Industry Experts Share Durability Strategies for Steel Bridges at IBC 2025

At the 2025 International Bridge Conference in Pittsburgh, Pennsylvania, the Short Span Steel Bridge Alliance (SSSBA) led an expert-driven session titled “Building for the Future – Corrosion Protection Systems for Steel Bridges.”

The session, held on July 15 as part of Workshop W-05 on Steel Design Topics, brought together leaders from across the industry to examine the full spectrum of corrosion protection strategies for steel bridges.

With corrosion protection being a critical factor in the durability and lifecycle performance of steel bridges, the session offered insights into current best practices, evolving technologies, and case studies from the field.

Dan Snyder of the American Iron and Steel Institute opened the session with an overview of the importance of corrosion protection and outlined the session’s goals: to present practical solutions, compare performance data, and explore emerging trends. He emphasized that selecting an appropriate corrosion protection system depends on a range of factors, including environmental conditions, life cycle performance, maintenance requirements, cost, component size, and aesthetic considerations.

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Weathering Steel

Presenter: Brandon Chavel, National Steel Bridge Alliance

Brandon Chavel detailed the science and advantages of uncoated weathering steel (UWS), highlighting its ability to form a protective patina that inhibits further corrosion. Chavel emphasized that while UWS offers excellent long-term durability and aesthetic appeal, its success depends on proper application in favorable environments.

He discussed the current version of the Uncoated Weathering Steel Reference Guide, developed in partnership with NSBA, Modjeski and Masters, and the University of Delaware, and provides designers with recommendations on when and how to use UWS effectively. A future version of the UWS Reference Guide will be published as an AASHTO/NSBA Steel Bridge Collaboration Guideline, incorporating the latest research along with addressing existing FHWA technical advisories.

Case studies, such as the 50-year-old Exchange Street bridge in Akron, Ohio, demonstrated UWS’s long-term viability. Design and maintenance practices—such as eliminating joints, improving drainage, and using sacrificial coatings in key areas—were highlighted as essential to maximizing performance.

Brandon Chavel, National Steel Bridge Alliance, discusses weathering steel at the 2025 International Bridge Conference.

Galvanizing

Presenter: John Krzywicki, American Galvanizers Association

John Krzywicki gave a comprehensive presentation on hot-dip galvanizing (HDG), a time-tested method that provides both barrier and sacrificial protection. With over 150 galvanizing plants across North America, HDG offers versatility, availability, and factory-controlled consistency. Krzywicki walked attendees through the galvanizing process, quality inspection protocols, and best practices for design to minimize distortion and enhance aesthetics.

He shared real-world success stories like the Stearns Bayou Bridge in Michigan, which has shown minimal degradation since it was galvanized in 1966. HDG’s synergy with duplex systems (paint over zinc) was also highlighted, with potential to double the expected lifespan of protective coatings. Krzywicki also referenced recent research by the University of Delaware, which showed galvanized bridges achieved above average performance in long-term corrosion studies.

John Krzywicki, American Galvanizers Association, discusses the advantages of galvanizing steel structures.

Metalizing

Presenter: Ben Bristol, Industrial Steel Construction

Ben Bristol introduced attendees to thermal spray metalizing, a process that applies a zinc or zinc-aluminum coating using high-velocity metal spray. Unlike paint, metalizing doesn’t require curing time and is cold-applied, making it suitable for both shop and field applications. Bristol noted that over 2,200 girders have been metalized at Industrial Steel Construction since 2015, with growing adoption by DOTs in the Midwest and East Coast.

While metalizing offers excellent durability, minimal maintenance, and no VOC emissions, Bristol acknowledged key challenges—such as the need for certified operators, specific PPE, and climate-controlled facilities for application.

Ben Bristol, Industrial Steel Construction, presents the metalizing process.

Paint Systems

Presenter: Derrick Castle, Sherwin-Williams

Derrick Castle wrapped up the technical presentations with a discussion on modern bridge painting systems, emphasizing their flexibility across new construction, rehabilitation, and maintenance. From single-coat zinc-rich primers to high-performance multi-coat systems, Castle emphasized the adaptability of paint to various service conditions. Aesthetic variety, fast cure times, and field-friendliness continue to make paint an important solution in the corrosion protection toolkit.

He also pointed to industry trends such as duplex systems and evolving single-coat technologies aimed at improving both performance and throughput for fabricators.

Derrick Castle, Sherwin-Williams, discusses the various painting system options for steel bridges.

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For additional guidance, technical support, or to schedule a webinar or workshop, contact Dan Snyder, Director of the SSSBA, at dsnyder@steel.org.