aca corrosion & materials february 2014

O f f i c i a l P u b l i c a t i o n o f T h e A u s t r a l a s i a n C o r r o s i o n A s s o c i a t i o n I n c • w w w . c o r r o s i o n . c o m . a u

Vol 39 No 1, February 2014ISSN 1326 -1932

& M A T E R I A L S

Inside this Issue:C&P 2014: Keynote Speakers

Industry Insight: Tanks for the Refreshment

Project Profile: Galvanized Finish Guards New Rail Work

Industry Insight: Protection of Water and Wastewater Concrete Structures - Pitfalls & Common Site Issues

University Profile: Charles Darwin University

Research Paper: Chemical Reactivation of Exterior Decorative Aerospace Topcoats

p.2 CORROSION & MATERIALS

Proudly presented by:

Major Sponsor:

EARLY BIRD

REGISTRATIONRegister before 20th June 2014

for the discounted conference

registration fee. Also, check

www.acaconference.com.au

for competition details

Darwin, Australia is a fascinating, tropical modern city, with a laid back lifestyle. Sail beautiful Darwin harbour at sunset, cruise next to crocodiles or swim in the crystal clear waterholes of Litchfield National Park.

The Northern Territory is a place with landscapes as diverse as they come, from Uluru, the spiritual heart

of the Australian continent in the dry Red Centre, to the teeming-with-wildlife tropical wetlands of the Kakadu and Nitmiluk National Parks in the Top End. In many ways the Northern Territory is the most quintessentially Australian of all the Australian States, and there is a little bit of everything for everyone.

www.travelnt.com

The Top End of Australia will host the 2014 Australasian Corrosion Association’s Annual Conference

Advances in Sensing and Monitoring

Cathodic/Anodic Protection

Coatings

Concrete & Architecture

Integrity Management

Manufacturing & Production

Marine Corrosion

Oil & Gas

Sustainability, Environment & Energy

Water & Wastewater

TECHNICAL STREAMS INCLUDE:


February 2014 www.corrosion.com.au p.3

Attending the 2014 Corrosion & Prevention Conference?

Edged with palm trees and a shimmering blue ocean, Darwin is a place unlike any other; the ideal destination to relax and explore pre or post conference.

Darwin is a tropical city offering a blend of cosmopolitan and outback adventure, and you can make it as action-packed or as laidback as you want it to be.

Swim with the crocs in the Cage of Death or wander the famous markets. Explore the history of Darwin and indigenous culture, cruise on the harbour or just relax at the wave lagoon and soak up the outdoor lifestyle.

Darwin also provides the gateway to the region known as the Top End which includes Kakadu, Litchfield and Nitmiluk National Parks. Experience adventure by taking to the skies on a scenic flight, jump in a waterhole for a refreshing dip or paddle a canoe through an awe-inspiring gorge.

Wildlife, wilderness, outback skies, indigenous art & culture; your options are endless!

For more inspiration, visit www.travelnt.com

Scenic flight over Katherine Gorge, Nitmiluk National Park

& M A T E R I A L S

ISSN 1326 -1932

Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257

EditorIan MacLeod – Western Australian Museum [email protected]

Associate EditorsResearch: Bruce Hinton – Monash University [email protected]

Professional Practice: Willie Mandeno – Opus International Consultants, [email protected]

News: Tracey Winn – The Australasian Corrosion Association Inc, [email protected]

ReviewersAndy Atrens – University of Queensland Nick Birbilis – Monash University Frederic Blin – AECOM Lex Edmond Harvey Flitt – Queensland University of Technology Maria Forsyth – Deakin University Rob Francis Warren Green – Vinsi Partners Graeme Kelly – Corrotec Services Grant McAdam – Defence Science & Technology Organisation David Nicholas – Nicholas Corrosion Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science & Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South Wales

Advertising SalesTracey Winn – The Australasian Corrosion Association Inc, [email protected] Ph: 61 3 9890 4833, Fax: 61 3 9890 7866

SubscriptionsPrint Version: ISSN 1326-1932 Subscription rates: Within Australia: AU$72.60, incl GST Outside Australia: AU$77, excl GST posted airmail

The views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.

The Australasian Corrosion Association IncPO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: [email protected] Internet: www.corrosion.com.au

Front Cover Photo: A brightly coloured container loader at an Australian port .

Photo by Phillip Minnis.

6 President’s Message

6 ACA Calendar of Events 2014

8 Executive Officer’s Message

9 ACA 2014 Training Calendar

10 News

20 Branch Xmas Function Photos

22 ACA Standards Update

26 ACA Foundation Ltd. Centurions

26 C&P 2014: Keynote Speakers

30 C&P 2013: Review

32 C&P 2013: Photos

The Australasian Corrosion Association IncThe Australasian Corrosion Association Inc (ACA) is a non-profit membership based organisation akin to a “learned society”. The ACA was established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion. It is dedicated to ensuring all aspects of corrosion are responsibly managed, protecting the environment and ensuring public safety. ACA members are drawn from a wide cross section of industries united by their common interest – to reduce the impact of corrosion in Australasia.

The ACA is a founder member of the World Corrosion Organization

CONTENTS

ACA Operations BoardPresident: Andrew Hargrave

Executive Officer: Wesley Fawaz

Operations Chairman: Paul Vince

Senior Vice President: Mohammad Ali

Junior Vice President: John Duncan

Immediate Past President: Allan Sterling

Directors:Kingsley Brown

Graham Carlisle

Matthew Dafter

Peter Dove

John Duncan

Fred Salome

Dean Wall

ACA Branches & DivisionsAuckland Division: Grant Chamberlain 64 21 245 9038

Newcastle: Karen Swain 61 0 418 854 902

New South Wales: Jim Galanos 61 2 9763 5611

Queensland: Cathy Sterling 61 7 3821 0202

South Australia: Dennis Richards 61 0 419 860 514

Tasmania: Grant Weatherburn 61 0 418 120 550

Taranaki Division: Ron Berry 64 27 671 2278

Victoria: John Tanti 61 3 9885 5305

Wellington Division: Monika Ko 64 4 978 6630

Western Australia: Gary Bennett 61 0 408 413 811

ACA Technical GroupsCathodic Protection: Bruce Ackland 61 3 9890 3096

Coatings: Matthew O'Keeffe 61 437 935 969

Concrete Structures & Buildings: Frédéric Blin 61 3 9653 8406

Mining Industry: Ted Riding 61 3 9314 0722

Petroleum & Chemical Processing Industry: Fikry Barouky 61 402 684 165

Research: TBA

Water & Water Teatment: Matthew Dafter 61 419 816 783

Young Corrosion Group: Dean Ferguson 61 0 425 784 932

* all the above information is accurate at the time of this issue going to press.

35 C&P 2013: Exhibitors

39 C&P 2013: Awards

42 New Product Showcase

44 Coatings Group Member Profile

45 University Profile: Charles Darwin University

46 Industry Insight: Tanks for the Refreshment

48 Project Profile: Galvanized Finish Guards New Rail Work

50 Industry Insight: Protection of Water and Wastewater Concrete Structures - Pitfalls & Common Site Issues

53 Research Paper: Chemical Reactivation of Exterior Decorative Aerospace Topcoats

58 Suppliers and Consultants

Corrosion & MaterialsCorrosion & Materials is the official publication of The Australasian Corrosion Association Inc (ACA). Published bi-monthly, Corrosion & Materials has a distribution of 2,500 to ACA members and other interested parties. Each issue features a range of news, information, articles, profiles and peer reviewed technical papers. Corrosion & Materials publishes original, previously unpublished papers under the categories “Research” and “Professional Practice”. All papers are peer reviewed by at least two anonymous referees prior to publication and qualify for inclusion in the list which an author and his or her institution can submit for the ARC “Excellence in Research Australia” list of recognised research publications. Please refer to the Author Guidelines at www.corrosion.com.au before you submit a paper to Brendan Pejkovic at [email protected] with a copy to [email protected]

ACA also welcomes short articles (technical notes, practical pieces, project profiles, etc) between 500 – 1,500 words with high resolution photos for editorial review. Please refer to the Article Guidelines at www.corrosion.com.au before you submit a paper to Brendan Pejkovic at [email protected]

CONTENTS


Happy New Year to all members.

It has been a busy time since taking on the presidency for 2014.

I am coming up to speed as I teleconference frequently with the

Executive Committee which is made up of the Executive Officer, Chairman, Finance Director and President of the ACA in between Board meetings.

On the agenda is establishing Good Governance for the ACA to go forward. Good Governance sets out fundamental principles and guidance that will provide a framework for the ACA to continue to improve principles and practices. This is applicable for all members as it will set the future structure of how the organisation is managed. The next Board meeting in February will primarily be focusing on the development plan for Good Governance.

In March the Executive Committee will be attending the NACE conference in San Antonio (USA) where an ACA /NACE Memorandum of Understanding (MoU) is to be signed. The MoU is an important step and will outline the way in which ACA and NACE will cooperate in programs, such as, conferences, meetings, exhibits, publications, technical activities and marketing. It is a positive step forward for the ACA.

In December I had the pleasure of attending our Tasmanian Branch meeting in Hobart where several

members including myself were presented with a 10 year membership certificate. Where has the time gone? I understand that other Branches will be handing out membership certificates to their local long serving members very shortly.

Also during that Branch meeting in Hobart, Incospec & Associates and Hydro Tasmania gave excellent technical presentations. Branch committees can offer great technical events for networking and continual professional development. It’s worth your while if you can take the opportunity to attend.

I look forward to meeting more of you during Branch meetings across Australia and NZ this year.

Hope you enjoy this edition of Corrosion & Materials and find it useful in your field of work.

Thank you.

Andrew HargraveACA President 2014

PRESIDENT’S MESSAGE

Andrew HargravePresident


Part of the role of the ACA is to organise events that bring together industry experts to present on new technologies, updates to standards, and share knowledge and experiences via case studies on a variety of projects. 2014 will be no different, with the events listed below scheduled in our Calendar of Events.

ACA members will receive further details on each event as appropriate throughout the year, but for now, please include these in your 2014 diary. For further information on these events for 2014 please don’t hesitate to contact Brendan Pejkovic ([email protected]) or Katherine Webber ([email protected]) in the ACA office on +61 (0)3 9890 4833.

Branch EventsEach of the eight ACA Branches will conduct regular technical events throughout 2014. To enquire, you may contact your local Branch at the following email addresses:

New South Wales: [email protected] New Zealand: [email protected] Newcastle: [email protected] Queensland: [email protected] South Australia: [email protected] Tasmania: [email protected] Victoria: [email protected] Western Australia: [email protected]

YCG EventsTargeting individuals under 35, new to the corrosion industry and/or interested in the corrosion industry, the ACA Young Corrosion Professionals conduct regular events. For further details email [email protected] or go to www.corrosion.com.au

Please refer to www.corrosion.com.au for up to date details on all ACA activities.

ACA Calendar of Events 2014

ACA CALENDAR OF EVENTS

Event 2014 Date Location

Future Leaders Forum 20-21 February Melbourne

Marine & Coastal Corrosion Seminar Series 8 May Auckland

Marine & Coastal Corrosion Seminar Series 13 May Hobart

Marine & Coastal Corrosion Seminar Series 15 May Melbourne

Marine & Coastal Corrosion Seminar Series 20 May Brisbane

Marine & Coastal Corrosion Seminar Series 22 May Sydney

Marine & Coastal Corrosion Seminar Series 23 May Newcastle

Marine & Coastal Corrosion Seminar Series 27 May Darwin

Marine & Coastal Corrosion Seminar Series 29 May Perth

Cathodic Protection Technical Group/Australian Electrolysis Committee Meeting 29 May Brisbane

Concrete Performance for Coastal Assets 12 June Melbourne

Corrosion in the Mining Industry 3 July Perth

Corrosion in the Oil & Gas Industries 24 July Brisbane

Corrosion in the Oil & Gas Industries 7 August New Plymoth, NZ

Corrosion & Prevention 2014 Conference 21-24 September Darwin

Protective Coatings Preventing Corrosion 20 November Brisbane


A key area of focus for the ACA at present is in the area of governance. It is widely acknowledged that good governance is a necessary condition for success.

During the 2013 Council meeting held in November, it was moved:

That the ACA engages a suitable external consultant(s) to review and make recommendations to the ACA Operations Board and ACA Council to undertake the following:

1. Assess the current ACA Constitution for its relevance and suitability in comparison to best practice

2. Assess the current ACA Board Structure and processes against current best practice and regulatory/legal requirements

3. Assess the current ACA operational business structures and processes against current best practice and regulatory/legal requirements.

The management of this process is assigned to the Governance Review Committee comprising of John Duncan (Chair), Fred Salome, Graham Sussex, Roman Dankiw, John Grapiglia, Allan Sterling and Paul Vince.

Steven Bowman who has conducted extensive Board, governance and strategic operational external reviews of Nonprofit Boards over the past 20 years was appointed prior to Christmas. Steven is regarded as one of the leading governance and senior executive facilitators globally in the Nonprofit and government sector.

The review commenced in the first week of January and includes a comprehensive independent review of Board processes, including Board strategic processes, Board structure, constitution, Board and stakeholder communication, Board compliance responsibilities and strategic operational issues that directly affect the governance of the ACA.

The findings and recommendations of the review will be presented to the Board and discussed at the 21st February 2014 Board meeting. Significant changes to the constitution are expected and members will be invited through a consultation process to comment and to vote on changes later in the year.

The Board is also conducting a facilitated strategic planning session on the 22nd February 2014 and a new three year strategic plan setting the ACA’s direction will be developed.

ACA finances are also a key focus area with completion of the 2012 and commencement of the 2013 audits a high priority. The ACA also recently appointed an accounting firm to undertake a process controls and financial management review. One of the recommendations from the review is to consolidate Branch accounts (excluding New Zealand) so they are maintained by the ACA Centre for full transparency and to maintain an accurate record of the Association’s financial situation as a whole.

The above activity indicates a strong commitment by the Board to a strong and viable future for the ACA; one

where the ACA is well governed, well organized and well managed.

The ACA-NACE relationship continues to strengthen with a new two year license agreement for the Coating Inspection Program signed in November 2013. The two organisations are also drafting a Memorandum of Understanding (MoU) to formalise a more cooperative relationship that is mutually beneficial to both organisations and its members. The aim is to sign the MoU at the 2014 NACE conference in San Antonio in March.

Many networking opportunities and dissemination of information through a range of events will again take place this year such as Branch events, the annual seminar series, technical group events and of course the annual conference (Darwin 21-24 September).

Please see www.corrosion.com.au and www.acaconference.com.au for further details and to add these important member and industry activities to your calendar.

I hope you all have a wonderful year ahead.

Wesley FawazExecutive [email protected]

EXECUTIVE OFFICER’S MESSAGE


ACA 2014 Training CalendarCorrosion Technology Certificate

Mbr Status Fee GST Total Fee

AU Mbr $2018.18 $201.82 $2220.00

AU Non Mbr $2367.27 $236.37 $2600.00

NZ Mbr* $2020.00 NZ Non Mbr $2370.00

Melbourne April 07th - 11th

Sydney July 21st - 25th

Brisbane November 10th - 14th

Introduction to Protective Coatings


AU Mbr $550.00 $55.00 $605.00

AU Non Mbr $672.73 $67.27 $740.00

NZ Mbr* $500.00 NZ Non Mbr $680.00

Darwin September 11th

Protective Coatings Quality Control


AU Mbr $1350.00 $135.00 $1485.00

AU Non Mbr $1645.45 $164.55 $1810.00

NZ Mbr* $1350.00 NZ Non Mbr $1650.00

Sydney June 02nd - 04th

Darwin September 24th - 26th

Perth December 8th - 10th

Coatings Selection and Specifications


AU Mbr $1350.00 $135.00 $1485.00

AU Non Mbr $1645.45 $164.55 $1810.00

NZ Mbr* $1350.00 NZ Non Mbr $1650.00

Brisbane April 28th - 30th

Perth July 28th - 30th

Coatings Inspection Refresher


AU Mbr $550.00 $55.00 $605.00

AU Non Mbr $672.73 $67.27 $740.00

NZ Mbr* $500.00 NZ Non Mbr $680.00

Darwin September 20th

New Zealand November 21st

Introduction to Cathodic Protection


AU Mbr $550.00 $55.00 $605.00

AU Non Mbr $672.73 $67.27 $740.00

NZ Mbr* $500.00 NZ Non Mbr $680.00

Melbourne March 12th

Brisbane July 11th

Cathodic Protection Monitoring


AU Mbr $1704.55 $170.45 $1875.00

AU Non Mbr $1868.18 $186.82 $2055.00

NZ Mbr* $1685.00 NZ Non Mbr $1865.00

Melbourne March 03rd - 06th

Brisbane July 14th - 17th

Sydney October 21st - 23rd

Cathodic Protection Advanced


AU Mbr $2018.18 $201.82 $2220.00

AU Non Mbr

$2367.27 $236.37 $2600.00

NZ Mbr* $2020.00 NZ Non Mbr $2370.00

Melbourne March 17th - 21st

Brisbane July 21st - 25th

Sydney October 13th - 17th

Corrosion & CP of Concrete Structures


AU Mbr $963.64 $96.36 $1060.00

AU Non Mbr

$1209.09 $120.91 $1330.00

NZ Mbr* $965.00 NZ Non Mbr $1210.00

Sydney May 21st - 22nd

Brisbane August 07th - 08th

ACA/ACRA Corrosion & Protection of Concrete Structures


AU Mbr $963.64 $96.36 $1060.00

AU Non Mbr

$1209.09 $120.91 $1330.00

NZ Mbr* $965.00 NZ Non Mbr $1210.00

Sydney June 19th - 20th

Brisbane November 27th - 28th

NACE - Coatings Inspection Program CIP Level 1


AU Mbr $3400.00 $340.00 $3740.00

AU Non Mbr $3883.36 $388.64 $4275.00

NZ Mbr* $3395.00 NZ Non Mbr $3900.00

Melbourne March 17th - 22nd

Sydney April 07th - 12th

Adelaide May 05th - 10th

Perth May 26th - 31st

Melbourne June 16th - 21st

Sydney July 07th - 12th

New Zealand August 11th - 16th


Melbourne October 20th - 25th

Perth November 24th - 29th

NACE - Coatings Inspection Program CIP Level 2


AU Mbr $3400.00 $340.00 $3740.00

AU Non Mbr $3883.36 $388.64 $4275.00

NZ Mbr* $3395.00 NZ Non Mbr $3900.00

Brisbane March 10th - 15th

Melbourne March 24th - 29th

Adelaide May 12th - 17th

Sydney July 14th - 19th

New Zealand August 18th - 23rd


Melbourne October/November 27th - 01st

Perth December 01st - 05th

NACE – Peer Review CIP Level 3


AU Mbr $1336.36 $133.64 $1470.00

AU Non Mbr $1568.18 $156.82 $1725.00

NZ Mbr* $1335.00 NZ Non Mbr $1568.00


Resits NACE – Coating Inspector Program Level 1 & 2


AU Mbr $909.09 $90.91 $1000.00

AU Non Mbr $1145.45 $114.55 $1260.00

NZ Mbr* $910.00 NZ Non Mbr $1165.00

Examination Tests will be conducted to coincide with scheduled programs – contact ACA for details

All registration fees are payable in Australian Dollars.

All registrations are subject to ACA’s published terms, conditions and policies.

* All NZ courses are GST free

For up-to-date course scheduling, please refer to www.corrosion.com.au

ACA 2014 TRAINING CALENDAR


NEWS

Rust is a civil engineer’s nightmare.

Across the United States, more than 200 million trips are taken daily across bridges rated structurally deficient or in need of significant maintenance and yearly inspection. One major culprit: corrosion of reinforcing steel.

Now, however, University at Buffalo (UB) researchers believe they can detect corrosion before the damage becomes severe by sending a jolt of electricity between opposite ends of steel cables. An inconsistency in the charge would alert them that the cable is suffering from corrosion and the bridge is in danger of falling.

“The No. 1 priority of all civil engineers is the safety of the public,” says Tresor Mavinga, a UB senior civil engineering and mathematics major involved in the research. “Corrosion can affect any structure, not just bridges, and we don’t want that to happen. We need to be as accurate as possible to save money, time and lives.”

Led by Salvatore Salamone, assistant professor of civil engineering, Mavinga and Alireza Farhidzadeh, a civil engineering graduate student, embedded piezoelectric transducers — devices that convert a signal from one form of energy to another — onto each end of a wire.

They then fired (sic) one volt of electricity through the metal using ultrasonic-guided waves, which can travel a long distance with little loss in energy, while monitoring the charge received at each end. The experiment was repeated with the same wire after it was rusted with a saltwater mixture. Because the cables are corroded, most of the energy from the electrical charge will be lost during the transfer between transducers.

Since the sensors and transducers are permanently attached to the cable, engineers can test the wires remotely off-site.

The new method of testing could do away with time-consuming and expensive visual tests, which often rely on drilling through concrete to inspect the cables or spotting cracks in the concrete caused by increased stress on the weakened wires.

According to the Federal Highway Administration, corrosion problems have increased significantly over the past three decades and are likely to continue. The increase is in part due to the rising use of road de-icing salts, which are extremely corrosive to the protective films on metals.

Improved testing is a needed step toward improvement of American infrastructure.

U.S. bridges were graded a C-plus by the American Society of Civil Engineers in its 2013 Report Card for America’s Infrastructure. And of the more than 17,000 bridges in New York, 12.5 percent are structurally deficient and 27 percent are considered functionally obsolete.

The report adds that one out of nine of the nation’s bridges is structurally deficient and that more than 30 percent of bridges have exceeded their 50- year design life; the average age of the nation’s bridges is currently 42 years.

By Marcene Robinson, originally published 5 Dec 2013 in UB Reporter, US.

Perth, Western Australia: Neptune Marine Services Ltd (Neptune) is pleased to announce its asset integrity business has entered into a Memorandum of Understanding (MOU) with Charles Darwin University (CDU).

The cooperative partnership is aimed at developing technical linkages between Charles Darwin University, Neptune and the industry in Northern Australia.

The specific services covered by the MOU include:

Establishment of NATA accredited mechanical and non-destructive testing services (NDT);

Establishment of an IRATA accredited rope access training facility and

Advanced welder testing and training.

Neptune’s Chief Executive Officer, Robin King, said “this agreement reflects Neptune’s strategy of pursuing strategic partnerships with respected organisations within our industry. It leaves Neptune well positioned to expand its asset integrity and training business into Northern Australia and better service the major resource projects currently under way in this region”.

Electricity used to peek inside bridge cables for corrosion

Neptune Signs MOU with Charles Darwin University

The steel cable tendon, which is found in most bridges, is suspended above a saltwater mixture with ultrasonic sensors attached at both ends for corrosion monitoring. Photo: Marcene Robinson


NEWS

Performance requirements for polyurea and polyurea/polyurethane hybrid coatings used to protect industrial structures are the focus of a new technical standard by SSPC: The Society for Protective Coatings.

SSPC-Paint 45, Two-Component, Thick-Film Polyurea and Polyurea/Polyurethane Hybrid Coatings, Performance-Based is designed to establish performance criteria for these coatings. Coating manufacturers and specifiers may use the standard as a set of performance benchmarks, SSPC said.

The standard was developed by committee C.1.9, Polyurea Coatings Committee, which is chaired by Dudley Primeaux of VersaFlex Inc.

Coatings that meet the requirements of the new standard may be applied on steel or concrete substrates, either directly to the substrate or over a compatible primer. Interior and exterior environments include fresh-water and salt-water splash zones, fresh- and salt-water immersion, and soil immersion.

SSPC-Paint 45 contains minimum performance requirements for two types of two-component polyurea coatings (Type I) and two types of polyurea/polyurethane hybrid coatings (Type II). Within each type, coatings may be classified as fast-cure (i.e., dry hard times of less than two minutes) or moderate cure (i.e., dry hard times ranging from two to 30 minutes).

The standard describes two performance levels based on resistance to deterioration by artificial weathering. Level I coatings are suitable for interior exposure; Level II coatings have demonstrated superior resistance to deterioration by artificial weathering (ultraviolet light) and are more appropriate for exterior exposure.

Additional performance properties evaluated by laboratory testing include tensile strength, elongation, tear strength, linear curve shrinkage, abrasion resistance, permeance and adhesion tests. Coatings for immersion service must also meet performance requirements for hardness retention, resistance to blistering and delamination, and resistance to mass and volume change.

SSPC announces new Polyurea Standard

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NEWS

Recently, during the Australasian Corrosion Associations Annual Conference in 2013 held at the Brisbane Convention Centre, the ACA was fortunate to host interviews conducted by NACE, for potential lecturer cadets.

The cadets were afforded the benefit of not having to travel to Houston to sit the interview, which has been the ‘norm’ in years past.

The interviews were for cadets in the majority of the courses on offer by NACE. There were several candidates from Australia applying as cadets for the NACE Coating Inspector Program (Level 1 and Level 2).

Several of our Australian residents were successful in gaining cadetship as a NACE CIP lecturer. Each cadet must now undertake lecturing assignments under a ‘mentor’ and gain acceptable recommendation from the mentor to be

appointed as a ‘Second Lecturer’ for the CIP Program.

The ACA congratulates the following people on their appointment as (NACE CIP Level 1 and Level 2) Cadet Lecturers;

Kingsley Brown Matthew Burkett Graham Carlisle Peter Dove Oscar Duyveston Justin Rigby Geoff White

For a person to be considered for the interview alone, each candidate had to meet a mandatory requirement. As a minimum each of the candidates had to be, or hold;

NACE Coating Inspector Certification.

A NACE member in good standing with a NACE Certified Coating Inspector Level 3 (PEER).

Must have taken or participated in and passed the course with a grade of 90% or higher. The instructor trainee assignment (and passing the final written exam with a score of 90% or higher) will fulfil this requirement for a candidate instructor who has not completed a required course/examination.

Minimum of 10 experience points gained as listed below. Note that each period of work experience can be used to acquire points in only one category:

one point for each year of field coating inspection work, plus

one point for each 1.5 years of work experience in a coatings related job with site experience (e.g., technical service, application supervision, or project management), plus

one point for each 2 years of work experience in the coatings industry.

Congratulations NACE Coating inspector cadet lecturers

Researchers said they have developed a topsy-turvy crab-like robot that will be able to locate cracks and corrosion in aging bridges and other steel infrastructure.

The research team from Osaka City University said on Dec. 17 that the robot can change its orientation from vertical to horizontal, scale steel surfaces and even move along a ceiling

while hanging upside down. The robot has four wheels with eight spokes apiece and attaches itself via powerful magnets at the end of each spoke.

“I was inspired by a crab I saw in a video that climbed a tree,” said Yogo Takada, an associate professor specializing in power system engineering at the university who developed the robot.

Operated by radio remote control, the robot can move at speeds between 15 to 20 centimeters per second. It is 34 cm long, 16 cm wide and weighs about 660 grams.

Takada said the project team hopes to put the robot into practical use in about three years through joint development with precision equipment manufacturers and other companies.

Robot crawls on walls, ceilings for bridge inspections

A bridge inspection robot scales a steel wall. Photo: Takehito Sato.


NEWS

Marine industries have long sought chemical solutions to the problem of marine fouling but now researchers at The University of Nottingham Ningbo China (UNNC) are using innovative approaches to look at how surface texture can be used as a non-toxic solution.

Marine fouling occurs when organisms, including red and green algae, hydroids, scallops, mussels and encrusting organisms such as barnacles and tubeworms, attach themselves to submerged surfaces such as ships’ hulls or oil rigs.

For the first time, existing research on surface structures and their effect on organisms’ ability to attach has been reviewed and the UNNC research team is using this information to develop new surfaces that can be used to prevent marine fouling from occurring.

The team – made up of engineering and marine biology experts – will test surfaces in the water at Meishan Port, a new deep water port on the east coast of China close to where UNNC is based.

They hope that the work, which is a new line of investigation, will lead to the development of a surface that will

provide a non-toxic solution to the problem of marine fouling, moving away from chemical-based solutions that have been investigated since the international ban on the use of tributyltin (TBT).

TBT is an effective but highly toxic chemical that was in widespread use until it was banned in 2008 due to its detrimental effects on marine life, which included severe deformities in shellfish and the accumulation of tin in other species.

The ban has led to significant effort being focussed on the search for an effective, environmentally friendly antifouling solution that can reduce the estimated US$1.5-3 billion spent a year on antifoulants and the repair and maintenance of offshore infrastructure required as a result of this natural phenomenon.

Marine fouling occurs worldwide and is an issue for most marine industries, from offshore oil and gas, to fishing equipment, to cooling systems, and can lead to huge economic and environmental costs.

On ships, for example, marine fouling can cause corrosion and deterioration

of the hull, as well as increased friction, slowing the ship’s manoeuvrability and increasing drag and therefore fuel consumption. This increased fuel consumption and the output of greenhouse gases, causes environmental as well as economic costs.

The transportation of invasive species around the globe, which may then cause huge damage to sensitive ecosystems, has also been a serious side-effect of marine fouling that occurs on cargo ships.

Felicia Wong Yen Myan, a PhD student whose paper The interaction of marine fouling organisms with topography of varied scale and geometry: a review, forms the basis of this line of investigation, said: “The huge environmental and economic costs associated with marine fouling mean it is crucial that effective, environmentally friendly solutions are found.

“Our research aims to find solutions that are capable of striking the balance between the economic needs of the aquaculture industry with the concerns of environmentalists, who are increasingly seeing the detrimental effects of invasive species being transported around the world.

“While a solution is a little while from being found, our research represents a definite shift away from chemical-based solutions to looking at how surface structures might contribute to a non-toxic way of dealing with marine fouling.”

This research reflects The University of Nottingham Ningbo China’s (UNNC) focus on working to contribute to China’s national priority to develop its marine economy knowledge and industry. A new £25m International Academy for Marine Economy and Technology will foster collaborations with industry, support China’s marine economy and contribute to the development of Ningbo’s port, which is one of the largest and most significant in the world.

Investigating surface texture could offer a non-toxic solution to marine fouling

Measurements and sampling in progress.


NEWS

Research on generating energy through developing new coatings for materials is to receive £2.5 million of funding, creating 40 research doctorate posts at Swansea University from September 2015.

The funding means that Swansea can set up a centre called COATED2, which will train researchers on how to develop new functional coatings for products.

For example, new coatings on steel and glass mean that everyday buildings can generate, store and release energy, effectively turning a building into its own power station.

COATED2 is a £6.5 million project, including the £2.5 million of funding announced today , which follows a successful bid to the EPSRC. It will be led by Dr James Sullivan and Dr Dave Penney from the College of Engineering at Swansea University.

Major companies work with the Swansea team, including Tata Steel, BASF, the world’s largest chemical company, and NSG Pilkington, one of the world’s biggest manufacturers of glass.

Some of the areas where Swansea researchers are already working, which are set to be boosted by this funding, include:

More efficient batteries which can store energy generated from photovoltaic coatings for use throughout the day.

New coatings for coins, making them more durable, in a project with the Royal Mint

Coatings for spacecraft which generate electricity from heat, in a project with the European Space Agency

Smart packaging for retail products using large area plastic electronics

Dr James Sullivan, director of the COATED2 centre, said:

"Today’s news is a real boost for our research, for the University and for our industry partners. It recognises that here at Swansea we have a team with an international reputation for their work on coatings and materials.

This work – which covers everything from reducing corrosion to improving energy efficiency – is playing an important part in tackling some of the major issues of our time, such as energy supply and sustainability.

We’re already working with some major companies and other leading universities, including Imperial College London, and these relationships will now grow with our 40 new researchers on the COATED2 project.

The project will not only spur the growth of new products and industries but also train the leaders of industry for the future."

£2.5 million funding and 40 research posts for new Swansea centre on coatings

Professor Dave Worsley of the College of Engineering, at SPECIFIC, a project which is devleoping coatings for buildings allowing them to generate, store and release energy.

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The ACA received an encouraging number of applications from future leaders of the corrosion industry to attend its 3rd annual Future Leaders Forum in Melbourne on the 20-21February 2013.

The two day personal and professional development forum will focus on

developing competencies in how to present technical papers, chair technical sessions, conduct group discussions and develop the art of expressiveness and communication in a professional and friendly environment.

The forum is an ACA Foundation funded initiative with all flights,

accommodation, etc. to be covered. A report of the forum will be published in the April issue of Corrosion & Materials.

The ACA has chosen the following list of future leaders to attend the 2014 forum:

Name Surname Organisation State

Terence Tjandra Savcor NSW

Will Von Moger Savcor NZ

Marius Gray Vector Ltd NZ

Joshua Logan Anode Engineering QLD

Daniel Frost Jotun QLD

Tim Lim WGIM QLD

Rochelle Bosworth GHD QLD

Hannah Watchman Dept of Planning, Transport & Infrastructure SA

Vijay Hillier Santos SA

Jason Maiolo Santos SA

Bradley Knott McElligotts Tas TAS

Simon Little Southern Prospect TAS

Bradley Slocum Select Solutions SP Ausnet VIC

Stephen Finger ALS Industrial VIC

Ain Beruldsen Savcor VIC

Darren Cram ATTAR VIC

Jordan May Quality Maritime Surveyors WA

Priya Pandarinathan Curtin University WA

Simon Poggioli Extrin Consultants WA

Philip Schmidli Woodside Energy WA

FUTURE LEADERS FORUM


NEWS

Station works for a major railway electrification project in South Australia attracted this year’s Sorel award from the Galvanizers Association of Australia (GAA).

Korvest Galvanisers primarily won for its treatment of impressively large-sized assemblies for a group of railway stations encompassing pedestrian overpasses, lift towers and enclosed stairways.

The rail electrification project included major redevelopments of both the Elizabeth and Munno Para stations on the northern Gawler line and construction of two major rail stations.

The award winner was announced at GAA’s 50th anniversary Gala Dinner held in Melbourne on Friday, 18 October attended by over 180 local and overseas members, guests and industry suppliers.

The other three shortlisted entries were:

Multi Use Entertainment Facility at ‘The Star’ casino, Darling Harbour NSW

The Moment sculpture on 220-apartment block, South Melbourne VIC

Golf Centre driving range and practice facility, Thornleigh NSW

Presented by GAA Chief Executive Officer Peter Golding, the award was accepted by Korvest Managing Director Alexander Kachellek, Korvest Galvanisers General Manager Steven Evans, and Technical Manager, Peter Freeth.

The Award was judged by two GAA Life Members, Mike Dennett and Colin Bain who between them brought over 60 years worth of galvanizing industry related experience and nous to the task.

They said that the winning Korvest Galvanisers entry scored highly on its market development potential and technical innovation by demonstrating that a high quality HDG coating can be applied to oversize assemblies without coating blemishes or distortion.

“Often larger components are not considered fit for galvanizing due to kettle size constraints and industry resistance to double-end dipping as well as weld joining of galvanized pieces,” Mr Evans from Korvest Galvanisers said.

“This project contained all of these elements that many engineers and architects shy away from but with careful planning and concise communication at all phases from technical, commercial, quality and documentation to logistics, a project like this can be executed successfully.

“Resistance to vandalism and the ability of galvanized coatings to withstand wear and tear of traffic made galvanizing the coating of preference.”

The Sorel Award commemorates French civil engineer Stanislaus Sorel who filed a patent in 1837 for a method of protecting iron from rust - the parent of the hot dip galvanizing process.

To be eligible to win a Sorel Award, a project needs to show how it (1) offered market growth potential for the industry, (2) exhibited engineering or other technical innovation, (3) provided economic benefits for the end user and (4) showed environmental or social responsibility. The 2014 Sorel Awards will be open for entries this coming June.

Rail Works Protection Tops National Award

(L-R) Korvest Galvanisers General Manager Steven Evans, Managing Director Alexander Kachellek and Technical Manager, Peter Freeth with GAA CEO, Peter Golding. Photo: Jorge de Araujo.


NEWS Marine & Coastal Corrosion

Long Term Asset Protection

OverviewMaterial selection and corrosion control in marine & coastal environments is essential in preventing the premature failure of important assets. Conventional methods, materials and coatings have a good track record. However we live in changing times, and there is a growing demand to:

• Extend the design life of existing assets • Reduce life-cycle costs• Increase competitiveness/reduce costs• Adjust for the effects of climate change and a low

carbon future• Employ alternative materials and coatings• Adopt innovative infrastructure and inspection technologies

This Seminar Series will feature presentations and case studies from experts and industry organisations who are

leading the way. It’s recommended for those wishing to ‘future proof’ their businesses, or for those wanting to know the latest trends in marine infrastructure and corrosion control to attend this seminar and speak to the experts.

Who should attend?Presentations should appeal to all industry sectors – including asset owners, consultants, specifiers, contractors, maintenance personal, suppliers and all those wanting to stay up to date with the latest trends.

ProgramEach locations’ speaker program may vary slightly depending on local contributions.

Auckland – Thursday 8 May 2014

Hobart – Tuesday 13 May 2014

Melbourne – Thursday 15 May 2014

Brisbane – Tuesday 20 May 2014

Sydney – Thursday 22 May 2014

Newcastle – Friday 23 May 2014

Darwin – Tuesday 27 May 2014

Perth – Thursday 29 May 2014

PROUDLY PRESENTED BY:

The ACA is recognised as a key provider of training for the Corrosion Prevention Industry. Attendance at ACA seminars and training courses can be used to accrue CPD points.

PROUDLY SPONSORED BY:

Register now at www.corrosion.com.au


NEWS

Corporate Gold

Atotech Australia Pty Ltdwww.atotech.comAtotech supplies and services “Chemical Solutions” for pre-treating plastics and metals prior to their subsequent metallic coating using Atotech chemistry or suppliers paints. Their package of chemicals and equipment are designed for decorative and functional electroplating; chemistry for paint and powder coat pre-treatment, paint waste management and waste treatment. Atotech support the chemistry with the supply of the latest green technologies and the best local service.

Corporate Bronze

APD Power Solutionswww.APDpower.com.auAPD Power Solutions provides high quality Electrical Design, Engineering, Testing & Commissioning services in the Utility (Power & Water), Mining, Rail, Oil and Gas industries across Australia in the Generation, Transmission, and Distribution sectors.

A speciality of their focus is protective coatings and electrical solutions related to the corrosion industry (including detailed earthing studies using CDEGS).

With a solid delivery record and a diverse range of technical skills, specialised software and equipment, APD is outcome focused & innovative, while adding value to clients.

Corporate Bronze

IDEAL MachineryKings Park NSW Specialising in Abrasive Blasting and Industrial Coatings. Off Shore Oil & Gas, Pumps, Pressure Vessels, Valving & Pipework, Mining applications etc. Structural and Architectural Steel work. Inorganic Zinc, Zinc Phosphate, Epoxy, MIO, Polyurethane, Poly Siloxane, Intumescent etc. Steel Grit or Garnet. 7000m2 site with 2000m2 factory floor, 2x Blast rooms 15m and 17m long. QA documentation, latest digital testing equipment, experienced staff.

ACA welcomes new members

Name Company/Institution Location

Michael Chapman WA

Bob Colman Coltech Planning QLD

Damien Curtis Contract Resources NSW

Matthew Deane Beca NZ

Ken Dunn VIC

Travis Farnell VIC

Mahdi Ferastkish VIC

Stephen Foley Newmont APAC WA

Graeme Fox Applus RTD WA

Aisha Ganash King Abdaziz University

VIC

Stewart Griffin SG Inspection Services

QLD

Hartantyo Seto Guntoro

PT Technip Indonesia

NSW

Steven Hamilton VIC

Curt Hendricks VIC

Sina Jamali University of Wollongong

NSW

Tristan Jan Santos SA

Ahmed Khaleel Victoria University VIC

Jim Kolaroff AGC Constraktione WA

Michael Lo Monash University VIC

Paul Lomas Mainteck NSW

Alexander Mackie Murphy Pipe & Civil Gas

WA

Name Company/Institution Location

Lymon Mailman APLNG QLD

Roger Marks Weld Cleaning Solutions

SA

Blane McGuiness Marine & Civil Maintenance

NSW

Medhi Medkalchi McConnell Dowell NSW

Dmitry Mezhubovski PIC WA

Kunal Monga AGC Industries WA

Robert Morrison WA

Varghese Chakko Nettikaden

Vector NZ

Barry Parsons OSD Pipelines VIC

Debi Prasad Pattnaik Qatargas WA

James Pere QLD

Cong Qiu Monash University VIC

Allan Smith WA

Nicholas Sprenger Jotun Australia QLD

Garry Sykes NZ

Jason Wagner JDP Applications QLD

Martin Wheelwright VIC

Haydyn Wood Engineering Inspection Services

SA

Xiaodu (David) Xu Origin Energy QLD

Christian Zaymund QLD

Marnix Zegwaard WA

Xian Zhou Monash University VIC

Individual/Student/Retired Members


Protective Coatings TrainingFrom basic concepts to carrying out quality control tests and producing specifications, these short ACA courses will improve your knowledge of protective coatings.

Introduction to Protective Coatings (1 day)

Darwin 11 September

This course provides an introduction to basic concepts of protective coatings; including the various types of coatings, the inspection requirements and considerations when selecting such products.

Protective Coatings Quality Control (3 days)

Sydney 2-4 June

Darwin 24-26 September

Perth 8-10 December

This course aims to formalise or improve the skills of carrying out basic quality control tests associated with protective coatings projects. It uses formal lectures, demonstrations, and extensive practical exercises as teaching methods.

Coatings Selection & Specification (3 days)

Brisbane 28-30 April

Perth 28-30 July

This course aims to provide participants with the ability to produce a clear and technically correct protective coatings specification. The course provides theoretical and practical information on coatings selection for corrosion control, largely based on ‘AS/NZS 2312 Guide to the Protection of Iron and Steel against exterior Atmospheric Corrosion’.

Inspection is only one part of ensuring a quality coating job, and selecting the correct coating system and writing a good specification are just as important. This course has been developed to provide information to assist the specifier to select the best coating system and to write a specification.



BRANCH CHRISTMAS FUNCTION PHOTOS


2014

Collaborate. Educate. Innovate. Mitigate.

THE CORROSION SOCIETY

www.nacecorrosion.org

Official Publications of CORROSION 2014

March 9-13, 2014Henry B. Gonzalez Convention CenterSan Antonio, Texas

6000+ Attendees 380+ Exhibitors

14 Industry TracksVast Networking Opportunities

Hours of Technical Education

Register Today for the World’s Largest Corrosion Conference & Expo

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13_1034


ACA STANDARDS UPDATE

ACA Standards Update

As in previous ‘Standards Updates’, Focus 1 will, summarise all relevant standards to the technical group in question. We will also bring the new standards update into Focus 1; these will be listed as Focus 1A and Focus 1B reports.

For this year we are adding the new Focus 2, where we bring to light some concrete related corrosion that needs more understanding by practitioners and or more specific detail in standards or codes of practice. We ask for reader feedback and interaction on this section to enable our practice to improve and corrosion to be further minimised, if not eliminated.

Focus 1AAs previously the focus will be a global standards and publication focus, searching through SAI Global Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to the ACA technical Groups, with this editions group focuses being the “Concrete Structures and Buildings” Technical Group.

These results are shown in Focus 1A report below.

Focus 1BA SAI Global search, as previously, at http://www.saiglobal.com/online/ for new standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and standards and amendments for ISO & IEC published from 19 November 2013 to 19 January 2014, using the key words and key word groups:

‘durability’.

‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’.

'paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’.

'galvanize' or ‘galvanized’ or galvanizing’.

'electrochemical' or ‘electrolysis’ or ‘electroplated’.

‘cathode’ or 'cathodic'.

‘anode’ or ‘anodic’.

'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’.

These results are shown in Focus 1B report below

Focus 2 This looks at a concrete related corrosion issues that need more understanding by practitioners and or more specific detail in standards and codes of practice. These results are shown in the Focus 2 report below.

Focus 1A Report Report on SAI Global Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “concrete and corrosion” for the “Concrete Structures and Buildings” Technical Group

A total of 164 publications were returned in the search, up from 156 publications this time last year.

Summary and highlights of the search There were no reference to AS, AS/NZS publications but one to BRANZ (Building Research Association of New Zealand)

BRANZ Bulletin 464 - Preventing Corrosion of Reinforcing Steel in Concrete

A filter for American Concrete Institute was applied giving 4 specific publications relating to this aspect whilst a filter for ASTM gave 10 publications. See below for publication title results.

ACI 222R:2001 (R2010) - Protection Of Metals In Concrete Against Corrosion

ACI SP 291 CD:2013 Corrosion Of Reinforcing Steel In Concrete - Future Direction: Proceedings - Hope & Schupack Corrosion Symposium Cd

ACI C 25:1993 - Concrete Durability: Corrosion Protection

ACI 222.3R:2011 - Guide To Design And Construction

Practices To Mitigate Corrosion Of Reinforcement In Concrete Structures

ASTM STP1065-90 - Corrosion Rates Of Steel In Concrete

ASTM STP1276-96 - Techniques To Assess The Corrosion Activity Of Steel Reinforced Concrete Structures

ASTM STP629-77 - Chloride Corrosion Of Steel In Concrete

ASTM STP713-80 - Corrosion Of Reinforcing Steel In Concrete

ASTM STP818-83 - Corrosion Of Metals In Association With Concrete

ASTM C1582/C1582M-11 - Standard Specification for Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete

ASTM STP906-86 - Corrosion Effect Of Stray Currents And The Techniques For Evaluating Corrosion Of Rebars In Concrete

ASTM G180-13 - Standard Test Method for Corrosion Inhibiting Admixtures for Steel in Concrete by Polarization Resistance in Cementitious Slurries

ASTM G109-07(2013) - Standard Test Method for Determining Effects of Chemical Admixtures on Corrosion of Embedded Steel Reinforcement in Concrete Exposed to Chloride Environments

ASTM C876-09 - Standard Test Method for Corrosion Potentials of Uncoated Reinforcing Steel in Concrete

A search on concrete gave 20 CIA results with no title mentioning corrosion and one about use of galvanized steel reinforcement; it also gave 102 Standards Australia results, non with corrosion in the title.

CIA CPN17-2008 The Use of Galvanised Reinforcement in Concrete

Welcome to the first corrosion related Standards Update for 2014. This Standards report focuses on concrete related

corrosion for the Concrete Structures & Buildings technical group.



Focus 1B Report SAI Global, search at http://www.saiglobal.com/online/ for new standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI AND standards and amendments for ISO & IEC, ALL published from 19 November 2013 to 19 January 2014.

This produced 94 Documents as listed below. There was 0 AS on AS.NZS Standards

New standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards or Amendments for ISO & IEC PUBLISHED between 19 November 2013 to 19 January 2014

Key word search on ‘durability’. - 0 new citations found. 3 AS AS/NZS of relevance to Concrete and Buildings TG from 1990.

AS 1580.481.5-2004 Paints and related materials - Methods of test - Coatings - Durability and resistance to fouling - Marine underwater paint systems

AS 2309-2008 Durability of galvanized and electrogalvanized zinc coatings for the protection of steel in structural applications - Atmospheric

AS/NZS 2699.3:2002 Built-in components for masonry construction - Lintels and shelf angles (durability requirements)

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 5 citations found; none from AS or AS/ASNZ. From 1990 there were 2 AS AS/NZS citations for “Corrosion and Buildings”

ISO/TR 16208:2014 Corrosion of metals and alloys - Test method for corrosion of materials by electrochemical impedance measurements

ISO/DIS 17093 Corrosion of Metals and Alloys - Guidelines for corrosion test by electrochemical noise measurements

ISO/FDIS 6509-1 Corrosion of metals and alloys - Determination of dezincification resistance of copper alloys with zinc - Part 1: Test method

IEC 61300-2-28 Ed. 2.0 Cor.1 (English 2013)

Corrigendum 1 - Fibre optic interconnecting devices and passive components - Basic test and measurement procedures - Part 2-28: Tests - Corrosive atmosphere (sulphur dioxide)

DIN EN 15280 (2013-12) Evaluation of a.c. corrosion likelihood of buried pipelines applicable to cathodically protected pipelines

AS 3566.2-2002 Self-drilling screws for the building and construction industries - Corrosion resistance requirements

DR AS/NZS 3566.2 Self-drilling screws for the building and construction industries - Part 2: Corrosion resistance requirements and requirements for non-conductive seals

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 8 relevant Publications found; none from AS or AS/NZS.

JIS H 0401:2013 Test methods for hot dip galvanized coatings

DIN EN 13438 (2013-12) Paints and varnishes - Powder organic coatings for hot dip galvanised or sherardised steel products for construction purposes

DIN EN 1953 (2013-12) Atomising and spraying equipment for coating materials - Safety requirements

PD CEN/TS 16498:2013 Paints And Varnishes - Coating Materials And Coating Systems For Exterior Wood - Assessment of Tannin Staining

PD CEN/TS 16499:2013 Paints And Varnishes - Coating Materials And Coating Systems For Exterior Wood - Resistance to Blocking Of Paints And Varnishes On Wood

I.S. EN ISO 16474-1:2013 Paints and Varnishes - Methods of Exposure to Laboratory Light Sources - Part 1: General Guidance (iso 16474-1:2013)

I.S. EN ISO 16474-2:2013 Paints and Varnishes - Methods of Exposure to Laboratory Light Sources - Part 2: Xenon-arc Lamps (iso 16474-2:2013)

I.S. EN ISO 16474-3:2013 Paints and Varnishes - Methods of Exposure to Laboratory Light Sources - Part 3: Fluorescent UV Lamps (iso 16474-3:2013)

Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ – 1 Standard Publications found.

JIS H 0401:2013 Test methods for hot dip galvanized coatings

Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ – 0 Standard Publications found

Key word search on ‘cathode’ or 'cathodic' - 1 publications found; none from AS or AS/NZS; 1 since 1990 for “Building and Cathodic”.

DIN EN 15280 (2013-12) Evaluation of a.c. corrosion likelihood of buried pipelines applicable to cathodically protected pipelines

NACE 01210:2010 Cathodic Protection for Masonry Buildings Incorporating Structural Steel Frames



Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 0 Standard Publications found – 4 after 1990 for “anode and buildings”, None from AS/ANZS

I.S. EN 14095:2004 Water Conditioning Equipment Inside Buildings - Electrolytic Treatment Systems with Aluminium Anodes - Requirements for Performance, Safety and Testing

BS EN 14095:2003 Water conditioning equipment inside buildings. Electrolytic treatment with aluminium anodes. Requirements for performance, safety and testing

DIN EN 14095 (2004-03) Water conditioning equipment inside buildings - Electrolytic treatment systems with aluminium anodes - Requirements for performance and safety, testing

UNE EN 14095:2004 Water Conditioning Equipment Inside Buildings - Electrolytic Treatment Systems with Aluminium Anodes - Requirements for Performance and Safety, and Testing

Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found

Focus 2 ReportThe following are two short case histories (presented in my PFT lecture at ‘Corrosion & Prevention 2013’

conference). These case histories show where corrosion has occurred between concrete steel reinforcing and metallic attachments. This is more common

than probably thought and results from the standards not properly mentioning this problem.

Case History 1 – Concrete Potable Water TankThis concrete potable water tank had a steel roof with steel trusses supported by galvanized steel posts, fastened to the floor with stainless steel fasteners.

The water in the tank ensured maximum wetness of the concrete, the electrolyte, resulting in maximum corrosion.

All posts were electrically connected to the steel trussed roof which in turn was bolted down to the top of the concrete tank. Any electrical connection between a roof or support column hold down bolt would have completed the electrolytic cell for all immersed members.

Corrosion was proportional to diffusion of oxygen to the entire wetted concrete steel reinforcement which acted as the cathode.



Case History 2 – Road side galvanized bolted down crash barriers

This galvanic coupled occurred during construction in a period of prolonged rainfall resulting in the persistence of the electrolyte at the grout footing interface.

This is a too often seen problem with bolted footings or base plates to concrete.

The corrosion rate of the immersed members was proportional to the concrete reinforcing area and oxygen diffusion to the reinforcing and the wetness and low resistivity of the concrete structure.

The corrosion here was less than that of Case History 1 because the concrete structure (which would include the concrete roadway was less wet as it was not immersed and wetness related to rainfall...

Why has this occurred?In my view it appears entirely reasonable to lock partially concrete embedded items such as hold down bolts to the reinforcing to meet the standards strength codes.

My search of “AS 3600—2009 Concrete structures” was not able to find specific requirements for partially embedded metal items and corrosion avoidance or protection of the protruding part of the embedded item. Necessary concrete cover for fully imbedded metal items was comprehensively covered.

“AS/NZS 2312:2002 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings” does address this issue in Figure 3.1 (in part) TYPICAL DESIGN PROBLEMS AND SOLUTIONS” reproduced below.

Section 3.3.3.6 Concrete also requires; “Steel that is partially embedded in concrete will be susceptible to corrosion within the concrete near the entry point; the coating on the steel should be non-conductive and extend a minimum of 200 mm into the concrete”.

From the Focus 1 standards searches above it can be seen that solutions to this particular problem cannot be easily found.

Discussion on this problem and its better resolution is welcomed. Please send comments to Brendan Pejkovic in the ACA office on [email protected]

The rust weeping below the footing is the clue that all is not well.

The footing interface showing loss of galvanizing and beginning of steel rusting.

The galvanized holds down bolts are shown (arrowed) and how electrical connection to the concrete reinforcing has occurred.

Arthur Austin ACA Standards Officer

Galvanized hold down bolts

An ACA Foundation Centurion is an individual that commits themselves to a contribution of at least AUD$100 annually.

Our first Foundation Centurion Donor is David Nicholas from Newcastle. In committing to the Foundation Centurion program, David said:

“It’s a pleasure to be an ACA Foundation Centurion as I have received so much

assistance and encouragement from the ACA community throughout my career. It’s a privilege to be able to support the association that has supported me and to contribute to the education of future generations of corrosionists.”

If you would like more information on becoming an ACA Foundation Centurion Donor, please refer to the Foundation page on the ACA website or contact Jacquie Martin

on [email protected] or phone +61 (0)3 9890 4833.

Please note that contributions to the ACA Foundation Ltd. Centurion Program of $2.00 or more are tax deductible.

ACA Foundation Ltd. CenturionsThe Foundation Centurion Donor Program was launched in April 2013

and has received broad support from individuals within the Australasian

Corrosion Community. The ACA Foundation would like to thank and

acknowledge the wonderful support of our Centurions.

Alex Shepherd

Alexander (Sandy) McPherson

Allan Sterling

Andrew Hargrave

Andrew Weatherburn

Brad Dockrill

Brian Kinsella

Brian Martin

Bruce Hinton

David Hopkins

David Nicholas

David Towns

Dean Wall

Fikry Barouky

Geoffrey White

Graeme Kelly

Graham Robert Carlisle

Graham Sussex

Grahame Vile

Harvey David Blackburn

Ian Godson

Ian MacLeod

Jim Galanos

John Bristow

John Grapiglia

Justin Rigby

Kingsley Brown

Les Boulton

Luke Emery

Luke Menefy

Matthew Dafter

Mike Rutherford

Nick Birbilis

Paul Van Gameren

Peter Dove

Philip Jack

Richard Brodribb

Ricky Bannon

Robert Butcher

Robert J Freedman

Robert Jeffrey

Roman Dankiw

Warren Green

Wayne Burns

Willie Mandeno


Corrosion of Concrete Structures Corrosion & CP of Concrete StructuresSydney 21-22 May 2014

Brisbane 7-8 August 2014

This course covers the background theory on corrosion and cathodic protection, including such aspects as selection and design of cathodic protection systems (impressed current and sacrificial), installation of cathodic protection systems, materials and equipment, problem troubleshooting and assessment and repair of structures.

Course Highlights:

• Modes of Concrete Deterioration• Assessment and Repair of Structures• Corrosion Fundamentals• Remediation Options• Selection and Design of

Cathodic Protection Systems• Materials and Equipment• Installation of Cathodic

Protection Systems• Control of Interference Currents• Commissioning of Systems• Criteria for Cathodic Protection• Operation and Maintenance of Systems• Problem Troubleshooting• System Records and Documentation

ACA/ACRA Corrosion & Protection of Concrete StructuresSydney 19-20 June 2014

Brisbane 27-28 November 2014

This course will provide a solid foundation of knowledge about the corrosion of both reinforcement and concrete, so that those working in this field can reach more effective solutions in the prevention and remediation of this ever-growing problem.

Course Highlights:

• The Characteristics of Cement and Concrete

• Concrete Deterioration Mechanisms • Corrosion of Reinforcement

in Concrete • Survey and Diagnosis of Concrete • On-site Measurements • Laboratory Measurements• Repair and protection of

Reinforced Concrete • Repair of Damaged concrete• Cathodic Protection• Further Electrochemical Methods• Preventive Measures for New Concrete



Major Sponsor:

CORROSION & PREVENTION 2014 – KEYNOTE SPEAKERS

Scott Collins

Santos Ltd, Australia

Scott Collins is the Team Leader of Plant

Integrity & Process Safety at SANTOS,

and is based in the Adelaide head office.

With a team of 15 metallurgists, corrosion engineers

and process safety engineers his responsibility is for

the asset integrity of all Santos’ onshore processing

facilities which includes some 3500 Pressure Vessels,

5000 PSV’s, 400 Tanks and the associated Piping and

Structures. He also is responsible for implementing

Santos’ process safety management system, completing

periodic formal safety assessments (Process Hazard

Analyses) and developing a deep process safety cultural

improvement in Santos staff.

He has been actively involved in improving Santos’

integrity performance from bottom quartile to top quartile

over the last 3yrs, and is now focussed on optimising

systems and processes and improving performance.

Recently this has involved implementing a fully

quantitative Risk Based Inspection (RBI) system across

all of Santos’ Central Australian Assets.

He has recently completed his MBA and has been with

Santos now for 10 years, prior to that he worked with

BHP on the ill-fated Hot Briquetted Iron plant in Port

Hedland. He has a passion for Process Safety and Asset

Integrity Systems and will be sharing his experience on

these topics.

Jason Farrugia

Dulux Protective Coatings, Australia

Jason Farrugia graduated from the

University of Melbourne with a Bachelor of

Science (Hons.) majoring in Chemistry, and

a Bachelor of Commerce majoring in Accounting & Finance.

Jason began at Dulux Group in 2001 as a Graduate

Chemist in the Product Innovation Group. After several

technical roles, he was promoted to Senior Team Leader,

New Technology. In 2009 he was invited to join Orica

Coatings, China as Research and Development Consultant

and was based in Shanghai for six months. On his return,

Jason was immediately appointed to Senior Team Leader,

Product Development in the Dulux architectural decorative

business. During his years in the Dulux technical group

Jason published a research paper and two patents.

In 2011 Jason accepted the role of Business Development

Manager in Dulux’s paint waste treatment systems

business, Envirosolutions.

In his current role as Product Innovation Manager, Protective

Coatings, Jason combines his chemistry and coatings

formulation knowledge with his commercial experience.

P F Thompson Memorial Lecture – 2014

Percival Faraday Thompson (1885-1951) is recognised

as Australasia’s pioneer in the science and technology of

metallic corrosion and its mitigation. In recognition of this

singular distinction the Australasian Corrosion Association

inaugurated the P F Thompson Memorial Lecture in 1951.

The Lecture is the Association’s premier dedicated Lecture

and the Lecturer is encouraged to mark P F Thompson’s

distinction by referring to or emulating the academic and

technical qualities for which Thompson became known,

particularly his prowess with practical demonstration.

Warren Green has been selected to be the 2014

P F Thompson Memorial Lecturer.

Warren Green

Vinsi Partners, Australia

Warren Green is a Director and Corrosion

Engineer at Vinsi Partners, based in

Sydney. He holds an MSc in Corrosion

Science and Engineering from UMIST and is a Fellow

and Chartered Professional Engineer with Engineers

Australia. Warren has been involved with the condition

assessment, remedial strategy development and

maintenance management of various reinforced concrete

and steel structures and buildings. He has provided

durability assessment and durability planning services to

major infrastructure and new build projects. Warren has

researched and published on concrete durability, corrosion

monitoring, cathodic protection, performance of concrete

repair materials and coatings, condition assessment of

structures, microbiologically influenced corrosion and

corrosion sensors.

He is also a Conjoint Fellow of the Faculty of Engineering

and Built Environment at the University of Newcastle, an

Adjunct Associate Professor of the Institute for Frontier

Materials at Deakin University and is involved in the newly

formed Australasian Centre for Infrastructure Durability.

Harvey Hack

Northrop Grumman Corp, USA

Dr. Hack is a Senior Advisory Engineer

for Northrop Grumman Corporation,

Undersea Systems. He received his PhD

in Metallurgy from The Pennsylvania State University. He is

a NACE Certified Corrosion Specialist, Cathodic Protection

Specialist, and Level III Coating Inspector, a Registered

Professional Engineer in Maryland, and a Fellow of NACE

International, ASTM International, the Institute of Corrosion,

and the Washington Academy of Sciences. He has received

the NACE T. J. Hull and Distinguished Service Awards, the

ASTM Frank W. Reinhart and Committee G1 Francis L.

LaQue Memorial Awards, the ASM/Penn State McFarland

Award, and the Sea Horse Institute Francis LaQue Award.

He is a former Chairman of the ASTM Board of Directors

and former President of the Council of Engineering and

Scientific Specialty Boards. Dr. Hack is the 2014-2015

President of NACE International. He has authored many

papers and books, primarily in the area of Marine Corrosion.

Richard Hays

Office of the Under Secretary of Defense for

Acquisition, Technology and Logistics, USA

Rich Hays currently serves as the Deputy

Director of Corrosion Policy and Oversight

(CPO) in the Office of the Under Secretary of Defense for

Acquisition, Technology and Logistics. Prior to coming to his

current position in 2010, he spent 27 years as a manager

and corrosion engineer for the Naval Surface Warfare

Center, Carderock Division (NSWCCD). Mr. Hays obtained

Bachelor’s and Master’s Degrees in Materials Engineering

from VA Tech. He holds certifications in both Systems

Engineering and Program Management from the Defense

Acquisition University.

In his current position, Rich is responsible for the

development of corrosion-related acquisition policy for major

weapon systems and defense infrastructure, implementing

CPO’s corrosion research and technology program, and

for oversight of major defense programs with respect to

materials sustainment.

Prabhaker Singh

University of Connecticut, USA

Dr. Prabhakar Singh holds the United

Technologies Corporation (UTC) Endowed

Chair Professor position in the Department

of Materials Science and Engineering and also serves as

the Director of the Center for Clean Energy Engineering

(C2E2) at the University of Connecticut.

In this capacity, Professor Singh is responsible for

developing strategies at state, federal and global level for

the integration of “Sustainable Energy” portfolios. Professor

Singh works with national and international agencies and

industries in validating and implementing both near and

long term solutions that establishes “sustainable living”.

Professor Singh conducts research in high temperature

energy systems with focus on systems efficiency, long

term operation, and functional and structural materials for

aggressive environments.

Dr. Singh has authored and co-authored more than 100

technical reports and papers along with 3 book chapters.

Dr. Singh holds more than 50 US patents and trade

secrets in fuel cell systems and their operation; advanced

metallic and ceramic functional materials; manufacturing

process optimization; catalysis and hydrocarbon

fuel processing, hydrogen separation and electrical

management of fuel cell systems. He has also written

more than 100 patent disclosures.



CORROSION & PREVENTION 2013


C O N F E R E N C E & E X H I B I T I O N

CONFERENCE REVIEW

OverviewThe ACA and its Queensland Branch welcomed over 500 delegates to the lovely subtropical city of Brisbane for Corrosion & Prevention 2013. The annual conference is established as the Australasian corrosion industry’s premier technical summit and trade exhibition and 2013 was no exception. Held over three days at the Brisbane Convention & Exhibition Centre, C&P 2013 embodied its theme “Where Theory Meets Practice” with a cutting-edge blend of the latest research and industry practice including six plenary lectures, six technical group forums and over 70 individual paper presentations.

The social programme was also very successful. The Sunday evening Welcome Function was held at the recently refurbished and reopened Brisbane City Hall. Whilst corrosion-related repairs were not on display, the heritage architecture of the building was spectacular. Monday’s Exhibition Opening and Young Corrosion Group events were also thoroughly enjoyed. On Tuesday evening the ACA Annual Dinner and Awards saw a live 20-piece big band entertain delegates and partners. Finally the Farewell Function closed the conference to a

backdrop of views of Brisbane and South Bank from the Sky Room.

Plenary SpeakersThe conference was officially opened on Monday morning by conference convenor and ACA Queensland President Geoffrey Will, Simon Ghobrial of major sponsor Anti Corrosion Technology and conference technical chair Francis Carroll. The traditional ACA Corrosion Clock, powered by a galvanic corrosion cell, was officially started by Bruce Hinton. The clock is used to time every ACA conference.

After the official opening, proceedings commenced with plenary lecturer Jack Tinnea of Tinnea & Associates from the USA. Jack gave a wide-ranging, thorough and entertaining account of corrosion testing and investigation procedures in reinforced concrete. This was followed by Fikry Barouky of Anti Corrosion Technology presenting on pipeline corrosion management in the oil and gas industry before the concurrent streamed sessions for the remainder of the day.

by Francis Carrol C&P2013 Technical Chair


CORROSION & PREVENTION 2013CONFERENCE REVIEW

On Tuesday morning delegates were treated to the annual PF Thompson Lecture delivered this year by Arthur Austin of ALS Industrial. Arthur very ably upheld the tradition of the PFT, started by Dr Edmund Potter in 1970, using practical demonstrations to illustrate typical forms of corrosion. The PFT is recognised as the highlight of the technical program each year. After completion of the PFT, Professor Frank Witte of Hanover Medical School was the fourth plenary lecturer. He amazed the audience with a review of intentional corrosion in medical implants, which is a very different approach from the usual focus on prevention of corrosion.

Professor Graeme George of Queensland University of Technology opened the Wednesday plenary session with a review of sensitive test methods for studying degradation of polymers and coatings. This was followed by Daniel Brosch of PPG Protective and Marine Coatings with his presentation “Fire and Ice” on coatings for both high-temperature fire protection and low-temperature cryogenic service. The conference committee thanks all of the plenary lecturers, both local and international, for their outstanding presentations.

Forums and Technical ProgrammeA feature of Corrosion & Prevention 2013 was the technical forums organised by the ACA Technical Groups. Forums held included Coatings, Cathodic Protection, Concrete Structure & Buildings, Water, Petroleum & Chemical Process Industries and Mining. The discussion was robust as usual in these sessions and very worthwhile for the attendees. These forums are an ideal setting for both formal and informal exchange of experiences, case studies, problems, ideas and solutions with experts in each field. ACA members are encouraged to engage with the Technical Groups and become involved in the Forum sessions in future conferences.

The technical paper programme was substantial as always and sessions were arranged to bring theory and practice together. Major areas such as corrosion mechanisms, materials, coatings, cathodic protection, pipelines, concrete structures and case studies were

spread over the three days of the conference. Less common areas such as biomedical corrosion, reliability methods and materials such as cast iron and weathering steel also featured.

Trade ExhibitionCorrosion & Prevention 2013 featured a large trade show with over 60 exhibitors. These included materials suppliers, equipment vendors, specialist contractors and consultants. Delegates were able to browse the stands throughout the conference and take the opportunity to discuss products and services with the exhibitors. Exhibitors benefited from broad exposure to corrosion industry practitioners from around Australia, New Zealand and the world.

ConclusionOn behalf of the ACA and the conference committee, thanks are extended to major sponsor Anti Corrosion Technology, supporting sponsors Dulux Protective Coatings, International Paint, PPG Protective & Marine Coatings and Russell Fraser Sales, event sponsors Denso, Incospec and Associates, Jotun and Zinga and all the exhibitors for their support of the conference. Thanks also go to the plenary lecturers, speakers, session chairs and all delegates without whom the conference would not exist. A special mention must be made of the ACA conference committee and ACA staff and in particular Katherine Webber for her outstanding work in organising the conference.

In 2014 the conference will be held in the Northern Territory for the first time – an exciting new venue for the ACA. Corrosion & Prevention 2014 will be held from 21-24 September at the Darwin Convention Centre to take advantage of the springtime climate. Delegates should note the earlier dates than usual for technical paper submissions, early bird registrations and sponsorship and exhibition opportunities.

Delegates are encouraged to book their registrations and accommodation early via the ACA conference website www.acaconference.com.au

Standard

Jotun blue

Black and white

DENSO NORTH AMERICA INC.

Major Sponsor: Supporting Sponsors: Event Sponsors:

CORROSION & PREVENTION 2013 PHOTOS



PHOTOS


CORROSION & PREVENTION 2013PHOTOS


CORROSION & PREVENTION 2013 PHOTOS


CORROSION & PREVENTION 2013EXHIBITORS


C O N F E R E N C E & E X H I B I T I O N EXHIBITORS

Anti Corrosion Technology (ACT) is an established Australian-based engineering company that was founded in 1993. ACT specialises in providing sustainable solutions in materials engineering and corrosion control for Oil & Gas, Water, Power Generation and Mining industries.

ACT is the sole Australian partner of STOPAQ B.V. who is the pioneer and manufacturer of the visco elastic corrosion protective coatings and sealants. ACT is the exclusive distributor of STOPAQ products in Australia offering unique cost effective solutions for external pipeline corrosion protection of field joints, HDD, steel pipe casing, road crossings and complete pipeline rehabilitation including valves and flanges as well as external corrosion protection of tank bottoms. In addition, ACT has selected an exclusive line of corrosion protective products and services for the rehabilitation of submerged structures such as piles and jacket legs for offshore operations.

ACT is a leader in conducting “Cost of Corrosion” studies and providing full technical support to assess, evaluate and improve asset integrity, through its service life cycle, to avoid unplanned shutdowns. ACT is also fully capable to work jointly with asset owners to establish a comprehensive Corrosion Management Program (CMP) from the design phase to the decommissioning phase. CMP is a proactive and systematic, dynamic and continuous improvement model for both the asset’s integrity and the operator’s competency.


CORROSION & PREVENTION 2013 EXHIBITORS


CORROSION & PREVENTION 2013EXHIBITORS


CORROSION & PREVENTION 2013 EXHIBITORS


CORROSION & PREVENTION 2013AWARDS

Each year a series of ACA Awards are announced and presented to successful recipients during the gala dinner at the annual ACA conference.

The ACA awards papers of outstanding quality presented at a conference, seminar or symposium held under the auspices of the ACA, or published in the ACA’s publication Corrosion & Materials. These papers are judged by the ACA Awards Committee comprised of Les Boulton, Bruce Hinton and Erwin Gamboa.

The ACA also recognises members for outstanding services to the Association through Life Membership and services to the industry through the Corrosion Medal.

AC Kennett AwardThe AC Kennett Award is awarded each year to the best paper presented under the auspices of the Association that deals with non-metallic corrosion. The recipient also receives a cheque for $1,500.

Antony Trueman, Steven Knight, John Colwell, Teruo Hashimoto, Elena Koroleva & George Thompson for the paper ‘Micro-structural Characterisation of Paint Using Ultra-Microtome SEM’ presented at Corrosion & Prevention 2012, Melbourne 2012.

SUMMARY: When trying to anticipate the occurrence of corrosion on military aircraft, account needs to be made for the protective coatings that are routinely applied. These coating are generally multi-layered and have both barrier protection and corrosion inhibition properties that prevent the onset of corrosion. These paint coatings can be considered to be composite materials comprising of a polymeric matrix with inorganic fillers that include stabilisers, wear resistant additives, extenders and corrosion inhibitors. To understand how the barrier and inhibitive properties of the paint function, an understanding of the microstructure and its influence on the failure of the coating is required. Unfortunately, the scale of the composite is such that conventional methods cannot represent the microstructure in 3-D. To overcome this, a new technique has been developed that enables the 3-D imaging of polymeric materials with high resolution (~ 150 nm in x & y, 50 nm in z). This paper will demonstrate this new technique when applied to the study of the failure of paint coatings and detail some of the information that can be obtained. The ability to generate finite element meshes that will be used to develop crack propagation models in the future is also demonstrated.

Best PapersIn pursuit of attracting quality technical papers, the ACA annually awards two certificates of merit for papers either published in Corrosion & Materials or presented at the annual conference. The award will be made only where the standard of papers is of a level warranting recognition; one certificate is for the best review paper and the other is for the best research paper.

Marshall Fordham Best Research AwardXian Zhou, Digby Macdonald, Nick Birbilis, Junhai Xia, Gang Sha & Simon Ringer for the paper ‘The Role of Precipitates upon the Electrochemical Stability of Aluminium’ co-authors presented at Corrosion & Prevention 2012, Melbourne 2012.

SUMMARY: Whilst the electrochemical stability of a metal is typically described in terms of equilibrium thermodynamics, in an engineering context, a likelihood of corrosion as predicted by thermodynamics is not as useful as knowing the kinetic response (i.e. how fast a metal reacts in a certain environment). This work presents a discrete effort towards developing an improved understanding and representation of kinetic stability for aluminium-based metals, as an engineering alternative to Pourbaix diagrams. The overall study will assess the environmental envelope for passivity of aluminium, and account for the influence of microstructural heterogeneities (grain size, precipitates and crystallinity), which are not presently considered in equilibrium thermodynamics. In prior work we presented kinetic stability diagrams for pure aluminium with different grain size and grain boundary density. In the present study, we convey preliminary kinetic stability diagrams as a function of pH and potential for Al-4wt%Cu alloys with different precipitate size distribution and density – to elucidate the effect of precipitate state upon electrochemical kinetics.



AWARDS

Aaron Sudholz received the AC Kennett Award on behalf of the award recipients.


David Whitby Best Review Paper AwardDerek Northwood, Riyad Hussein & Xueyuan Nie for the paper ‘The Application of Plasma Electrolytic Oxidation (PEO) to the Production of Corrosion Resistant Coatings on Magnesium Alloys: A Review’ presented at Corrosion & Prevention 2012, Melbourne 2012.

SUMMARY: Magnesium alloys are widely used in the automotive, aerospace, electronics and sports/leisure equipment industries because of their excellent physical and mechanical properties including low density and high strength-to-weight ratio. However, magnesium is a highly reactive metal and requires surface modification using protective coatings to obtain adequate environmental resistance to corrosion and wear. Several techniques have been used for the surface engineering of Mg alloys including anodizing, conversion coatings, electrochemical plating, physical vapor deposition (PVD) coatings and organic coatings. Plasma electrolyte oxidation (PEO), which evolved from the conventional anodizing process, has emerged as one of the most effective ways of improving corrosion resistance. As is the case for all surface engineering technologies, the successful development of PEO coatings is dependent on adequate substrate pretreatment together with choice, and control, of electrolyte composition and process parameters. In this paper we will review the effects of processing parameters (DC, AC, current density, voltage, current mode, duration and temperature) magnesium alloy substrate and chemical composition of electrolyte on the coating morphology and composition, and ultimately the corrosion resistance of coated Mg-alloys. The review will also examine some new developments which involve the co-deposition of materials such as polymers, within the PEO layers to produce composite coatings with much improved corrosion resistance.

Life MembershipLife Membership is awarded for outstanding service to the ACA over an extended period either to a Branch or the Council and is awarded only as agreed by Council.

Peter FarinhaPeter has a PhD in Corrosion Science and Engineering from the University of Manchester, along with a Bachelor of Science in Analytical Chemistry and an MBA- Business and has over 25 years’ experience in the corrosion mitigation industry.

He is the author and co-author of a number of publicly available papers and technical documents, and has presented at both national and international conferences over the years. He has been Plenary Lecturer on numerous occasions for various professional associations, including delivering the PF Thompson Memorial Lecture in 1995.

Since joining the ACA in 1982, whilst still at university overseas, Peter was elected to his Branch Committee in 1984, and during his 20 year period he held the roles of President & Secretary.

He was first elected to ACA Council in 1993 and held various roles until 2004 including Australasian President in 1996 and served as the Chairman from 1999-2003.

Willie MandenoWillie has over 30 years’ experience in the field of protection of materials in New Zealand. He graduated with a Bachelor of Engineering (Civil), is a Chartered Professional Engineer and a Fellow of the Institution of Professional Engineers of New Zealand.

Willie has been an ACA Member since 1984 and has been a committee member of the New Zealand Branch in various roles including president from 1994-1995.

CORROSION & PREVENTION 2013 AWARDS

Xian Zhou received the Marshall Fordham Best Research Award.

Derek Northwood received the David Whitby Best Review Paper Award.


CORROSION & PREVENTION 2013AWARDS

He was Australasian President from 1999-2000 (following 2 terms as Vice President), and represented his branch on the Operations Committee from 1997-2010.

Willie was awarded the Corrosion Medal in 2008 in recognition of his work in the field of degradation of materials. The citation for that referred to the extensive work he had done in fields of science and technology of application of protective coatings on civil engineering structures in New Zealand. Willie has also been awarded the Best Review Paper (1991) and the Arthur Kennett Award (1996).

He has presented at ACA conferences for decades, has lectured extensively on NACE and ACA courses on coatings & coatings inspection and is still a member of the Corrosion & Materials editorial committee.

Corrosion MedalThe Corrosion Medal is the Association’s most prestigious award. It is bestowed for outstanding scientific or technological work in the field of corrosion in Australasia.

Maria ForsythMaria is currently the chair of Electromaterials and Corrosion Sciences at Deakin University. Maria has made internationally significant contributions to the field of Electromaterials Science. Her work extends from the development of important insights into the fundamental mechanisms that govern electrochemical processes, to the practical application of her expertise to battery materials and corrosion mitigation.

Overall, Maria has co-authored more than 270 publications in high quality journals including several in Nature and Science and her publications have received more than 8000 citations with a current citation rate of >1000 citations per year. She is widely sought after as an invited speaker at international conferences and was awarded The Dean’s Award for Excellence in Research at Monash University in 2007.

One of the key impacts made by Maria is in her training of young scientists and engineers in technologically important fields, and in particular the corrosion engineering field.

Maria has been an active member of the ACA for more than 20 years and has published and presented papers at ACA conferences since the early 1990s. She has facilitated the invitation of keynote, lead and international speakers to ACA conferences and has been a Reviewer for Corrosion & Materials for in excess of 15 years.

Peter Farinha received ACA Life Membership.

Willie Mandeno received ACA Life Membership. Maria Forsyth received the Corrosion Medal.


NEW PRODUCT SHOWCASE

SHOWCASEComprehensive materials analysis in a single benchtop unit

To provide affordable yet comprehensive compositional materials analysis at the structural and elemental level, Olympus has developed the BTX Profiler which combines X-ray Diffraction (XRD) and X-ray Fluorescence (XRF) analysis into a single, attractive benchtop instrument that won't break the bank.

The BTX Profiler’s non-destructive mineralogical and elemental analysis capability is of particular significance for several industrial sectors. According to Andrew Taylor, Regional Sales Manager with Olympus, the BTX can be used for single sample measurement or for unattended multi-sample measurements. The close-coupled transmission geometry

means that the device only requires a low powered X-ray source and a small amount of sample.

For further information, please contact:

Australia www.olympus-ims.com

Dorthe Svarrer, Sales & Marketing Coordinator Industrial Business Division Telephone: +61 (03) 9265 5467 E-Mail: [email protected]

New Zealand www.olympus.co.nz

Faizal Sahib Ph (+64) 9 836 9993 E-Mail: [email protected]

Olympus BTX Profiler

Tcorr Inspection has recently been appointed the Australasian agent for IRIS (Intelligent Reporting Inspection Software). IRIS is the definitive reporting software for the individual inspector; inspection, blasting and coating companies; and the engineering, oil, gas and mining industries. This intuitive versatile cloud-based software references most international Standards and provides excellent QA documentation. The workflow is direct and simply follows the usual path of any coatings inspection regime. For early subscribers, the App function for iPhone/iPad and Android will be

provided free which allows offline reporting. The data can then be uploaded to the main system once online. IRIS has been trialled on large scale offshore projects and small civil projects with great success. The IRIS software allows clients access to real-time inspection data and reporting.

For more information and a 7 day free trial period, visit www.iris-reporting.com

Alternatively, please contact:Andrew [email protected]: +61 419 821 799

IRIS (Intelligent Reporting Inspection Software)


SHOWCASESHOWCASE

NEW PRODUCT SHOWCASE

Industrial videoscopes enter a new era with the introduction of the Olympus IPLEX RX and RT models. The unique PulsarPic™ image processor reduces noise and sharpens images to produce exceptionally high-resolution images in low-light conditions and the WiDER™ (Wide Dynamic Extended Range) image processing capability enhances detail in shadowed and highlighted areas to produce bright, contrast-balanced images across the entire depth of field.

The rugged, compact design features ergonomic, lightweight handsets for quick-access to most operations as well as the Olympus power-assist TrueFeel™ scope articulation control. A daylight-view monitor allows accurate inspections even in direct sunlight. An intuitive icon-

based menu system allows quick and accurate selection of the right menu option.

For further information, please contact:

Australia www.olympus-ims.com

Dorthe Svarrer, Sales & Marketing Coordinator Industrial Business Division Telephone: +61 (03) 9265 5467 E-Mail: [email protected]

New Zealand www.olympus.co.nz

Faizal Sahib Ph (+64) 9 836 9993 E-Mail: [email protected]

Olympus introduces the IPLEX RX and IPLEX RT industrial videoscopes

Combining accurate gloss measurement with state of the art electronics the new Elcometer 407L Dual and Triple Angle Glossmeters have the ability to measure almost any surface finish – from high gloss to matt - at different measurement angles (20, 60 and 85 degree reflective angles).

The individual gloss measurement values, together with the date and time of measurement, can be stored into the Elcometer 407L’s internal memory. On board statistics provide the user with the highest, lowest, average and standard deviation for each batch of data.

User definable limits provide the User with instant feedback whether the

surface finish is acceptable or should be rejected.

All Elcometer 407L glossmeters have USB and Bluetooth® data output which allows readings to download to the ElcoMaster™ 2.0 Data Management Software (supplied with each gauge). Users can now generate instant professional gloss inspection reports, or combine gloss readings with climatic and dry film thickness measurements in one summary report.

For more information on the range of Elcometer 407L dual and triple angled glossmeters, please contact Paul Jenkins at Philro on 1300 503 610

New Elcometer 407L Dual and Triple Angle Glossmeter


Q: In what year was your company established?

A: 2005

Q: How many employees did you employ when you first started the business?

A: We started with three employees and at the end of our second year we completed construction of our current facility which enabled us to grow the business considerably.

Q: How many do you currently employ?

A: We currently employ 15 permanent employees and supplement with additional staff when needed. During full scale production, we run as many as 25 staff over 2 shifts.

Q: Do you operate from a number of locations in Australia?

A: Our primary operation is based out of our facility in Brisbane; however a large percentage of our business is for the export market. We are currently completing the coating of the new jetty at Christmas Island. We are fully equipped with mobile blasting equipment.

Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.)

A: Our core business includes abrasive blast cleaning, and the application of a full range of high quality protective coatings. Our company has a reputation for producing high quality work.

Q: What markets do you cover with your products or services? eg: oil &

gas, marine, chemical process, general fabrication, tank lining, offshore etc.

A: We service a broad spectrum of clients from transport, mining, oil & gas including internal pipe and tank work, heavy fabrication and engineering industries and the commercial building industry.

Q: Is the business yard based, site based or both?

A: While the bulk of our work is carried out at our facility we have recently completed a number of large scale site based projects including One One One Eagle Street and the newly opened Eye of the Storm ride at Sea World. We are fully equipped with mobile dust collectors, mega blaster and spray painting ventilation systems.

Q: What is your monthly capacity or tonnage that you can blast and prime?

A: Our facilities are equipped with two 20 metre drive through heated booths which allows us high capacity production year round.

Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.)

A: In addition to our core business, we offer transportation and site work project management and technical support.

Q: What is the most satisfying project that you have completed in the past two years and why?

A: One One One Eagle St, an award winning, $700 million building in Brisbane’s CBD. We built 25 individual spray booths and painted 52, 16 metre

high mullions in the foyer in a satin mono metallic polyurethane. The job was conducted without any disruption to the several thousand office workers and visitors who access the building and the project was completed a month ahead of schedule and on budget.

This project showcased our versatility and ability to deliver a quality outcome

Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job?

A: Think outside the box when it comes to finding solutions to difficult jobs. Understand the client’s expectations and manage the job closely and communicate the expected result to the team.

Q: Do you have an internal training scheme or do you outsource training for your employees?

A: Training is a big part of continuous improvement under ISO 9001 requirements. We utilise both our in house expertise and outsource specialist training.

Brisbane Abrasive Blasting Bay 6/451 Sherwood Rd Sherwood Qld 4075 PO Box 323, Brisbane Market Qld 4106 Phone: 07 3278 6833 Fax: 07 3278 6933

Brisbane Abrasive Blasting

COATINGS GROUP MEMBER PROFILE


UNIVERSITY PROFILE

With approximately 22,000 students Charles Darwin University is the Northern Territory's major tertiary institution. Campuses and education centres are located across the Northern Territory, in Palmerston, Tennant Creek, Yulara, Jabiru, Katherine, Nhulunbuy (Gove), Alice Springs and the University's main campus in Casuarina, Darwin.

The University offers a wide range of courses, from VET through to undergraduate and postgraduate, and is fast gaining a national and international reputation for excellence in both teaching and research, and is currently ranked in the top 2% of the world’s universities by the Times Higher Education World University Rankings, refer to http://www.cdu.edu.au/international/rankings. Research is a key component of Charles Darwin University's strategic vision – approximately 25 per cent of all research and development carried out in the Territory is conducted by the University.

The School of Engineering and Information Technology offers courses in engineering and information technology in both on-campus internal mode as well as in distance mode. The North Australian Centre for Oil and Gas (NACOG) was recently established to build skills and provide research and training capacity to help the recent oil and gas boom in North Australia. The Centre has a research and teaching role.

One of the research themes of the Centre is corrosion engineering. The Centre also carries out research into multiphase flow behaviour.

Corrosion is a major problem in the tropics with higher than average temperatures and humidity. Recently, research on microbiologically influenced corrosion, or MIC, was initiated to see how tropical waters affected the corrosion of AA5083 material. Since welding is a widely used joining method, weldments were included in this research. It was found from preliminary experiments that in general base material corroded at a much higher rate than what was reported in literature. We believe that microbes may be the cause of this increase. The research was carried out in specially maintained facility at the Australian Institute of Marine Sciences (AIMS) in Darwin. DNA testing of the biofilm was carried out by the AIMS researchers and showed a whole range of bacteria including the often quoted microbes, sulphate reducing bacteria. This work is still in progress.

Staff at CDU also have a keen interest in the corrosion issues of the mining sector, as this sector contributes significantly to the NT economy. Hardfacing alloys are used as overlays in the mining industry to combat wear. The most popular of the alloys is the one based on chromium carbides. These are often used in situations where corrosion resistance is also needed such as in the alumina industry which involves high pH and abrasive particles. It is well known that chromium can provide corrosion resistance in a limited pH range and chromium carbides remove chromium from the matrix. A study has been initiated to look in to the corrosion behaviour of chromium carbides under different pH and with different alloying elements.

Charles Darwin University has been helping the local industry by providing advice on matters related corrosion mitigation and selection of materials. The annual conference of the ACA in Darwin in September will further highlight the issues of corrosion in Darwin.

ContactAssoc Prof Krishnan KannoorpattiSchool of Engineering and ITCharles Darwin UniversityDarwin NT [email protected] 08 8946 6219

Charles Darwin UniversityNorth Australian Centre for Oil and Gas

Fig.1 Hand rail on bridge across Elizabeth river in Palmerston. The handrail is anodised and dyed to a golden colour. Very little corrosion seen.

Fig.2 Palmerston fishing jetty – In contrast to the structure in Fig.1, the structure is partially immersed during high tide. Marine organisms have attached themselves to the structure. Very little is known about the effect of biofilms and microbes on the corrosion behaviour of aluminium. CDU is carrying out research on this aspect.


Brisbane Abrasive Blasting


INDUSTRY INSIGHT

Tanks for the Refreshment:volume transport of clean, healthy essentials of life

Not by road alone – Milk by rail in New ZealandHow can a country with 0.1% of the world’s population produce 2.2% of the world’s milk and do it in a way that takes trucks off the roads and reduces the carbon footprint of milk production? There is no single answer but part of the solution is transport of raw milk by rail.

It was in 1929 that the first road tanker made of Type 302 (UNS S30200) stainless steel was used to transport raw milk to a dairy, and stainless steel milk tanks have been used continuously ever since. And in countries where the production of milk is particularly intensive and the volumes are high, even railways are called into service.

Railways excel at moving bulk liquids. Over the years, improvements in insulation and cooling equipment have resulted in purpose-built rail-mounted stainless steel milk tanks capable of carrying large volumes of raw milk from rail-head milk tanks to receiving stations at a dairy factory. These containers are “intermodal”: they can be shifted from one mode of transport

Tanks are everywhere. In their infinite variety of shapes, sizes and uses, they are vital to a functioning society.

When it comes to food, however, and chances of contamination or colonization by bacteria, there is only one reliable

candidate. That is why trucks with stainless steel tanks carrying edible oils, sugar, milk and all the other raw

materials that go into the manufacture of foodstuffs are common sights on highways and, on occasion, railways.

Less commonly, they are used to transport potable water. The reasons, however, remain the same: longevity,

strength, corrosion resistance, and ease of cleaning and sanitation.

Four times every day dedicated milk trains pass through the New Zealand countryside carrying raw milk to a processing plant. Photo courtsey Andrew Hamblyn.

Originally published in Nickel, October 2013 Issue Volume 28-3, published by the Nickel Institute


INDUSTRY INSIGHT

(such as a truck) to another (such as a rail car).

Two sizes of rail-mounted inter-model tanks are in use: one of 40,000 litres (about 10,000 gal.) made of Type 316L (S31603) and one, such as seen below, of 25,000 litres (about 6,600 gal.) made of Type 304 (S30400). These are called “iso-containers” because they conform to the International Organisation for Standardisation standard for refrigerated milk containers. Construction and maintenance of road and rail-mounted milk tanks must also comply with globally recognised 3-A sanitary standards.

New tankers for old – Clean drinking water when and where needed in New DelhiIndia differs from New Zealand in every metric imaginable and faces different challenges: old infrastructure or lack of new infrastructure in fast-expanding urban mega-cities; climatic extremes of heat and drought; constrained water supplies and falling water tables. These are some of the realities facing many large cities in India and New Delhi, the country’s second-largest, is a case in point.

The water authority for the New Delhi National Capital Territory has long maintained a fleet of water tankers and in times of need they can supply minimum local needs until repairs are made, additional capacity is installed, or the summer heat abates.

This long-standing service had traditionally used carbon steel tankers, the interiors of which were periodically painted with a coal tar paint to slow the inevitable corrosion. But the injurious chemicals that leached from the coatings, together with increasing volumes of rust particles as the tanks aged, led to many complaints about the quality of the water.

The recent decision to privatise this part of the water distribution system provided an opportunity to review the state of the equipment and see if something better could be found. It was quickly seen that nickel-containing stainless steel was the preferred material to replace carbon steel tanks.

Why stainless steel?Stainless steel does not require the coal tar lining of the previous generation of water tankers. This has an immediate

positive impact on the acceptability of the water to consumers and removes a long-term health hazard. While taste may be of lesser importance when you are lacking water, the fact that stainless steel does not affect the flavour of water is also welcome.

The tanks are expected to give many years of service and carry thousands of loads. As a matter of good practice, their interiors will be regularly cleaned and rinsed. Ordinary soap and water is sufficient most of the time. If, however, some contamination is accidentally introduced into the tank, stainless steel will tolerate whatever strong cleansing or disinfecting agents are needed to restore it to a safe state.

While identifying the most appropriate material for the water tanks was not difficult, there were initial concerns about the cost differential between carbon steel and stainless steel. This changed when the Delhi water authority and its contractors took into account the low maintenance and repair requirements of stainless steel tanks. This means a higher availability of the equipment and, overall, fewer trucks to achieve the same distribution capacity. Moreover, the projected service life of the tanks is five times longer than the typical three to four years associated with carbon steel tanks. Seen in this light, the apparently “expensive” stainless steel was highly competitive.

The picture improved even further when the superior strength of the stainless steel allowed a thinner gauge of sheet (4 mm) to be used. Depending on the size of the tanker, the total weight is between 500-1,100 kg (1,100-2,400 lbs.) lighter than the old carbon steel versions. The fuel savings over the life cycle of the tanker are expected to be significant and, in addition, air pollutants will be proportionately reduced.

Thus in January 2013 the first of 385 truck-mounted water tanks made of Type 304 (UNS S30400) stainless steel entered service in the National Capital Region of New Delhi.

“We are so pleased ” said Mr. R.S. Tyagi, Chief Engineer of the Delhi Jal Board. “We knew stainless steel was the best material for the purpose but going through the process of calculating the true cost of different material choices made stainless steel the clear winner.” The other winners, of course, are the citizens of New Delhi who will be receiving clean, safe and refreshing water in times of need.

Ready for the streets and suburbs of New Delhi: one of the fleet of new water distribution trucks with their nickel-containing stainless steel tanks. Photo: Firoz Alam/Fabtech Industries.


The major rail station upgrades and new developments associated with the Adelaide Metro rail electrification project successfully demonstrate that oversize components on large-scale projects, otherwise considered too big for existing plant capacity, can be hot dip galvanized (HDG) to overcome a major limiting factor when considering corrosion protection options.

These rail stations demonstrate that while it is not always possible to break components down into single dip sections if all parties embrace the use of double dipping, the long term benefits afforded by HDG can be realised.

The rail electrification project included major redevelopments of both the Elizabeth and Munno Para stations on the northern Gawler line and construction of two major rail stations at Seaford and Seaford Meadows on the southern line as part of a 5.7km dual track extension.

These projects required station work creating safe, attractive and welcoming transport infrastructure that is user friendly and economical.

Across the four rail stations a total of 850 tonnes of structural steelwork was galvanized comprising platform canopies and heavy pedestrian overpasses, lift towers and access stairs as well as ancillary steelwork

including sign gantries over the rail tracks, lighting towers, bike sheds and decorative screens.

The high hardness and durability afforded will significantly reduce ongoing maintenance costs by resisting attempts at vandalism, a major concern given they are high traffic amenities which provide idle time while waiting for trains.

The challenges posed by the design of key components were identified early on with all stakeholders to ensure fabrication detailing for a quality result.

The fully enclosed pedestrian overpasses, lift towers and enclosed stairs for each station required early intervention during the design process, to ensure they could be broken down efficiently to enable HDG. Segments were up to 3.6 to 3.8 metres high, up to 10 metres long and weighed up to five tonnes, thus comprising large double dips.

Once fabrication commenced, the galvanizer was in constant contact with the fabricators, particularly with respect to the draining and venting of the large rectangular hollow section frame segments for the pedestrian overpasses, lift towers and access stairs. Initial concerns over the adequacy of shop repair when welding the segments together were allayed with the assistance of the GAA technical note on this topic.

Not only will the likely reduction in vandalism damage contribute to lower maintenance costs and reduced volatiles from paint repair, the reduced risk of degraded visual amenity going forward should encourage commuters to use the rail network in greater numbers.

With a key requirement of the rail station projects being the provision of attractive and welcoming structures to promote patronage, HDG provides a vital contribution to overall project aesthetics.

PROJECT PROFILE

Galvanized Finish Guards New Rail Work

Provided by Galvanizers Association of Australia


PROJECT PROFILE

These station works for a major railway electrification project in South Australia earned the 2013 Sorel Award for Galvanizers Association of Australia (GAA) member, Korvest Galvanisers, primarily for its treatment of impressively large-sized assemblies for a group of railway stations encompassing pedestrian overpasses, lift towers and enclosed stairways. The judges said that the winning Korvest Galvanisers’ entry scored highly on its market development potential and technical innovation, by demonstrating

that a high quality HDG coating can be applied to oversize assemblies without coating blemishes or distortion.

Project TeamDeveloper/Owner: South Australian GovernmentSpecifier: SA Department of Planning,

Transport and InfrastructureProject Managers: York Civil, Thiess/McConnell Dowell Construction and BardavcolMain Contractors: Manuele Engineers and Advanced Steel FabricationsHot Dip Galvanizer: Korvest Galvanisers

1. No hold ups due to weather – steel can be galvanized in any weather conditions

2. Speed – modular design compatibility to speed up construction

3. Tough coating system – reduces transport damage & minimises on-site repairs

4. Inbuilt durability – minimises in-service damage from vandalism & accidental knocks

5. Withstands UV – the surface is immune to damage from the extreme Australian sun

6. Superior corrosion protection – provides initial and lifetime cost savings

7. Aesthetics – natural good looks

8. Sustainable – Zinc and steel are 100% recyclable

Eight Reasons to Choose Hot Dip Galvanizing


Protection of Water and Wastewater Concrete Structures - Pitfalls & Common Site IssuesThe Issue: Protection of concrete structures in potable water and waste water assets in today’s economic environment is a very expensive technical process for all parties involved. Down time of the Asset for any period of time can be an inconvenience to the community and expensive in terms of lost output and production.

The reason for protecting these concrete structures may be to refurbish, upgrade or expand an existing asset after years of exposure to the elements or environment it was designed for, and/or to extend the structures life.

A new Asset can be required because the existing structure is past its use by date, population growth in a region requires new infrastructure to be built to cope with local demand, or new technology is required to be installed, i.e. odour control, or replacement of worn out equipment.

Regardless of whether it is a new build or a refurbishment project, many different people and companies come together with a common goal, we hope, to get the job done on time, on budget, with a quality outcome that meets the specification, with all making a reasonable return from the project, plus making the owner happy.

The following article discusses some of the different processes that may take place before a coating system is installed, and how these processes in the early stages can impact on the end result and life of the coating.

IntroductionProtecting concrete structures in waste water and potable water environments can be time consuming and costly if not carried out correctly by experienced contractors. There are a vast number of coatings available these days from many suppliers both local and international. Coatings can include thin film coatings or high build depending on the application and the environment the coatings have been designed to handle.

Anyone that has been involved with an ACA coatings course will remember the common phrase, “Preparation is the key factor in any project’s success”. This statement is not only relevant to a coating but relevant to many other areas in construction process leading up to the coating’s installation. Regardless of the coating system or the supplier, surface prep and during the construction all people and stages need to be prepared in order to obtain a successful result.

Common Issues That Affect Long Term Performance:Unfortunately, as a supplier we receive calls saying our coating has failed but when we visit the site or check how the material was applied or mixed, we see that a number of issues during the construction process that resulted in the coating not performing as was expected. The coating is usually installed in the later stages of the project when the budget is getting down to the wire.

Many reasons can contribute to site related coating issues, and the following will highlight just some of these. Some of the common site-related issues can include:

Supervision- inexperienced supervisors, or a supervisor being spread too thinly around the site. Not being aware of the requirements of the contract or the standard of concrete finish required that can affect the quality of the coating finish.

Construction techniques- A simple oversight can cause a huge problem down the track, not cleaning out the forms before pouring as an example. Old form work or steps between formwork sheets result in a poor finish and this can affect the performance of the after trade. The subcontractor pricing the coating usually has not allowed for correcting these issues in his quote.

Placement of the concrete- Poor compaction, waterstops not placed correctly resulting in leaks, tight locations for concrete to flow into voids, boney concrete, through bolt

holes not filled correctly and leaking, low cover to reinforcing steel.

Concrete quality- Not constructed as per the specification requirements- i.e. Class 3 finish, in accordance with AS 3600-2009- Concrete Structures, AS 3610-1995 Formwork for concrete, AS 3735-2001 Concrete Water retaining structures, all involved with these structures should be aware of the relevant Standards in place. Most specifications refer to these Standards but is everyone aware of what they say? or have the contractors read them? Litigation-If there is any litigation these are the first documents, after the contract and specification that are referenced.

Surface preparation- Issues during construction may lead to the substrate not being delivered as specified, which means the coating applicator has to spend for time and money to prepare the substrate. Even the use of a curing compound that was not specified may have to be removed. The builder may decide to do the prep to save time and funds. This can create an issue in itself. If problems arise who is responsible? What if the prep isn’t satisfactory to the contractor, will the builder pay for the extra prep.

The coating- When the funds are getting tight the scope may change and this can result in short cuts being taken, for example we have seen instances where pin holes aren’t filled or the coating is thinner than the specification requires, or the surface isn’t flat enough (Figure 1 & 2). All these factors can affect the performance, durability and longevity.

Installation- If the contractor makes a decision to disregard the published technical data by changing the installation process (as they have been doing it their way for 20 years). The industry has changed significantly with better QA checks on site, for example by conducting spark testing looking for holidays in the coating, which is a great step forward.

INDUSTRY INSIGHT


What makes a good long term coating from a supplier’s point of view? Initial field trials in similar

environments. Some materials field trial can take 5-10years of testing before it goes to market.

Clean surface with a good surface profile for a good key, holidays/ pinholes filled and faired up with appropriate repair products.

Correct film thickness builds.

Following recoat times, mixing methods and application methods as stated on datasheets and published literature.

Adapting to the site conditions, temperature, wind, dew point, surface prep between coats if necessary.

If a problem arises stop fix the problem and move on. It is better to stop and have a 50m2 problem than continue and have a 2000m2 problem.

Case Study No.1- Extending the life of a structure- “If it sounds too good to be true it probably is.”This project shows a concrete inlet works suffering from H2S attack. The coating selected was sold as a new

technology material that can be applied without stopping the flow and can be applied from above without entering the confined space and having excellent resistance to H2S. The substrate was a very rough, 10mm profile, with only a thin film applied approximately 0.5mm, (Refer to Figure 3). How do you measure the film thickness on such a rough surface? During a routine inspection approximately 3 years later the coating was almost non-existent with a further 100mm - 200mm of concrete severely attacked.

The end result was a premature failure of the coating, which may have been a perfectly good coating but not provided with a suitable substrate to perform properly. Poor surface preparation prior to the coating resulted in structural damage that required a hefty repair bill. The solution sounded too good to be true and it was. The coating could have been a great product but a missing step in the process prior to the coating let it down.

Case Study No.2- Specification, Surface Preparation and Code Compliance- the perfect Storm This project indicates what can happen when a number of quality issues

prior to the coating application come together with the end result being poor outcomes, double handling or double processes for all concerned and potentially an expensive legal bill. No one wins except lawyers in legal cases.

This project was running behind with civil works almost complete, the mechanical team were waiting for this structure to be finished as it was a critical path item.

The concreter/ form work contractors had cash flow issues and as a result the quality wasn’t what it should have been; cutting corners, reusing old form work, not cleaning out forms, poor compaction of the concrete, the list was long. Quality concerns were raised on the project relating to class of finish Class 2 and Class 3 finishes in the specification etc. The builder decided to do the surface prep for the coating contractor to save time as lost time charges were about to be applied. This structure needed to be completed so the progress claim could be made.

The first coating was removed and revealed many quality issues not previously seen; formwork not cleaned, through bolts not filled correctly, low cover, repaired leaks had injection ports at the surface, nails, cold joints and poor quality mortar systems used, water leaks. All the surface preparation was taken over by the builder to save money and what they thought …time.

There are also concerns with the builder preparing the substrate for the coating contractor. Once the coating subcontractor starts to apply the coating they have accepted the preparation work. This should be considered by the specialist applicator and whether the builder has the appropriate skills to complete these works, in this project they did not.

INDUSTRY INSIGHT

Figure 1: Poor substrate for a coating- Blow holes, foreign objects, powdery surfaces.

Figure 3: Previously completed work. Thin film coating applied to a rough surface. How can the client know he received the coating thickness he asked for and was pinhole free?

Figure 5: Epoxy coating applied to tank. Many patches due to poor surface preparation and many pinholes.

Figure 2: Non flat surface, leaks in formwork, expensive repair costs for the applicator, will he get paid?

Figure 4: Premature failure of the coating with Asset virtually now past its serviceable life.


INDUSTRY INSIGHT

Conclusion From the discussion points above it can be seen that it is important that all people are working together to ensure a satisfactory result for the client. If one or a number of steps are not carried out correctly in the construction process this can lead to a premature failure in the coating, reducing the life expectancy of the Asset or lead to expensive rectification and shut down costs. It can even result in expensive legal cases that drain huge amounts of time and funds, not to mention damaging relationships for future work.

Therefore it is extremely important that the works are carried out by individuals and companies that are aware of the contract specification, have knowledge of /or familiar with the relevant Australian Standards where applicable’ or the manufacturer’s technical information. They also need to work closely together allowing each to carry out their required roles. Again it is important to say that if an issue arises, stop and fix the problem then move on. Having to go back later and repair failures can become very costly and inefficient.

Lastly, the cheapest tenderer may not be the most suitable when the decision process is being made on a performance based outcome, as the cheapest price could indicate lower experience levels or insufficient allowance for preparation. Buy cheap, and do it twice or three times- nobody wants this.

Grant Dowling Sika Australia Pty Ltd

Figure 6: Non-conformance to Class 3 finish to concrete. Figure 7: Low cover can affect the durability.

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