performance expectations
- Performance based contracting, including the use of warranties and defined performance metrics
- Quality assurance and inspection requirements, with attention to inspection timing, documentation, and acceptance criteria
- Inspector and contractor qualification requirements, recognizing their influence on coating performance outcomes
- Agency commitment to long-term preservation, including funding strategies and policy support for proactive coating management.
Key Technical Findings
A consistent theme across participating agencies was the importance of early, data driven evaluation of existing coatings prior to selecting a preservation strategy. Agencies reporting successful outcomes emphasized tailoring surface preparation and coating selection to actual field conditions, rather than defaulting to full coating removal.
The scan also highlighted the role of clear, enforceable specifications and inspection protocols in achieving consistent coating performance. Agencies with well-defined quality control and quality assurance frameworks, including documented inspector qualifications and contractor requirements, reported greater confidence in coating durability and reduced rework.
Performance-based approaches, including warranties, were identified as tools that can reinforce accountability when paired with realistic performance criteria and agency oversight. However, the scan emphasized that contractual mechanisms alone are not enough without ongoing agency commitment to inspection, documentation, and long-term maintenance planning.
Implications for Bridge Owners
Findings from Scan 15-03 reinforce that steel bridge coating preservation is most effective when treated as a strategic asset management function rather than a reactive maintenance activity. Agencies that integrate condition assessment, materials expertise, and rigorous inspection in their coating programs are better positioned to extend service life and manage corrosion risk across their bridge inventories.
Leadership involvement in national research efforts, such as chairing an NCHRP domestic scan, supports broader industry knowledge transfer and helps advance consistent, technically sound preservation practices across agencies.
About the Author
Paul Vinik, PE
Paul Vinik is an Executive Vice President / Branch Manager of GPI’S Florida branch. Paul graduated from the University of South Florida with a Bachelor and Master of Science in Chemical Engineering. His graduate studies and thesis were focused on polymer science and characterization. He earned his Professional Engineer’s license in 2004 and is Chair of the Board of Directors for the Association for Materials Protection and Performance (AMPP). Paul is a certified instructor of the Corrosion and Protection of Concrete Structures as well as several structural steel coating courses. He is PCS, BCI L2 and CP2 certified. Paul currently serves as the Branch Manager of GPI’s Florida branch. Prior to joining GPI, Paul worked for the Florida Department of Transportation (FDOT) and served as State Structural Materials Engineer. During this tenure, he was responsible for the Department’s Corrosion and Coating Programs including research, specifications, and statewide technical guidance. Paul has been actively involved in the American Association of Highway and Transportation Official’s National Transportation Product Evaluation Program and the TSP2 Bridge Preservation Partnership. Paul serves on the FHWA’s Bridge Preservation Expert Task Group and chairs the NSBA Steel Bridge Alliance TG8 Coatings group.
