Client: RAIL VIKAS NIGAM LIMITED

Problems Faced:

The main challenge was the bridge’s location, which meant it was under constant risk of corrosion due to the coastal conditions surrounding it. 

Considering the Pamban Bridge’s constant risk of osmotic blistering and corrosion, it needed specialized coating solutions that were capable of shielding it from the negative impacts of saltwater and humid conditions.

Solutions Offered:

Berger Paints India Limited is the industry leader in this segment and our expertise in advanced coating solutions saw us devise customized solutions for the New Pamban Bridge project.

RVNL in consultations with CECRI Karaikudi approved the painting scheme offered for steel Girders of lift span and approach spans of the new Pamban rail bridge laid parallel to existing bridge No 346 at Km 655/000 to 657/200.

• Innovative Coating System: With a thorough understanding of the kind of detrimental effect that salt water could have on the Pamban Bridge’s structural integrity, Berger Paints developed a coating system for application over thermally sprayed zinc, which acted as the first layer of defense. The coating system involved an Epoxy universal primer (Epilux 45 ZNPH Primer) and then top coated with acrylic polysiloxane coatings system to give long-term durability. This primer acted as a shield against corrosive elements, (without the need for application of any etch coating for application on thermally sprayed zinc) while ensuring that the bridge's core structural elements remain well-protected. 
• Tailored to Coastal Conditions: Berger Paints' finish paint (BR Acrylic Polysiloxane Coating) was formulated to combat the effects of cyclic weathering, high humidity, and intense sunlight. The coatings were designed to resist peeling, chipping, and fading, maintaining their protective properties even in the harshest weather conditions.
• Quality Control: The primer was tested under aggressive lab tests for close to 17 parameters in the case of primer and 23 tests for finish and the field trials further established the coating system before approval was obtained from Berger Paints' technical team worked closely with the bridge construction crew to ensure meticulous surface preparation and application. Regular inspections ensured that the coatings were applied optimally, maintaining consistent protection across all surfaces.
• Environmental Responsibility: Berger Paints developed coatings with minimal environmental impact, reflecting a commitment to both effective protection and responsible manufacturing.

Results:

Berger Paints' role in the New Pamban Bridge project achieved remarkable results:

• Greater Resistance to Corrosion: Our specialized coatings acted as a powerful shield and prevented salt and moisture from affecting the bridge's structural integrity. 
• Increased Durability: By applying Berger Paint’s cutting-edge coatings, the Pamban Bridge's lifespan was extended, ensuring its continued functionality for decades to come.
• Sustainability and Responsibility: Berger Paints' environmentally conscious coatings underscored the project's commitment to responsible development. 
• Collaborative Success: The partnership between Berger Paints and the Southern Railway showcased the value of expertise and collaboration in infrastructure projects.

Conclusion:

Berger Paints India Limited's role in the New Pamban Bridge project showcased the indispensable role of innovative coating technologies in protecting infrastructure from nature's corrosive elements.

By offering tailored solutions and a commitment to protecting the environment, Berger Paints contributed to the success and sustainability of the New Pamban Bridge.