In this Transportation Research Synthesis (TRS), state-of-the-art practice of highway bridge maintenance painting using high-ratio calcium sulfonate alkyd (HRCSA) and hot water pressure wash (HWPW) is reviewed and different state DOTs are surveyed. In summary, low-toxic HRCSA causes less pollution, eliminates waiting time between layers of coatings, and performs well for corrosion prevention. However, like any other protective coating system, optimum HRCSA performance requires following the manufacturer’s specifications. Contrary to what the term “one-coat system” may suggest, HRCSA application is a multi-step process that requires HWPW surface preparation. Based on the literature review and survey findings, without further testing and trials, HRCSA is recommended only for maintenance tasks that can strictly fulfill the manufacturer’s specifications, i.e., an initial HWPW followed by the multi-step process and sufficient drying time before an extreme weather event.
