how to avoid premature coating failures

How to Avoid Premature Coating Failures

Presenter: Regis Doucette Chlor*Rid Intnl., Inc. (201) 664-5487 [email protected] Removal of Soluble Salts After Detecting Their Presence

CSI Webinar 10/19/10

AwarenessRecognitionElimination

Objective: Reduce liability of premature coating failure from corrosion with better knowledge and field-tested specification detailsGoal: Achieve full life cycle coating performance

Coating project costs: 80/20 rule applies 80% Surface Preparation 20% Coating

NACE Eastern Area Conference, Oct. 12, 2010

Why salts are a big issue? Lead based coatings are banned. Lead formed insoluble salts.Visual standards are insufficient. Salts are nonvisible.Specifications may not adequately address nonvisible contaminants. Residual salts are a leading cause of premature coating failure.Testing and removal is always much less than the cost of premature failure.Salts are a controllable variable!

Uhlig and ReviesCorrosion & Corrosion Control:The most important single factorinfluencing the life of a paint isthe proper preparation of the metal surface

H. Mitschkes award winning 2001 JPCL article: A 1g/cm2 increase in chlorides has the potential to reduce coating life by 50%.


Reality CheckPrior to 1995, it is estimated that at least 3 out of 4 contractors suffered major failures during projects or shortly thereafter. Most coatings did not survive more than 5 to 7 years. Now with changes, including (soluble salt remover), we have an approximately 70 to 90% reduction in lifecycle costs, have reduced premature coating failures and increased service life.

Non vendor specific edit

What are Soluble Salts? Ionic contaminants Water soluble inorganic compounds Primarily chlorides, sulfates, and nitrates Non-visible contaminants Can bond electrochemically to the metal substrate

Sources Marine environments (sea water-chlorides) Abrasives (chlorides/sulfates) De-icing salts (chlorides) Environmental fallout & acid rain (sulfates/nitrates):Stack gasesAuto/vehicle emissions Chemical processes/plants & power plants (many combinations of salts) Water and sewage treatment facilities Lightning

Sulfuric Acid Reigns Supremehttp://www.turi.org/library/turi_publications/massachusetts_chemical_fact_sheets

SulfatesChloridesNitrates

Non-visibleVisually clean substrates are not adequate

Soluble salts require testing to be detected

Which salt is the problem? - Primarily dependent on service environment

Pinky fingerprint approximates 1 square centimeter

M&M candy sliced into one million pieces --single slice = 1 microgram

Salt packet from McDonalds for fries --disolved in water --then spread over 1,000 sq ft would deposit 1 microgram per square centimeterg/cm2

Microgram per square centimeter

Relative Size Chart40 mil

Perspective -- SizingHairBeach Sand

Chart1

1000

100

10

0.1

0.001

Relative Size

Sheet1

Relative Size

Beach Sand1000

Human Hair100

Bacteria10

Virus0.1

Soluble Salts0.001

To resize chart data range, drag lower right corner of range.

Detrimental Effects of SaltsInterferes with adhesionAccelerates corrosionCauses blistering of coatings

Corrosion CellA corrosion cell consists of 4 components

An anode ( - provided by steel itself)A cathode ( + provided by steel itself)A metallic pathway (provided by steel itself)An electrolyte (salt + moisture = electrolyte)

CathodeAnodeMetallic pathwayElectrolyteCoating failureCorrosion products

Electrolytethe ONE and ONLY variable we can control isSalts are hygroscopic = Draw moisture

All liquid applied coatings are permeable and salts will draw moisture through the coating film, thereby providing the electrolyte needed for corrosion activity

Some coatings are less permeable than others

Osmotic BlistersThe same hygroscopic action which causes corrosion also causes osmotic blistering

The hygroscopic action of salts builds up pressure within a blister which can exceed the bond strength of the coating

A.B.A = Fingerprint effect B = Random test sample location would yield imperfect results

Salt Corrosion Cycle Iron +Salt + Moisture = RUST + Acid

Fe + 2H+ Fe+2 + H2 Fe+2 + O2 +4H+ Fe+3 + 2H2OFe+3 + 3Cl- FeCl3 2FeCl3 + 3H2O Fe2O3 + 6HCl Without remediation, repeat reaction cycle

Detecting Soluble SaltsLab analysis Time consuming and costly.Field testing Conductivity Ion specific

Testing for SaltsTwo parts:ExtractionsAnalysis

Detecting Soluble SaltsExtraction methodsSwabbing (DI water) [25 35%]Patch Cell (DI water) [45 60%]Wet filter paper (DI water) [??]Magnetic cell (DI water) [45 60%]Sleeve method (proprietary acid solution) [80%]Boiling (lab; destructive field sample) [90 95%] Quantitative analysis(Sources: SSPC TU4; Third party laboratories)

Analysis methodsTwo distinct methods: Conductivity measures all conductive constituents. Ion specific measures the specific ion of concern; chloride, sulfate, or nitrate.

Conductivity Method Measures everything conductive in the sample. Many species are not detrimental to the coating film nor induce premature coating failure. Measures all minerals. Conversion to chloride level is an estimate. Assumes a lab correlation based on 100% chlorides. Conductivity and reactivity are different.

ABCDEFGHIJK--LMNOPQRS

Conductivity vs Chloride Ion Specific19 panel tests with derived index for analysis

Plotted test points sorted by ascending values of Chloride Ion Specific results.

Sorted by ascending values of Conductivity results.

Ion specific method: Measures the specific problematic ion. Can measure different ions chlorides, sulfates, and nitrates. Reagent liquid chemicals can measure chlorides, but usually result in a range ( > to < ).

Ion specific method limitations: Quantab strip: Lot specific factor for calculation. Does not read below 30 ppm; 7.5 g/cm2 equivalent with Bresle and 3 ml DI. Reagent liquid chemicals can measure chlorides, but usually result in a range ( > to < ).

Chloride Analysis by Ion Detection Tubes Sealed ampoule, break both ends and immerse in extract solution Cl- read from calibrated tube in PPM and micrograms per square centimeter ISO 8502-5

Analysis of Sulfate Electronic turbidity methodAdd barium chloride to extract solution to form BaSO4 Measure absorbency/transmittance New Field Test Kit ISO 8502-11Maryland BridgeI-95 DelawareCasciano Bridge near Newark A/P

Analysis for NitratesDip pillow end of nitrate strip into extracted solution for 2 secondsWait 1 minute and compare color on pillow to color on comparator cardNASA GantrySt. Lawrence Seaway

Criteria for Chlorides:Units = g/cm2* Equivalents

Source Immersion Atmospheric Suppliers 2 - 5 5 - 15 NAVSEA 3 5 NAVFAC ND ND IMO 3* DNV 2 2


Risk Levels for Soluble Salts:

Soluble saltChlorideNitrateSulfateUnitg/cm2g/cm2g/cm2Low Risk0 to 30 to 50 to 10Medium Risk3 to 85 to 1010 to 20High Risk>8>10>20


Cumulative RiskThreshholds for each, but risk additive & not independent nor mutually exclusiveHow much weight should go on thin ice?

Chlorides

Sulfates

Nitrates

Units for Soluble Salts Surface Concentration:Micrograms per square centimeter Abbreviated (g/cm2) Solution Concentration: PPM (parts per million) Convert to g/cm2 based on volume and areaNote: 10 mg/m2 = 1 g/cm2

StandardsSSPC Guide 15extraction proceduresanalysis procedureunits, conversionsISO chloride ion, sulfate ionconductivityextraction

Removal


The electrochemical attachment of salts to the substrate (adsorption) are greater than the forces applied to remove them.Bonding strengthWhy are salts left behind if theyare water soluble?

Surface Preparation MethodsUltra High Pressure washing- Profile impact- Salt mitigationAbrasive blasting & Pressure wash (3000 psi min) cycles with water.- Multiple passes. - Bonded salts.- Time and cost.Wet abrasive blasting - Micronic particles. - Rinsing required.Abrasive blast followed a soluble salt REMOVER wash. - Cost effective.

Coatings EconomicsGoal: Achieve lowest cost/ft2/yr for the expect coating lifeBased on actual experience by NAVFAC since instituting revised specifications in 1995.

Total Surface Area:90,000 ft2Service: Tank LiningInsufficient Surface Prep:$500,0005 yr coating cycleProper Surface Prep:$515,00015 yr coating cycle

Cost/ft2/yr (todays $):Cost /yr over 15 yrsInsufficient Surface Prep: $1.11/ft2/yrProper Surface Prep: $0.38/ft2/yr


Chart3

515500

437.75375

372.0875250

316.274375125

268.833218750

241.949896875500

241.949896875375

241.949896875250

241.949896875125

241.9498968750

241.949896875500

241.949896875375

241.949896875250

241.949896875125

241.9498968750

Proper Surface Prep

Insufficient Surface Prep

Year

Initial Project Cost ($K)

Coating Life Cycle Comparisons

CoatingsDepletionRate

1515500

2437.75375

3372.0875250

4316.274375125

5268.833218750

6241.949896875500

7241.949896875375

8241.949896875250

9241.949896875125

10241.9498968750

11241.949896875500

12241.949896875375

13241.949896875250

14241.949896875125

15241.9498968750

CoatingsDepletionRate

Proper Surface Prep

Insufficient Surface Prep

Year

Initial Project Cost ($K)

Coating Life Cycle Comparisons

CoatingsCost

Coatings

Total Cost for 15 Year Coating ProtectionProject Cost

Historical Specification:Total Surface area:

Insufficient Surface Prep:$500,000

Proper Surface Prep:$525,000

Sheet3

SummaryAwareness: Salts may be presentRecognition: Incorporate testing in specifications Testing to quantify levels presentElimination: Traditional surface prep methods may not remove salts adequately. Cost effective use of acidic soluble salt remover Test to verify prior to coating.

Uhlig and ReviesCorrosion & Corrosion Control: A poor paint system on a properly prepared metal surface usually outperforms a better paint system on a poorly prepared surface


Strive for ProductsProvenEfficientImproves AdhesionAssists in removal of surface oilsCost effective SafeEasy to useEnvironmentally friendly

Ten Best Management PracticesIndustry AssociationsQuality ControlIn Service/Field

Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186The purpose of this technical committee report is to increase the industry awareness of the following: The effects of various nonvisible soluble salt contaminants on a coatings performance; An approach to risk assessment regarding the costs of soluble salt removal versus the risk of futurecoating failure; Identification of the indicators of salt contamination; and Various methods of salt contamination removal.Section Headers as presented on Page 1 of this report, verbatim


Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186Appendix BPreparing a SpecificationB1 Specification requirements regarding salt testing are usually driven by the specification writers knowledge of salt test kits.B2 Some of the basic components of a specification associated with nonvisible soluble salts include, .(next slide)B.3 Numerous sampling methods are described in SSPC-Guide 15. . B.4 Appendix C is an example of a portion of a written specification for a lining that incorporates these components.Appendix B has been provided courtesy of the Salt River Project (SRP)Tempe, AZ


Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186(a) Identify a field test kit or method for extraction and the method of analysis for each type of salt contaminant;(b) Determine at what point in the project activity testing occurs, taking into consideration surface preparation methods and procedures;(c) Choose the number of tests to be performed or a method for identifying the number and frequency of testing;(d) Give guidance on or select test locations;(e) State what level of soluble salt contamination is acceptable (see the product data sheet for the coating, or consult the coating manufacturer); and(f) Indicate remediation method(s) and subsequent retesting for previously noncompliant surfaces.


Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186Effect of Salt Contamination on Coating PerformanceRisk AssessmentSalt Contamination SourcesWater-Soluble Salt Contaminants (Chlorides, Nitrates, and Sulfates)Recognition and Identification of Salt ContaminantsField Tests to Detect the Presence of SaltsSalt Removal MethodsProject-Specific Sampling Protocols and Acceptance Criteria

Section Headers as presented on Page 1 of this report, verbatim


Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186ReferencesAppendixes:A. Area-Based Sampling Protocol and TestingB. Preparing a SpecificationC. Example Lining Specification

Section Headers as presented on Page 1 of this report, verbatim (continued)


Surface Preparation of Soluble Salt ContaminatedSteel Substrates Prior to CoatingNACE International Publication 6G186www.nace.orgStoreMembers free; non-members $31


Technical Guide #15The Society for Protective Coatings Draft Version American Petroleum InstituteSpecificationBEST PRACTICES (BMP)Unified Facilities Guide SpecificationsSocieties

Quality Control Called in specsWarranty ONLY

Repeated mentor advice to test for salts rather than risk fiascoSpecificationBEST PRACTICES (BMP)Several pages address similar to Dewpoint, RH, Temp. KEY CriteriaQC Caring

Quality Control -- Fleets & Structures proper washdown should not harm assets

Concrete and other repairs, intercoat adhesion issuesSpecificationBEST PRACTICES (BMP)Pipelines/structures when redoing CP clean properlyIn Service/Field

NAVSEA: 009-32 Standard Item Chloride limit: 3 g/cm2 immersion. FY-10: Water wash to meet the limit after abrasive blast. Can require multiple washes. FY-11 (Prelim): Allows the use of an approved salt remover.Approval via the F718 from the coating manufacturer ONR funded research at Carderock and CTC, Johnstown support efficacy and acceptability of an established and time tested soluble salt remover.

Surface Preparation IssueIndustry standards are generally visual. Present coatings cannot tolerate salts. Non-visible contaminants are getting more attention. Soluble salt removal is critical to coating life cycle performance.

Enclosed LifeboatCourtesy of US Coast Guard

Cable for aft hookPRIOR VIDEO and these next 5 slides courtesy of US Coast Guard

Courtesy of US Coast Guard

Case 1Type: Crude Oil TankerDWT: 135,000 Age Of Vessel : 16 Years, Total Steel replacement : 1,200 Metric Tonnes Case # 1..Renewals were carried out on various internal structures in Cargo & Ballast tanks including areas on the bottom platingCourtesy of US Coast Guard

Case 1Case 1.. Contd..The Final ProductArrival ConditionThe renewal Process on the Ship....Courtesy of US Coast Guard

Type: Oil Tanker , DWT: 108,628 Age Of Vessel : 15 Years, Total Steel renewal was : 150 T .. And steel renewal was Limited only to Ballast tank areas Case 2..What happened : Case # 1 = 1200 Tonnes and Case # 2 = 150 Tonnes. Reason : The Ship owner in Case # 2 did better Preventive Maintenance during her trading Years!!Case 2Courtesy of US Coast Guard

The B-307 was flown to Dulles in 2003 for delivery to the Smithsonian

Boeing Removes Corrosion Inducing Salts from Ditched Aircraft


Repairs:

Incorporating Salts into a SPECIFICATIONTHE GOOD THE BAD and THE UGLY


WHAT IS A SPECIFICATION?

(Class response)

A specification is the legal written word requiring a contractor to perform certain tasks.

The GoodSpecify- State in detail (Websters College Dictionary)

A specification should clearly state what is required of the contractor.

A specification should sequentially delineate each course of action.

The Bad

Do not repeat statements in a specification. State it only once. Even a slight change in verbiage will give different meanings to the intended meaning.

Do not use ambiguous statements such as or equal. If or equal is used clearly state what is equal.

The UglyDo not use long sentences. Short sentences are more easily understood.

Use concise and accurate industry language. mg/cm2 is not micrograms per square centimeter.

PPM does not convey the correct information regarding contamination on a surface.

Specification Language(answer these questions)WhatWhereWhenHowHow many

WHAT?

What salts need to be tested:chlorides, sulfates and/or nitrates

WHERE?

Where are the tests to be taken:in corroded areas, at welds, on the floor, on the ceiling, on the sidewalls etc.

WHEN?

When are tests to be taken:

before and/or after surface preparation, after a storm re-contaminates the surface etc.

WHY?

Test because the specification requires a maximum acceptable level be achieved prior to coating application

HOW MANY?

Test per specified frequency:

(5 tests per 1000 sq ft. or part thereof)

SALTS IN A SPECIFICATIONTest before preparation (this is a baseline)Wash before preparation if salts do not meet specification (prevent possible impregnation) Prepare surface Test after preparation (this establishes if remediation is required)Remediate if necessaryRetest to establish if specification is met

Test Where?Test at locations of corrosion

Test at locations of coating failure

Test at weld seams

Exactly Where Do I Test?On metal loss areas- 70% of total tests.Next to welds (30%) (vertical and horizontal).If no metal loss areas are visible, select areas representative of the surface as a whole.Areas not washed by rainfall

When do I test?Prior to surface preparation (this establishes a starting base level)After surface preparation but prior to coating (this determines if further surface cleaning is needed)After decontamination (if salts meet the required level, coating may progress).Between coats if coating has become contaminated.

How many tests do I take?New Construction/Complete Removal/ReplacementFive (5) tests for the first 1000 square feet (1002 meters) or part thereof.Two (2) tests per 1000 square feet for the next 3000 square feet (3002 meters) or part thereof. One (1) test per 2000 square feet (2002 meters) on the remainder or part thereof.

Ft2 (m2) Number1,000 (100) 52,000 (200) 5+2=73,000 (300) 5+2+2=94,000 (400) 5+2+2+2=116,000 (500) 5+2+2+2+1=128,000 (800) 5+2+2+2+1+1=1310,000(1,000) 5+2+2+2+1+1+1=1412,000(1,200) 5+2+2+2+1+1+1+1=1514,000(1,400) 5+2+2+2+1+1+1+1+1=1616,000(1,600) 5+2+2+2+1+1+1+1+1+1=17

REPAIR ATMOSPHERIC Recommended Number and Distribution of Measurements: Spot Repair for Used Surfaces How Many Tests??? (Repair)

Ft2 (m2) Floor Measurements Ceiling Measurements Wall Measurements1,000 (100) 5 5 52,000 (200) 5+2=7 5+2=7 5+2=73,000 (300) 5+2+2=9 5+2+2=9 5+2+2=94,000 (400) 5+2+2+2=11 5+2+2+2=11 5+2+2+2=116,000 (600) 5+2+2+2+1=12 5+2+2+2+1=12 5+2+2+2+1=128,000 (800) 5+2+2+2+1+1=135+2+2+2+1+1=13 5+2+2+2+1+1=1310,000 (1,000) 5+2+2+2+1+1+1=14 5+2+2+2+1+1+1=14 5+2+2+2+1+1+1=1412,000 (1,200) 5+2+2+2+1+1+1+1=15 5+2+2+2+1+1+1+1=15 5+2+2+2+1+1+1+1=1514,000 (1,400) 5+2+2+2+1+1+1+1+1=16 5+2+2+2+1+1+1+1+1=16 5+2+2+2+1+1+1+1+1=16

Tank Linings Recommended Number and Distribution of Measurements: New and Old SurfacesThat Require Full Coating

(EXTERNAL SURFACES AND STRUCTURES)How Many Tests??? (Tanks)

MAINTENANCE PAINTINGAtmospheric/Immersion

For the first five (5) spots one (1) test per one (1) spot.

Remainder of structure - one (1) test per five (5) spots.

Where, When, How Many and Allowable Levels


ACCEPTABLE LEVELS

Immersion at Ambient Temperature

Chloride Nitrate Sulfate Low Risk 0 to 3 0 to 5 0 to 10 Med Risk 3 to 8 5 to 10 10 to 20 High Risk >8 >10 >20

Atmospheric at Ambient Temperature Chloride Nitrate Sulfate Low Risk 0 to 7 0 to 10 0 to 15 Med Risk 7 to 15 10 to 20 15 to 30 High Risk >15 >20 >30

Uhlig and ReviesCorrosion & Corrosion Control: A poor paint system on a properly prepared metal surface usually outperforms a better paint system on a poorly prepared surface


1. A fast, cheap job is not good.2. A cheap, good job is not fast.

3. A good, fast job is not cheap.

Summary of Key Points Soluble salts are widespread Salts cause coating failure Levels of acceptance Field methods for extraction Field methods for analysis Specification writing

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The lifeboat was successfully launched and sailed for 20 minutes. At the conclusion of the test, the lifeboat was re-connected to the davit pendant lines for recovery and stowing. After doing a short load test out of the water, the boat was winched / hoisted by the crew.

When the lifeboat was approximately 2 ft from stowing position, the aft pendant hook inadvertently released causing the lifeboat to swing on the foreword pendant, which also released causing the lifeboat to fall in the sea from a height of 65 ft.

One person been declared dead upon arrival to the hospital, one in critical condition, and five with various injuries.

Soluble Salts Presentation by Regis NACE Eastern Area ConferenceNACE Eastern Area ConferenceSoluble Salts Presentation by Regis *Soluble Salts Presentation by Regis NACE Eastern Area ConferenceNACE Eastern Area ConferenceSoluble Salts Presentation by Regis Cable sheet rusted and broken*Soluble Salts Presentation by Regis NACE Eastern Area ConferenceNACE Eastern Area ConferenceSoluble Salts Presentation by Regis Two Vessels of the same age. from the same Yards with identical trading Patterns.. can show a wide variation in their general condition and rate of Corrosion

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how to avoid premature coating failures

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removal of soluble salts

adequatesoluble salts

residual salts

coating life

combinations of salts

formed insoluble salts

soluble salts0

cost of premature failure