choosing a qualified contractor and choosing

Choosing a Qualified Contractor andChoosing a Qualified Contractor andSurface Preparation & Coatings

P t d bPresented by: David Van Zee

NACE Certified Coating Inspector # 9285NACE Certified Coating Inspector # 9285 SSPC CCI # 21145

Brian HuffmanProtective & Marine Coatings Rep

Sherwin-Williams Protective CoatingsSSPC CCI # 21154

What is corrosion?What is corrosion?According to the National Association of Corrosion g

Engineers, (NACE):

Corrosion is the deterioration of a material, usually a metal, because of a reaction with its environmentenvironment.

The cost of corrosion in the United States wasThe cost of corrosion in the United States was estimated at $300 Billion in 1994, representing 4.5% of the GNP.

Causes of corrosion in W&WWCauses of corrosion in W&WW

A corrosion cell on steel in comprised of 4A corrosion cell on steel in comprised of 4 components and all must be present for corrosion to take placecorrosion to take place Anode

Cathode Cathode Metallic Pathway

Electrolyte Electrolyte


Since an anode and cathode can exist onSince an anode and cathode can exist on the same piece of steel, the only protection mechanism is to remove theprotection mechanism is to remove the electrolyte from the equation. Coatings protect by three basic principlesprotect by three basic principles. Barrier Protection

Inhibitive Protection Inhibitive Protection Sacrifical Protection


Concrete degradation can take placeConcrete degradation can take place through many different factors. Some of the key factors are:the key factors are: Chemical Attack

Erosion Erosion Microbial Induced Corrosion

Poor Construction Poor Construction


Concrete degradation can be reduced orConcrete degradation can be reduced or stopped by protecting the structure from it environment through barrier protectionenvironment through barrier protection methods

Rust issues in a pipe galleryRust issues in a pipe gallery

More close up examplesMore close up examples

Steel tanks and corrosionSteel tanks and corrosion

Concrete issues on a clear wellConcrete issues on a clear well

Close up of concrete tanksClose up of concrete tanks

Concrete degradation on a clarifierConcrete degradation on a clarifier

You have corrosion now what?You have corrosion now what?

Have project specified by a qualifiedHave project specified by a qualified professional

Manufacturer / material supplier Manufacturer / material supplier Engineering group

Qualified industrial painting contractor Qualified industrial painting contractor Previous coating specification

What is a written specification?What is a written specification? Websters 20th Century Dictionary defines a y y

Specification as:

A particular and detailed description of a thing: specifically a statement of particulars describing the dimensions details or peculiarities of anythe dimensions, details, or peculiarities of any work about to be undertaken as in architecture, building, engineering, etc.

A typical specification includes:A typical specification includes: General description Substrate preparationp Reference standards

and codes

p p Repairs / remediation Material selection

Scope of work Safety / Insurance

Coating application Mil thickness

Pre-job conference Coating materials

S li i

Work schedule Inspection

Sampling coatings Workmanship

Documentation

Why is the specification important?

When developing or writing anyWhen developing or writing any specification, the goal should be to produce a clear concise and technicallyproduce a clear, concise and technically correct document. This goal is seldom more difficult nor the risk so great asmore difficult, nor the risk so great as when writing specifications for High-Performance Coatings Tank Linings orPerformance Coatings, Tank Linings or Corrosion Protection Systems for steel and concrete surfacesand concrete surfaces.

Why is a specification so important h f ili ?to the facility owner?

Shifts responsibility to a professional moreShifts responsibility to a professional more qualified to access problems and solutions

Most important step toward a qualityMost important step toward a quality completed project

Allows for apples-to-apples proposalAllows for apples to apples proposal comparison

Outlines to contractors exactly what isOutlines to contractors exactly what is required to complete the job

Guarantees a predictable end resultGuarantees a predictable end result

How to choose a quality contractorHow to choose a quality contractor

Certifications: NACE Coating Inspector Program, g p gSociety for Protective Coatings program

Experience level references from other municipalities Insurance coverage Insurance coverage Quality Assurance program What does the contractor

do to ensure a quality end-result Safety program Compliance with OSHA and EPA

standards Request list of approved industrial contractors fromRequest list of approved industrial contractors from

manufacturer

What to consider in managing a i jcoatings project

Timing / scheduling / down timeTiming / scheduling / down time Budget / pricing Service life of assetService life of asset Disruptions to operations Environmental impact Environmental impact

Removal of existing coatings facility owner disposal or contractor disposal p

Lead concerns is there lead present? Safety

When things go wrong da case study

Neutralization tank at WWTP needed repairNeutralization tank at WWTP needed repair Plant manager received multiple proposals

to fix problems internal and externalto fix problems internal and external Different solutions were offered Bids were approximately $1,000 apart Contractor was chosen, repairs were , p

completed

Tarboro NC -- February 2008Tarboro, NC February 2008

Steel tank with concrete floorSteel tank with concrete floor

A leak was noticed; the tank was d i d li h f il d li idrained revealing the failed lining

6 months later summer 20086 months later summer 2008

Failure: 100% - floor 50% - wallsFailure: 100% floor, 50% walls

Exposed aggregate on tank floorExposed aggregate on tank floor

Wholesale failure of lining systemN h ?Now what?

Plant manager requested new proposalsPlant manager requested new proposals based on current situation

NACE certified coating inspector consulted NACE certified coating inspector consulted to conduct failure analysis and manage projectproject

Original contractor currently on site i ti d t tiremoving coating and starting over

Impact of these problems:Impact of these problems: Headaches for plant manager to deal with p g

problem again Additional expenses:

Down time to take tank out of service again Charges for coating inspector to consult and manage

projectproject Expenses to repair exterior damage

Fortunately the rake arm and other equipment was not damaged with the failure of the system

Potential legal issues

Benefits of hiring a quality contractor

Partner to help solve maintenance problemsPartner to help solve maintenance problems Anticipate possible issues Manage project around your operationManage project around your operation Long-lasting, quality finished project Assume some of the risks Assume some of the risks Stand behind their workmanship You get the project done right the first time You get the project done right the first time

saving you time, money, etc.

Painting: Its all in the prep!Painting: It s all in the prep!

60% - 80% of premature coating60% - 80% of premature coating failures are due to poor / substandard

f tisurface preparation

Surface preparationSurface preparation

Purpose ConsiderationsPurpose

Clean surface

Considerations

Exposure conditions Remove rust Provide anchor profile

Generic type coating Economics

Promote adhesion Environmental and safety

Surface prep noteSurface prep note

Paints adheres to the surface by mechanicalPaints adheres to the surface by mechanical and / or chemical bond

Whatever interferes with that bond will also i t f ith dh iinterfere with adhesion

Surface preparation standardsSurface preparation standards

The basic standards for preparing metalThe basic standards for preparing metal substrates are a joint effort between:

The Society for Protective Coatings, (SSPC)(SSPC)

National Association of Corrosion Engineers, (NACE)

Standards and MethodsStandards and MethodsSSPC-SP 1 Solvent cleaningSSPC-SP 2 Hand tool cleaningSSPC-SP 3 Power tool cleaningSSPC-SP 5 / NACE 1 White metal blast cleaningSSPC SP 6 / NACE 3 Commercial blast cleaningSSPC-SP 7 / NACE 4 Brush-Off blast cleaningSSPC-SP 8 PicklinggSSPC-SP 10 / NACE 2 Near-white blast cleaningSSPC-SP 11 Power tool cleaning to bare metalSSPC-SP 12 / NACE 5 Surface preparation and cleaning p p g

of steel and other hard materials by high and ultra-high water jetting

SSPC-SP 13 /NACE 6 Surface Preparation of Concrete

SSPC-SP1SSPC SP1

Solvent CleaningSolvent CleaningRemoval of oil, grease, dirt, soil and

contaminants by cleaning with solventcontaminants by cleaning with solvent, vapor, alkali, emulsion or steam

This is the first step dictated by all surface preparation methods!

SSPC-SP2SSPC SP2

Hand tool cleaningHand tool cleaningRemoval of loose rust, loose mill scale and

loose paint by hand chipping scrapingloose paint by hand chipping, scraping, sanding and wire brushing

Loose is described as what can be removed with the edge of a dull putty knife

SSPC-SP 3SSPC SP 3

Power tool cleaningPower tool cleaningRemoval of loose rust, loose mill scale and

loose paint by power tool chippingloose paint by power tool chipping, descaling, sanding, wire brushing and grindinggrinding

Loose is described as what can be removed with the edge of a dull putty knife

SSPC-SP6 / NACE 3SSPC SP6 / NACE 3

Commercial blast cleaningCommercial blast cleaningRemoval of all visible oil grease, dust, dirt,

mill scale, rust, coating, oxides, corrosionmill scale, rust, coating, oxides, corrosion products, and other foreign matter when viewed without magnification for at least g66.6% of a 9 square inch area

Random staining shall be limited to no more than 33% of each unit area

SSPC-SP 10 / NACE 2SSPC SP 10 / NACE 2Near white blast cleaninggRemoval of all visible oil, grease, dust, dirt, mill

scale, rust, coating, oxides, corrosion products, and other foreign matter when viewed withoutand other foreign matter when viewed without magnification for at least 95% of a 9 square inch area.

Staining consisting of light shadows, slight streaks, or minor discolorations caused by stains of rust, o o d sco o at o s caused by sta s o ust,mill scale, or previously applied coatings shall be limited to 5% of area.

SSPC-SP 12 / NACE 5SSPC SP 12 / NACE 5Surface preparation and cleaning of steel andSurface preparation and cleaning of steel and

other hard materials by high and ultra-high pressure water jetting prior to recoating

Level of standard is determined by amount of pressure.

SSPC-SP12 / NACE 54 l l f l i4 levels of pressure cleaning

Low pressure water cleaning: cleaning performed at pressure less than 5,000 PSI

High pressure water cleaning: High pressure water cleaning: cleaning performed between 5,000 and 10,000 PSI

High pressure water jetting:High pressure water jetting: cleaning performed between 10,000 and 30,000 PSI

Ultra-high pressure water jetting: g j g cleaning performed at pressures above 30,000 PSI

SSPC-SP13 / NACE 6SSPC SP13 / NACE 6Surface Preparation of Concrete

Gi th i t f fGives the requirements for surfacepreparation of concrete by mechanical,h i l th l th d i tchemical, or thermal method prior to

the application of bonded protectivecoating or lining systemscoating or lining systems.

A minimum concrete surface strengthA minimum concrete surface strength,maximum moisture vapor emission rate, andsurface profile range should be specified insurface profile range should be specified inthe specification.

Coating InspectionCoating Inspection

Someone once wrote inspect what youSomeone once wrote, inspect what you expect.

A certified professional coating inspector can A certified professional coating inspector can be the most cost effective insurance policy that an owner can purchase.p

Coating InspectionCoating Inspection

With todays technically advancedWith today s technically advanced coatings and application methods this is a task that should not be left to a generaltask that should not be left to a general construction inspector or the consequences could be enormousconsequences could be enormous.

Certified professional coatings inspectors use tools specifically design to insureuse tools specifically design to insure compliance with your specification.

Replica Tape for Measuring Surface Profile

SSPC-VIS 1-89SSPC VIS 1 89

VIS 1-89Initial Conditions

Mill Scale Mill Scale & Rust

Uniform Rust Uniform Rust & Pitting

SP6 Commercial BlastSP6 Commercial Blast

Start With Rust Grade BStart With Rust Grade B Start With Rust Grade DStart With Rust Grade D

SSPC-VIS 3SSPC VIS 3

SSPC VIS 4SSPC-VIS 4

Sling PsychrometerSling Psychrometer

Surface ThermometerSurface Thermometer

ICRI No. 03732 CSP Surface Profile Replica Coupons

ICRI Concrete Surface Profile C Co c e e Su ce o eReplicas

Before AfterBefore After

No more rustNo more rust

Look at those nuts, bolts and fl !flanges!

Rust No RustRust No Rust

Before and after of a steel tankBefore and after of a steel tank

And heres another oneAnd here s another one

5MG clear well cleaned and i dpainted

Clear well and back wash tankClear well and back wash tank

Beautiful finish on this clear wellBeautiful finish on this clear well

It sure was ugly!It sure was ugly!

Repaired and coated clarifierRepaired and coated clarifier

And another shot or twoAnd another shot or two

Questions?Questions?For more info contact: For more info contact:

David Van Zee Brian HuffmanCarolina Management

Team, LLCPO Box 1409

Sherwin-Williams Co.Protective Coatings

OPO Box 1409Enka, NC 28728828-648-7708 office

113 Oakwood DrWinston Salem NC 27103

336 558 3335 mobile828 648 7708 office919-414-8867 mobile

www.CMTcoatings.com

336-558-3335 mobile336-725-3066 fax

[email protected] [email protected]

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