English 
Reading Time: 5 minutes
Engineers and architects face the challenge of developing innovative, environmentally sustainable and safe bridge designs that stand the test of time. However, recent advances in FEVE (fluoroethylene vinyl ether) fluoropolymer bridge coatings have significantly improved the durability of these structures, enabling them to endure harsh environmental conditions for decades.
With over 617,000 bridges across the U.S., many are showing their age—42% are at least 50 years old, and 7.5% are classified as structurally deficient. As these aging bridges require increasing attention, the focus has shifted from building new ones to maintaining and extending the lifespan of existing structures. Furthermore, the American Association of State Highway and Transportation Officials now mandates that new bridges be designed for a service life of 75 years, a significant increase from the previous 50-year standard.
Innovative materials like LUMIFON® FEVE resins are stepping up to meet these demands. When used in bridge coatings, these resins not only enhance the aesthetic appeal of bridges but also provide superior protection against corrosion caused by severe environmental conditions. This ensures both new bridges and refurbishments achieve greater durability and a longer operational life.
What are LUMIFLON FEVE Resins??
First introduced by AGC in 1982, LUMIFLON FEVE resins are alternating copolymers of a fluoroethlyene unit and several different vinyl ethers. The fluoroethylene (FE) component provides durability and weatherability, while the vinyl ether (VE) units provide transparency, flexibility, crosslinking capability, and improved pigment dispersion and adhesion. Together, these properties result in a range of advantages, such as:
- Ambient curing for on-site applications
- Exceptional resistance to weather, corrosion, and chemicals
- High-gloss finishes
- Solubility in various coating formulations
These resins are available in multiple grades to suit almost any type of coating application. These include:
- Solvent-based resins
- Powder coating resins
- Environmentally friendly solid resins designed for low VOC and HAPS-free coatings
- Water-based options, such as emulsions and dispersions
Additionally, their low molecular weight allows for easy blending with other polyols, enhancing versatility in coating formulations.
Weathering and Corrosion Resistance
Bridge coating systems made with FEVE resins are easy to apply and provide exceptional durability, lasting two to three times longer under UV exposure compared to traditional coatings. Their unique chemical structure offers superior resistance to corrosion caused by water, oxygen, and chloride ions, significantly extending the lifespan of bridges and industrial structures while reducing the need for frequent repainting.
AGC performs both accelerated and real-time weathering and corrosion testing to evaluate the long-term durability of FEVE resins. These tests monitor changes in the material’s properties due to environmental exposure. Results consistently show that they maintain their gloss and film thickness while offering outstanding resistance to chalking and corrosion, outperforming competitive products.
Outperforms Competitive Coating Technologies
LUMIFLON resins outperform traditional coating technologies, including polysiloxanes, acrylics and urethanes. Accelerated weathering tests reveal that FEVE-based coatings last five times longer than acrylic urethanes and eight times longer than alkyd coatings.
Innovative Solubility and Versatility
Unlike most fluoropolymers, which are insoluble in solvents, LUMIFLON fluoropolymer resins are solvent-soluble. Coatings made with these resins can cure at both ambient and elevated temperatures, making them suitable to apply in the field and in the factory. Additionally, LUMIFLON-based coatings can be applied at lower temperatures than PVDF (polyvinylidene fluoride) coatings and offer extended lifespans of up to 60 years, much longer than those of polyurethane topcoats, which typically last 10-20 years.
Enhanced Aesthetics
FEVE resin-based bridge coatings preserve the visual appeal of structures for years. Coatings retain vibrant, clean colors with minimal fading or discoloration over time.
They resist fading, chalking, peeling, and corrosion, preventing degradation of the primer layer and the substrate.
They also provide excellent pigment dispersion, enabling clear and colored formulations in over 230 colors with gloss levels ranging from high gloss to flat finishes, providing flexibility for diverse design needs.
Life-Cycle Cost Savings
FEVE-based bridge coatings offer significant cost savings due to their exceptional durability. While the initial cost of the topcoats may be 2-4 times higher than standard polyurethane topcoats, their 30–60 year lifespan reduces maintenance and recoating frequency. Over time, these coatings can deliver lifecycle cost savings of 15–30% compared to polyurethane, which typically requires reapplication 2–3 times within the same period.
Environmental Considerations
FEVE resin-based coatings are environmentally friendly, requiring less frequent reapplication and reducing waste, making them a more sustainable coating option. Powder coatings made with FEVE resins are low in volatile organic compounds (VOCs) and contain no solvents, lead or chrome. They also cure at lower temperatures, minimizing energy use. Additionally, only a single coat is required. The EPA recommends powder coatings as a sustainable option, and using FEVE-based powder coatings can contribute to LEED credits and certifications for buildings.
Proven Applications
For over 32 years, FEVE resins have provided long-term protection for diverse substrates, including iron, concrete and plastic. They are ideal for both new construction and rehabilitation projects.
One notable example is the I-74 Mississippi River Bridge, completed in 2021 to replace the Iowa-Illinois Memorial Bridge. Designed with a LUMIFLON FEVE-based fluoropolymer coating, the bridge features durable steel arch ribs and a basket-handle configuration. This project, named the “Top Bridge of 2022” by Roads and Bridges Magazine, highlights LUMIFLON’s role in creating future-ready infrastructure.
To enhance the bridge’s durability, both the arches and exterior surfaces of the bridge’s approaches are coated with Sherwin-Williams Fluorokem® paint formulated with LUMIFLON. This ensures long-term ultra-weatherability and corrosion-resistance, protecting degradation caused by environmental elements such as UV light, wind and rain. The high-performance resin can withstand severe ultraviolet light exposure for more than twice as long as conventional coating resins.
A LUMIFLON FEVE-based bridge coating was also used to revitalize Florida’s iconic Sunshine Skyway Bridge, widely regarded as the flagship bridge of the Sunshine State. Completed in 1987, it holds the distinction of being the longest cable-stayed concrete bridge in the world.
When the Florida Department of Transportation embarked on a project to repaint the bridge’s yellow cables and provide corrosion protection for the ship impact system on both sides of the main channel, they chose Tnemec’s Series 1071V Fluoronar®, an advanced FEVE fluoropolymer coating. This system, powered by LUMIFLON FEVE resin technology, delivers outstanding durability and extends the lifespan of the coating.
Given the bridge’s constant exposure to UV radiation, moisture, and salt, selecting a coating capable of preserving its structural integrity over time was critical.
Thanks to FEVE-based bridge coating, the Sunshine Skyway Bridge will maintain its vibrant color and glossy appearance for decades, continuing to embody its sunny namesake with unmatched performance and aesthetic appeal.
As the largest custom fluoropolymer compounder in the world, our fluoropolymer experts can help solve your toughest challenges with the right resin to customize a fluoropolymer product. We supply a variety of advanced functional fluoropolymer products, such as fluoropolymer films, fluororubber, fluoropolymers for paints, fluorine gases and solvents.
For more information about on how to use powder and liquid LUMIFLON FEVE-based resins as components for building, structure or bridge coatings, watch our webinar Powder and Liquid FEVE Coatings for Curtail Wall & Infrastructure Applications.
