Is it feasible to establish a structural bond between glass and anti-corrosion coatings? In the construction of segmented steel structures like gridshell roofs, connection profiles must be attached to the steel substructure. Welding or bolting the connection profiles is common, but these methods can damage the anti-corrosion coating and compromise corrosion protection. Alternatively, bonding the glazing to the substructure eliminates mechanical intervention and enables the creation of a continuous corrosion protection layer while preserving the design advantages of structural bonds. Currently, the structural bonding of glass to anti-corrosion coatings is not regulated. Anti-corrosion coating systems typically consist of a primer coat and a top coat. Designers need to consider the adhesion of the additional layers in the load path in structurally loaded bonds to anti-corrosion coatings. However, the
force transfer through this multi-layer system and the durability of such bonded joints remains insufficiently investigated. To address this challenge, a series of experimental tests were conducted, including tear-off tests and tensile tests. In total, four different coating systems were examined. Additionally, the effect of accelerated aging on the load-bearing capacity of the structural bond was investigated. The combination of an epoxy-based primer coat and a polyurethane-based top coat showed the best results. The findings of the small part tests led to an application in a full-sized, double-
curved steel gridshell with dimensions of 5 m x 3 m. This demonstrator was used to conduct additional tests for air permeability, resistance to driving rain, and wind load on a façade test wall, demonstrating the practical applicability of the structural sealant bond. The investigations provided the load-bearing capacity of structural bonds on anti-corrosion coated steel surfaces experimentally using both small-
scale and component-scale tests.