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2 1 INTRODUCTION The U.S. Army Corps of Engineers and a consortium of three technical societies (AWS [American Welding Society], NACE [National Association of Corrosion Engineers] International, and SSPC [The Society for Protective Coatings]) have developed metallizing guides. They are Thermal Spraying: New Construction and Maintenance (U.S. Army Corps of Engineers, Washington, D.C., January 29, 1999) and "Guide for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel" (ANSI/AWS C2.18A-XX, SSPC CS 23.00A-XX, and NACE International TPX #XA), which is currently under development. These guides provide detailed information about metallizing in general. The objective of this guide is to compile existing information about metallizing into a form directed toward steel piling designers and users. The guide is intended to focus on the specialized needs of steel pilings: The presence of edges and crevices, Geometric shapes, Different exposure zones and interactions between zones, Abrasion/erosion factors, and The effect of mechanical damage to coating. This guide covers the procedures for the application and use of thermally sprayed metal coatings (TSMCs) for corrosion control applications on piles used in highway construction. Surface preparation, materials selection, test methods, and field repair are also discussed. The guide provides the information necessary for a user to select, specify, and apply a metallized coating for steel piles in freshwater, brackish water, or seawater environments. This guide contains Information needed to successfully apply thermally sprayed metal technology to the corrosion protection of steel piles used in highway construction. A brief description of metallizing and the various methods of applying metallic coatings to steel, emphasizing the most appropriate means of both shop and field application of metallic coatings to steel piles. This guide discusses only wire-arc and wire-flame spray techniques because these are the most effective techniques for coating steel piles. Descriptions of appropriate TSMCs, their life expectancies under various exposure conditions, methods of application, and any specific advantages and disadvantages. A discussion of coating selection. A listing of specifications and existing documents useful in the selection and application of TSMCs. Applicator, equipment, and inspector qualifications and certifications. Surface preparation methods and equipment. Application methods, equipment, and tolerances. A review of sealer coatings and a generic specification. Inspection and quality control (QC) requirements. A review of the effects of mechanical damage and maintenance and repair methods. Safety and environmental considerations. Glossary/definitions of terms and abbreviations.