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Vol 39 No 2, April 2014 ISSN 1326 -1932
Inside this Issue: Technical Note: The Cold Shoe Shuffle in the Heat of the Pilbara – 3D Laser Analysis Project Profile: The World’s First Hybrid Corrosion Protection Systems for Prestressed Concrete Bridges Project Profile: Making ‘The Moment’ Last University Profile: Curtin Corrosion Engineering Industry Centre Industry Insight: Protecting Pipelines from Corrosion Under Insulation Research Paper: Sensitive Methods for Studying the Environmental Performance of Protective Coatings
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p.2 CORROSION & MATERIALS
Darwin Convention Centre
Proudly presented by:
21–24 September 2014
Major Sponsor:
www.acaconference.com.au
Prize Sponsor:
EARLY BIRD REGISTRATION
COMPETITION
Register before 20 June 2014 for the early bird conference registration fee and go into the draw to win one major prize of: 2 return domestic economy flights, 4 nights’ accommodation at the Vibe Hotel Waterside Darwin and
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April 2014 www.corrosion.com.au p.3
CONTENTS
The Australasian Corrosion Association Inc The 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
6
President’s Message
7
ACA Calendar of Events 2014
8
Executive Officer’s Message
9
ACA 2014 Training Calendar
10
News
16
Branch & YCG News
22
Future Leaders Forum Review
24
ACA Standards Update
30
New Product Showcase
32
ACA Certification Program
Front Cover Photo: ‘The Moment’ sculpture adorns a new apartment block in Melbourne’s Art Precinct. Photo courtesy of Damian Vick & Geelong Galvanizing.
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ISSN 1326 -1932 Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257 Editor Ian MacLeod – Western Australian Museum ian.macleod@museum.wa.gov.au Associate Editors Research: Bruce Hinton – Monash University bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants, willie.mandeno@opus.co.nz News: Tracey Winn – The Australasian Corrosion Association Inc, twinn@corrosion.com.au
Reviewers Andy 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 Sales Tracey Winn – The Australasian Corrosion Association Inc, twinn@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscriptions Print 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 Inc PO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: aca@corrosion.com.au Internet: www.corrosion.com.au
CONTENTS
34
Technical Note: The Cold Shoe Shuffle in the Heat of the Pilbara – 3D Laser Analysis
36
Project Profile: The World’s First Hybrid Corrosion Protection Systems for Prestressed Concrete Bridges
38
Project Profile: Making ‘The Moment’ Last
40
Coatings Group Member Profile
42
Industry Insight: Protecting Pipelines from Corrosion Under Insulation
45
University Profile: Curtin Corrosion Engineering Industry Centre
46
Research Paper: Sensitive Methods for Studying the Environmental Performance of Protective Coatings
54
Suppliers and Consultants
ACA Operations Board President: Andrew Hargrave
Corrosion & Materials Corrosion & 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 bpejkovic@corrosion.com.au with a copy to bruce.hinton@monash.edu 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 bpejkovic@corrosion.com.au
ACA Branches & Divisions Auckland Division: Grant Chamberlain
64 21 245 9038
Executive Officer: Wesley Fawaz
Newcastle: Karen Swain
Operations Chairman: Paul Vince
New South Wales: Jim Galanos
61 2 9763 5611
Senior Vice President: Mohammad Ali
Queensland: Cathy Sterling
61 7 3821 0202
61 0 418 854 902
ACA Technical Groups Cathodic 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
Junior Vice President: John Duncan
South Australia: Dennis Richards
61 0 419 860 514
Immediate Past President: Allan Sterling
Tasmania: Grant Weatherburn
61 0 418 120 550
Directors: Kingsley Brown Graham Carlisle Matthew Dafter Peter Dove John Duncan Fred Salome Dean Wall
Taranaki Division: Ron Berry
64 27 671 2278
Research: TBA
Victoria: John Tanti
61 3 9885 5305
Water & Water Teatment: Matthew Dafter 61 419 816 783
Wellington Division: Monika Ko Western Australia: Gary Bennett
64 4 978 6630 61 0 408 413 811
Petroleum & Chemical Processing Industry: Fikry Barouky 61 402 684 165
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.
PRESIDENT’S MESSAGE
held in San Antonio as I write this President's message. Before I provide some feedback regarding the NACE conference, the ACA Board meeting was held on Friday 21st February and on the consecutive day the strategic plan workshop was held. The Board meeting went well and a summary of the meeting will be distributed by our Executive Officer shortly to all Branches within ACA.
Andrew Hargrave President
Hello members, It has been a busy time since the last issue of Corrosion & Materials. I am in the USA at the NACE conference being
The strategic plan workshop was held on the Saturday 22nd February. It identified key elements or words within our vision / mission statement and the workshop focused on those key elements or words for the group to develop a 3 year plan. One example of this is the word ‘disseminate’ that is used within our mission statement. It is one of the primary objectives that the ACA be leaders in disseminating a broad knowledge of corrosion management throughout Australia and New Zealand. Together with its alliance partners we will do that and hence while attending
the NACE conference the ACA / NACE Memorandum of Understanding (MoU) was signed. I speak for all members that we look forward to a closer relationship with NACE. Our meeting with NACE, whilst at the conference, has opened the opportunity to expand NACE training courses into Australasia. Other meetings took place during the conference which included SSPC regarding the C7 and C12 certification and with ICorr. Overall it has been a privilege and pleasure to attend the NACE conference while representing the ACA. Looking ahead, May 2014 looks to be busy with the AGM as well as the Marine & Coastal Corrosion Seminars in full swing and I am scheduled to present in Hobart, Auckland, Perth and Darwin. I hope you enjoy this edition of the ACA Corrosion & Materials. Thank you. Andrew Hargrave ACA President 2014
ACA Coatings AWARDS
Rust Award
The ACA Coatings Technical Group are now calling for nominations for the annual Rust and Nightingall Awards.
The purpose of the Rust Award is to honour a protective coatings contractor for their meritorious and/or innovative performance in the field, or in recognition of their significant contribution to their industry. Nominations should be guided by the following criteria: • Outstanding achievement in commercial coatings work, demonstrating innovation, durability or utility. • Outstanding industrial or commercial coatings project demonstrating longevity of the original coating. • Outstanding achievement demonstrating aesthetic merit in industrial coatings work. • Outstanding achievement in the completion of a difficult or complex industrial coatings project.
Nightingall Award The Nightingall Award was established to recognise distinguished achievement in the development, manufacture or application of protective coatings or advancement of the protective coatings industry.
Full details and nomination forms can be found at www.corrosion.com.au. Nominations close 30 June 2014. Awards will be announced at Corrosion & Prevention 2014 in Darwin 21–24 September. p.6 CORROSION & MATERIALS
ACA CALENDAR OF EVENTS
ACA Calendar of Events 2014 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.
Event
2014 Date
Location
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
Melbourne
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 Plymouth, NZ
Corrosion & Prevention 2014 Conference
21-24 September
Darwin
Protective Coatings Preventing Corrosion
20 November
Brisbane
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 (bpejkovic@corrosion.com.au) in the ACA office on +61 (0)3 9890 4833.
Branch Events
Each 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: nsw@corrosion.com.au New Zealand: nz@corrosion.com.au Newcastle: ncl@corrosion.com.au Queensland: qld@corrosion.com.au South Australia: sa@corrosion.com.au Tasmania: tas@corrosion.com.au Victoria: vic@corrosion.com.au Western Australia: wa@corrosion.com.au
YCG Events
Targeting 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 ycg@corrosion.com.au or go to www.corrosion.com.au
Please refer to www.corrosion.com.au for up to date details on all ACA activities.
April 2014 www.corrosion.com.au p.7
EXECUTIVE OFFICER’S MESSAGE
Congratulations to ACA members who were recognised during the conference awards dinner:
From the recent ACA governance review, the highest priority recommendation was an update of the ACA Constitution to ensure that it more accurately represents ‘best practice’ in membership associations. The ACA has acted promptly on this recommendation and has drafted its new Constitution thanks to Governance Review Chair John Duncan. This is now being made available to Branch committees for comment and once the Constitution is ready for member voting, it will be provided to members who will be asked to vote on the change either by a ballot or in person during a Special General Meeting at the Darwin conference in September. The ACA will be conducting its Annual General Meeting in May 2014 which will include the presentation of its 2013 financial statements. A notice to members will be announced soon. Strategic planning has been a recent key undertaking of the Operations Committee in conjunction with a selection of members. The new strategic plan will lead and guide the Association over the next few years ensuring that the ACA is looking forward. A shortened version of the plan will be available on the ACA website for members. I recently attended the 2014 NACE conference in San Antonio, USA along with President Andrew Hargrave, Chairman Paul Vince, Finance Director Fred Salome and a strong contingent of ACA members.
ick Birbilis of Monash University N was the first Australian awarded as a Fellow of NACE. Nick was recognised for sustained contributions to understanding in the corrosion community through editorial and organisational activities. onika Ko of Quest Integrity Group M was awarded the A.B. Campbell Award in recognition of the most outstanding paper by a young author published in Materials Performance or Corrosion each year. S ebastian Thomas of Monash University was awarded the Corrosion Best Paper Award in recognition of the most outstanding manuscript published in Corrosion for the preceding calendar year. Training opportunity meetings were held with several key international industry partners during the conference and the ACA hopes to soon announce new training offerings in Australasia arising from these meetings.
The annual Seminar Series is back next month and will focus on Marine & Coastal Corrosion. Technical programs for all locations are available and members are strongly encouraged to register and bring their colleagues, clients, suppliers etc. along for a great professional development and networking opportunity. Enclosed in this issue of Corrosion & Materials is the Preliminary Program for the 2014 Darwin (21–24 September) conference which as you will see, is on track for a very strong technical program. Accommodation in Darwin is in high demand and I have been asked by the NT Convention Bureau to encourage all those coming to the conference to book your hotels well in advance. A reminder to please refer to www.corrosion.com.au and www.acaconference.com.au for further details and to add these important member and industry activities to your calendar. Wesley Fawaz Executive Officer wesley.fawaz@corrosion.com.au
A Memorandum of Understanding (MoU) was signed in San Antonio between ACA and NACE (photo of signing pictured right) which formalises a more cooperative relationship that is mutually beneficial to each organisations members. ACA members will be provided with a 25% discounted price on NACE publications and further details to take advantage of this will be available soon also.
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p.8 CORROSION & MATERIALS
ACA 2014 TRAINING CALENDAR
ACA 2014 Training Calendar Corrosion Technology Certificate
Cathodic Protection Monitoring
Mbr Status
Fee
GST
Total Fee
Mbr Status
Fee
GST
Total Fee
AU Mbr
$2018.18
$201.82
$2220.00
AU Mbr
$1704.55
$170.45
$1875.00
AU Non Mbr NZ Mbr* Melbourne
$2367.27 $2020.00
$236.37 NZ Non Mbr
April
$2600.00 $2370.00 07th - 11th
Sydney
July
21st - 25th
Brisbane
November
10th - 14th
Introduction to Protective Coatings
AU Non Mbr NZ Mbr* Brisbane Sydney
$1868.18 $1685.00
$186.82
$2055.00
NZ Non Mbr
$1865.00
July
14th - 17th
October
21st - 23rd
Cathodic Protection Advanced
NACE - Coatings Inspection Program CIP Level 2 Mbr Status
Fee
GST
Total Fee
AU Mbr
$3400.00
$340.00
$3740.00
AU Non Mbr
$3886.36
$388.64
$4275.00
NZ Mbr*
$3395.00
NZ Non Mbr
$3900.00
Adelaide
May
12th - 17th
Sydney
July
14th - 19th
New Zealand
August
18th - 23rd
Mbr Status
Fee
GST
Total Fee
Darwin
September
15th - 20th
Mbr Status
Fee
GST
Total Fee
AU Mbr
$2018.18
$201.82
$2220.00
Melbourne
October/November
27th - 01st
AU Mbr
$550.00
$55.00
$605.00
$2367.27
$236.37
$2600.00
Perth
December
01st - 05th
AU Non Mbr
$672.73
$67.27
$740.00
AU Non Mbr
Darwin
September
NZ Mbr*
$2020.00
NZ Non Mbr
$2370.00
Brisbane
July
21st - 25th
NACE – Peer Review CIP Level 3
Sydney
October
13th - 17th
11th
Protective Coatings Quality Control Mbr Status
Fee
GST
Total Fee
AU Mbr
$1350.00
$135.00
$1485.00
AU Non Mbr NZ Mbr*
$1645.45 $1350.00
$164.55 NZ Non Mbr
$1810.00 $1650.00
Sydney
June
02nd - 04th
Darwin
September
24th - 26th
Perth
December
8th - 10th
Coatings Selection and Specifications
Mbr Status
Fee
GST
Total Fee
AU Mbr
$1336.36
$133.64
$1470.00
Corrosion & CP of Concrete Structures
AU Non Mbr
$1568.18
$156.82
$1725.00
Mbr Status
Fee
GST
Total Fee
NZ Mbr*
$1335.00
NZ Non Mbr
$1568.00
AU Mbr
$963.64
$96.36
$1060.00
Darwin
September
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
Mbr Status
Fee
GST
Total Fee
AU Mbr
$1350.00
$135.00
$1485.00
ACA/ACRA Corrosion & Protection of Concrete Structures
AU Non Mbr
$1645.45
$164.55
$1810.00
Mbr Status
Fee
GST
Total Fee
NZ Mbr*
$1350.00
NZ Non Mbr
$1650.00
AU Mbr
$963.64
$96.36
$1060.00
Perth
July
28th - 30th
AU Non Mbr
$1209.09
$120.91
$1330.00
NZ Non Mbr
$1210.00
Coatings Inspection Refresher
NZ Mbr*
$965.00
Mbr Status
Fee
GST
Total Fee
Sydney
June
19th - 20th
AU Mbr
$550.00
$55.00
$605.00
Brisbane
November
27th - 28th
AU Non Mbr
$672.73
$67.27
$740.00
NZ Mbr*
$500.00
NZ Non Mbr
$680.00
NACE - Coatings Inspection Program CIP Level 1
Darwin
September
20th
Mbr Status
New Zealand
November
28th
Introduction to Cathodic Protection Mbr Status
Fee
GST
Total Fee
AU Mbr
$550.00
$55.00
$605.00
AU Non Mbr
$672.73
$67.27
$740.00
NZ Mbr*
$500.00
Brisbane
July
NZ Non Mbr
$680.00 11th
Fee
GST
Total Fee
AU Mbr
$3400.00
$340.00
$3740.00
AU Non Mbr
$3886.36
$388.64
$4275.00
NZ Mbr*
$3395.00
NZ Non Mbr
$3900.00
Adelaide
May
05th - 10th
Perth
May
26th - 31st
Melbourne
June
16th - 21st
Brisbane
June
23rd - 28th
Sydney
July
07th - 12th
New Zealand
August
11th - 16th
Darwin
September
08th - 13th
Melbourne
October
20th - 25th
Perth
November
24th - 29th
16th - 20th
Resits NACE – Coating Inspector Program Level 1 & 2 Mbr Status
Fee
GST
Total Fee
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
April 2014 www.corrosion.com.au p.9
NEWS
UCF NanoScience Center develops program to create graphene spray to fight corrosion The University of Central Florida’s NanoScience Center is developing a new program to make a graphenebased spray coating that would help multiple industries easily and inexpensively fight corrosion. The center is building on the recent success of UCF spin-off Garmor, Inc., in making a powder form of super-strong graphene available to industry. “We can use graphene and composite materials to produce new ways for automotive, aerospace, oil and gas,
the military and even the medical industries to take advantage of this extremely powerful material,” said Sudipta Seal, director of the NanoScience Technology Center and Advanced Materials Processing Analysis Center and a professor of Materials Science and Engineering.
Restrepo, will assist with formulating the graphene oxide. The scientists will modify graphene, which originates from graphite similar that found in pencil lead, so it can be adhered to a plastic host and sprayed onto a surface while retaining its innate strength and elasticity.
Seal has published articles on the strength and flexibility of aluminum composites reinforced with carbon nanotubes that is central to the process.
NanoScience Professor Lei Zhai will focus on developing the material to host the graphene and ensure the graphene keeps its electrical and mechanical performance when embedded.
The goal of the program to is to provide a cost-effective, large-area polymer/ graphene-based coating technology to both strengthen mechanical components such as materials used for the construction of aircraft and cars, and protect materials such as gas and oil pipelines from corrosion. The research program will concurrently focus on developing graphene oxide, a plastic host and a plasma spray.
NanoScience Professor Lei Zhai.
Garmor, Inc., a UCF spinout company that has licensed technology developed by NanoScience Center researchers Richard Blair and David
The composite development element is being led by Seal, who will configure the graphene agent for performance testing on steel, aluminum, and high strength plastic. The coated substrates will be evaluated for their mechanical (abrasion and strength), as well as corrosion performance. Companies and potential students interested in learning more about the project should contact Seal at Sudipta.Seal@ucf.edu. Source: University of Central Florida
Membership Recognition - Thank You Letter Mr A Hargrave, President, Australasian Corrosion Association Inc, PO Box 112, Kerrimuir, Vic, 3129 Dear Andrew, Thank you most sincerely for the beautifully framed magnificent certificate acknowledging my longterm membership of the association and which arrived today. It made me very proud. The certificate now hangs in my entrance hall where it will be seen by all visitors.
p.10 CORROSION & MATERIALS
Little did I realise when I arrived here on a three year contract at the beginning of 1966 that I would still be here nearly 50 years later. I have enjoyed my years in the Association both technically and the fellowship also being able to make contributions to our work over the ensuing 45+ years. It was my deep regret that I could not collect the certificate personally due to my increasing physical infirmity. The advance of the Association, especially since the 1980's, its doubling
of membership is most rewarding. the ACA has been the most lively, closely knit and energetic of all the learned institutions where I have membership. Yours most sincerely,
NEWS
Valspar Gifts $1M to Research Lab Materials-science research at the University of Minnesota has taken a million-dollar step forward with help from The Valspar Corp. The new Valspar Materials Science and Engineering Lab, underwritten by the company, is expected to open this US autumn to students in the Department of Chemical Engineering and Materials Science at the university in Minneapolis, where Valspar is headquartered. The Valspar Foundation's $1 million gift to the university's College of Science and Engineering will be used to provide equipment for the new undergraduate laboratory. 'Second to None' The Valspar lab will be located in the department's Gore Annex of Amundson Hall, a $27.6 million, 40,000-square-foot addition that is expected to be completed later this year. The lab will be opened in the fall, although full completion is not expected until early next year. The lab will include testing equipment that characterizes the mechanical performance of materials; electron micoscopes that image at the nanoscale; and other equipment that can measure magnetic, electrical and optical properties. “This gift from Valspar allows us to grow our undergraduate materials science and engineering program and outfit the new lab with state-of-the-art equipment that is second to none,” said Dr. Frank S. Bates, head of the Department of Chemical Engineering and Materials Science.
“We are thankful for Valspar’s support and forward-looking mission to help us build one of the best materials science and engineering programs in the country.” Hometown Partnership The lab is part of a larger alliance between Valspar, the world's sixthlargest paint and coatings company, and the university. Valspar said the company and university have a “shared mission to develop world-class materials science and products” and can collaborate in close proximity. The gift announcement comes as Valspar completes a $30 million expansion of its Minneapolis R&D facility. With completion scheduled for this spring, the Valspar Applied Science and Technology (VAST) Center will enable the current campus to accommodate up to 135 additional researchers and technologists.
of companies "begin recognizing this emerging field as critical to their success," the university said. The materials-science field has drawn in oil companies, computer chip manufacturers, medical device companies, and others. In recent decades, the number of materials science and engineering students in the University of Minnesota program has increased four-fold, the university said. “The university grew the materials science and engineering program very purposefully with world-class faculty, quality graduate programs and, now, a robust undergraduate program,” Bates said. “This new lab will allow us to deliver on our promise of excellence and put Minnesota at the forefront in materials science and engineering.”
“The alliance of Valspar with the University of Minnesota is clearly a strong match with our strategy for science and innovation leadership in the coatings industry,” said Dr. Cynthia Arnold, Valspar’s Senior Vice President and Chief Technology Officer. “Valspar will benefit from the University’s outstanding interdisciplinary program for materials science, a specific coatings program, and proximity to one of our major research laboratories.” Expanding Field The University of Minnesota’s materials science and engineering program has "seen tremendous growth in demand" as a wide range
The new Valspar Materials Science and Engineering Lab will be located at the University of Minnesota's new Gore Annex of Amundson Hall.
New International Standards Search Tool on-line SpecSource Global have recently released CoatSTRSM, the all-new search tool for finding international protective coating standards. Enjoy fast, easy access anytime.
April 2014 www.corrosion.com.au p.11
NEWS
Protective coatings for steel bridges: A guide for bridge and maintenance engineers The New Zealand Transport Agency has released a publication titled ‘Protective coatings for steel bridges: A guide for bridge and maintenance engineers’. Its Foreword states; Steel bridges comprise approximately 20% of New Zealand state highway bridges and, with the inclusion of the Auckland Harbour Bridge, represent an asset replacement value of over $2 billion. Protective coatings are often less than one third of a millimetre in thickness and are required to protect highly stressed steel from corrosion in often aggressive marine environments. Historically the full potential life of these coatings has not been achieved due to less than optimum coating selection, specification, application or maintenance. The ultimate objective of this guide is to optimise the long term capital and maintenance costs of steel structures through
the implementation of best practice in the selection, application and maintenance of protective coatings on steel structures. Section 8 of the guide covers Quality Assurance and lists the minimum qualifications for bridge coating specifiers, applicators and inspectors. These include: ualified coating specifiers shall be used Q to prepare or peer review the coating system specification., The required qualification shall be one of the following: – NACE Protective Coating Specialist – Australasian Corrosion Association (ACA) Technician or Technologist with successful completion of the ACA’s Coating Selection and Specification Course and/ or certified to NACE Coating Inspection Program (CIP) Level 2.
Protective coatings for steel bridges A guide for bridge and maintenance engineers Published: February 2014
enders will only be accepted from T coating application contractors who are accredited under the Australian Paint Contractors Certification Program (PCCP). (Note that from 1 July 2015 this will be a mandatory requirement nly coatings approved by an O independent body such as APAS, NEPCOAT or NORSOK shall be used. n independent inspector shall be A employed to audit the quality of the work. The inspector’s minimum qualification shall be NACE Coating Inspector Certified Level 2. This guide is available for download from the New Zealand Transport Agency website from the following link: www. nzta.govt.nz/resources/protectivecoatings-steel-bridges/index.html
Pipe Crawling Underwater X-Ray Machines Find Leaks Before They Happen They say an ounce of prevention is worth a pound of cure, but when it comes to an underwater pipeline carrying oil or natural gas, staying ahead of leaks can actually help prevent a billion dollar cleanup. So researchers at GE are developing an underwater submersible that uses X-rays to check pipelines for signs of corrosion and deterioration before something catastrophic happens.
that are usually far from friendly to most electronics.
However it's not like researchers can simply toss a medical-grade X-ray machine off a boat and then move into position on a submerged pipe. Since those pipelines sit on the bottom of the ocean floor, there are tremendous pressures and temperatures to deal with
Their creation hasn't been put into service yet, but once perfected it will descend and attach itself to an underwater pipeline and then slowly slide along its length, taking X-ray shots of every inch. Those images will then be beamed to the surface
p.12 CORROSION & MATERIALS
So to make the company's X-ray hardware survive a trip to the abyss, engineers at GE's healthcare and oil/gas divisions, working with companies like BP and Oceaneering, repackaged the machine's delicate guts into a rugged case that can easily survive extreme depths and temperatures.
where engineers and experts can study them and spot problems so they can be remedied before they turn into environmental disasters. Story: Gizmodo.com
NEWS
Seeing a Future in the Pipeline The National Facility for Pipelines Coating Assessment has been launched at Deakin University’s Geelong Waurn Ponds campus. Located within the Proof-of-Concept Building at the Institute for Frontier Materials, the facility is an initiative of the Energy Pipeline Co-operative Research Centre. The new facility was set up in response to industry needs, with the launch on 5 March attended by around 50 guests, including a number of CRC and pipeline industry representatives, as well as Deakin staff and students. The initiative will provide an independent facility to perform oil and gas pipeline coating testing and will help to build Australia’s capability to support pipeline coating selection and development through cutting edge research. The facility is jointly managed by Deakin’s School of Engineering and the Institute for Frontier Materials. Deakin’s Deputy Vice-Chancellor (Research) Professor Lee Astheimer congratulated the facility’s managers for developing the project so quickly.
“Deakin was a relative late-comer to the CRC, which was established in 2010, so it has been wonderful to see the rapid rise of both the CRC and this facility,” Professor Astheimer said. “Our staff have been busy identifying research needs and taking the initiative to find solutions that will have an impact on energy efficiency and infrastructure sustainability throughout Australia.” At the launch, industry representatives commented on the desperate need for the facility as a critical part of the industry, particularly given the age of a number of major pipelines in Australia, with many coming towards the end of their lives. Alan Bryson, Integrity Manager with East West Grid, APA Group, said that corrosion was one of the major risks of energy pipelines, with premature corrosion potentially leading to costly problems and serious situations. “Public utilities used to provide this type of research, but privatisation and competition have meant that no
one company in industry has had the critical mass necessary for this type of research and testing. We will now get the independent testing that we need to support the commercial aspects of our work,” Mr Bryson said. Professor Valerie Linton, CEO of the Energy Pipelines CRC, said a feature of the CRC was its strong partnership with the Australian Pipeline Industry Association, which has around 500 members and represents about 50 companies. “This CRC sets the benchmark for genuine collaboration,” Professor Linton said. EP-CRC program leader, Deakin’s Professor Mike Tan, said that research will focus on coating, testing and understanding corrosion behaviour so that “fundamental understandings will support applied, focussed research.” The Energy Pipelines CRC is a collaboration between Deakin, the University of Wollongong, Adelaide University, the ANU and industry, represented through the Australian Pipeline Industry Association.
Professor Lee Astheimer and Prof Valerie Linton officially open the National Facility for Pipeline Coating Assessment.
Mr Craig Bonar, APA Group and lead industry adviser for the EP-CRC and Prof Mike Tan, Deakin University at the opening of the National Facility for Pipeline Coating Assessment.
April 2014 www.corrosion.com.au p.13
NEWS
ACA welcomes new members Corporate Platinum Samaras Structural Engineers www.samarasgroup.com Delivering remarkable efficiency, Samaras' state-of-the-art 6,200m² undercover surface treatment workshop has ample capacity, featuring a full recovery system blastroom 6.4m(w) x 6.4m(h) x 25m(l) and supported by a (8) eight wheel Wheelabrator, which together gives Samaras the capacity to handle numerous projects at the same time. Samaras' expertise, capabilities and experience together with their quality assurance systems allows them the flexibility to handle a range of projects from the single coat primer based systems to multi-coat architectural finishes, all painting systems can be accomplished, efficiently and under full QA control. Xypex Australia www.xypex.com.au Xypex Australia has over 20 years’ experience with products and systems designed to extend the service life and reduce future maintenance costs associated with Concrete structures. With proven Crystalline technology, Xypex provide solutions to many of the causes of concrete degradation.
Corporate Gold
Corporate Bronze
Sonomatic www.vsonomatic.com Sonomatic is committed to providing engineering driven inspection solutions that enable clients to manage the integrity of maturing assets, while making informed and cost-effective decisions crucial to the extension and safety of plant life. Sonomatic services to Industry: Statistacal reveiw of inspection data ILI Fitness for Service Assessment Finite Element Assessment NII Assessment to G103 Advanced Non-Intrusive Inspection Technologies Automated inspection solutions Time of Flight Diffraction Corrosion mapping Automated Pulse Echo Medium and Long Range Inspection Technologies Inspection of inaccessible areas (CHIME/Multiskip) Automated tools for sub-sea inspection (ROV)
GF Engineering www.gfengineering.com.au GF Engineering was established in 1973. They are ISO 9001 and ISO 3834 part 2 approved with over 200 compliant welding procedures specialising in pipe spooling fabrication for the oil, gas, chemical, power, mining and water markets. Their proven expertise in carbon, stainless, duplex, super duplex and other exotic steels is well documented. They also supply a niche market with structural fabrication, pressure vessels classes 1, 2 & 3, plate work, chutes, pipe supports, trestles, handrails, steps and ladders. In addition to workshop fabrication, they have a W.A. site installation team and a dedicated QA/ QC and document control department with continuous day and night shift to ensure delivery in full on time. Their clients range from major Australian oil and gas providers, refineries and organisations who require a high level of quality and documentation.
Individual/Student/Retired Members Name
Company
Alden Carrick David Chua
KJV Gorgon
Declan Collins
Branch
Christopher McCarthy
Queensland
Allisha Milestone
Western Australia New South Wales
Craig Davies
Giovenco Industries
New South Wales
Braydon Davies
Giovenco Industries
New South Wales
Jimmy Encio
Broadcast Australia
New South Wales
Joe Erhardt
PFP Systems
Victoria
Clint Harvey
Direct Blast
Western Australia
Luke Henderson
ODC Corrosion Control
Robert Igunga
Jakeb Norman
CMC Painting
Western Australia Queensland
Curtin University
Ajay Orpe
Western Australia New Zealand
Daniel Price
BAE Systems
Western Australia
Paul Sawyer
Savcor
Western Australia
Mervyn Spindler
South Australia
Beau Tickner
RBC (QLD) Pty Ltd
Queensland
Brian Traynor
Killard Excavations
New South Wales
Western Australia
Kate Voss
Incite Pivot
Queensland
Oil Search
Australasia
Kenneth Ward
Azzona
Victoria
Israel Kuilenge
Oil Search PNG Ltd
Australasia
Michael White
Ronald Maine
Oil Search PNG Ltd
Australasia
Sindee Wong
Curtin University
Western Australia
Nicholas Marris
DITS Pty Ltd
Western Australia
Guangning (Jason) Yu
University of South Australia
South Australia
p.14 CORROSION & MATERIALS
Queensland
Protective Coatings Training From 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)
Protective Coatings Quality Control (3 days)
Coatings Selection & Specification (3 days)
Darwin 11 September
Sydney 2-4 June
Perth 28-30 July
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.
Darwin 24-26 September
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’.
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.
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.
Register now at www.corrosion.com.au April 2014 www.corrosion.com.au p.15
BRANCH & YCG EVENTS
ACA Auckland Meeting Report/ AGM February 2014 The first ACA Auckland Division Meeting for 2014 was held at the Sprig & Fern Tavern in Freemans Bay on 27th February 2014. The meeting was addressed by Sean Ryder (Phoenix Solutions) and Les Boulton (LBA) outlined some recent aspects of stainless steel applications in New Zealand. Jacquie Martin, from the ACA Centre in Melbourne, was welcomed to the meeting by the Chairman Grant Chamberlain. Sean Ryder commenced the evening with an outline of his recent work for Auckland City Transport (AT) assessing the condition of the metal fixings/ fastenings on all the wharves managed by AT around the Waitemata and Manukau harbours and the islands. The talk was entitled: ‘Selection of materials for marine structures’. The conclusion from his extensive survey of the CCAtreated timber wharves was that the present metal fasteners made mostly from galvanised steel and 316 stainless steel (SS) would not survive for much longer into the future due to corrosion. Many of the large timber pole fasteners needed replacement soon in order to protect the public. After extensive investigations grade 254SMO (6Mo SS) was selected from the candidate alloys for all replacement fixings and fasteners to be installed on the wharves. The high alloy 6Mo SS was most cost-effective fixing material to provide the strength and durability required by AT to meet their criteria for timber wharf safety and ongoing maintenance requirements. Les Boulton then gave a presentation on ‘Corrosion on renewable energy solar power installations’. The increase in micropower installations for commercial and residential solar power in NZ in recent years has been driven by the desire to tap into more sustainable resources such as wind, geothermal and solar power. The solar power industry provides many sizes of photovoltaic (PV) cell installations at high cost. Nevertheless, the NZ industry is growing exponentially. However, many PV installations have poorly designed metal structural racking systems which are prone to general and galvanic corrosion after a few years exposed in a marine environment. Les showed some recent case studies that illustrated
p.16 CORROSION & MATERIALS
corrosion problems on installed solar power systems. The global solar power industry is on a steep learning curve and it needs to embrace the basics of corrosion control and design against corrosion. The new Auckland Museum PV installation on the roof of the central city building will employ a combination of FRP and 316 SS for the racking system to ensure longevity and durability. However, the present day PV silicon panels on offer will only last about 20 years in service before replacement is required.
Following an extensive Q&A session, Chaired by Grant Chamberlain, the ACA Auckland Division AGM was held. The following members were elected to the Auckland Committee for 2014: Wayne Thomson, Les Boulton, Grant Chamberlain, Aaron Davey, Sean Ryder, Bruce Fordyce, Raed El Sarraf, John Duncan and Michel Nieuwoudt. The pictures show some of the Auckland Committee and attendees during and after the Auckland meeting with Jacquie Martin (ACA Centre).
BRANCH & YCG EVENTS
ACA at the Uni of Newcastle Graduate Careers Expo
The ACA Stand at the University of Newcastle Graduate Careers Expo, represented by Igor Chaves and Karen Swain from the Newcastle Branch.
April 2014 www.corrosion.com.au p.17
BRANCH & YCG EVENTS
Newcastle Branch AGM and Technical Night By delivering a synergistic combination of professional networking, entertainment and practical case study the Newcastle Branch fulfilled its promise towards its 2014 Annual General Meeting. The site: a cruise around the well-known steel city of Newcastle focusing on the potential risks to its various marine infrastructures. The crew: Newcastle branch members, spouses, partners, business associates and a delightful staff who provided an indulgent service. David Nicholas, branch member well recognised for his contribution towards the ACA Centurion Program, was not shy to boast his skills by taking on the role of the boat's captain. Indeed a memorable night.
The evening was two-fold, consisting of the AGM where the 2014 committee was voted in, combined with a ‘show and tell’ experience hosted by Warren Green – Vinsi partners and Robert Jeffrey – The University of Newcastle. Warren and Robert reiterated their findings when investigating past, existing and potential future problems related to Accelerated Low Water Corrosion (ALWC) coupled with Microbiologically Influenced Corrosion (MIC) along the Newcastle Harbour. More information on their publication is readily available on association’s website. The outgoing committee was thanked for their tireless work in supporting the Newcastle Branch. Special mention
was made to Karen Swain, Newcastle Branch’s former Secretary and Brad Dockrill, Newcastle Branch’s former treasurer. Karen’s extraordinary organisation and leadership skills allied to Brad’s accounting and management expertise proved invaluable to the branch’s success over the years. The evening was brought to a delightful and emotional end with the handing of Long Service awards to members who have contributed immensely to the association over the past 15 and 25 years. Role modelling the committed member, Garry March from NPC Industries Pty Ltd awarded a 50+ years membership award reminded us all how the association has grown over the past half of a century!
Show and Tell with Robert Jeffrey from the University of Newcastle. Topic: Steel Pile tidal corrosion on Newcastle harbour.
Newcastle Branch members network as they enjoy the AGM cruise.
Newcastle Branch members network as they enjoy the AGM cruise.
Newcastle Branch members network as they enjoy the AGM cruise.
Newcastle Branch Committee for 2014: From Left to Right: Lee Wicks (front), Robert Jeffrey (back), Andrew Dickinson (front), Wayne Sharman (middle), David Nicolas (front), Warren Green (Back), Simon Krismer (middle), Robert Melchers (back), Bill Livingston (front), Igor Chaves, Matt Dafter. Absent: Nathan Spencer, Phil Layton, Rob Freedman, Brad Dockrill.
Karen Swain – 2013 Newcastle Branch Secretary delivers a Membership Award to Ross Kelly.
p.18 CORROSION & MATERIALS
Garry March – NPC Industries Pty Ltd receiving 50+ Years Membership Award.
2014 Scholarships to Support Attendance at Corrosion & Prevention 2014 After the outstanding success of the ACA Foundation Ltd. 2013 Scholarship Program, the Foundation is delighted to release Round One of its Scholarship Program for 2014. The purpose of these Scholarships is to support recipient’s attendance and participation in Corrosion & Prevention 2014. The Scholarships include; 3 x Scholarships for Post Graduates to attend Corrosion & Prevention 2014. Registration (valued at $335) plus $1,000 towards accommodation and flights 3 x Scholarships to assist delegates who have not previously attended a Corrosion & Prevention conference. Registration (valued at $1,400) plus $750 towards accommodation and flights
The President of the ACA Foundation Ltd. Dean Wall commented that “the 2014 scholarship will provide numerous opportunities for recipients to engage in professional development, the program also reinforces the Foundations commitment to promote corrosion education amongst our industries and the broader community.“ Additional Foundation scholarships will be announced in the coming months. For more information on the ACA Foundation Ltd. 2014 Scholarship Program including criteria, deadlines and the application process please refer to the scholarship section of the ACA website or contact Jacquie Martin on +61 (0)3 9890 4833.
1st Round Scholarship Applications Close – Wednesday 30 April
April 2014 www.corrosion.com.au p.19
BRANCH & YCG EVENTS
Victorian YCG at GB Galvanisers This photo is of the Victorian YCG (with a couple of older corrosionists visible) at the GB Galvanisers visit on February 14. GB showed in detail the process of galvanising large structures from; receipt, preliminary inspection, cleaning, to galvanising in large baths of molten zinc, to clean up – called ‘fettling’, to final QA inspection and then to shipment. The Group was shown the issues to be considered in successful galvanising which included; structure design and finish as well as the importance of choosing materials that can be successfully galvanised. The visit was most informative and everyone enjoyed it.
Victorian YCG Lawn Bowls The YCG held a Barefoot Bowls event on February 19 in order to launch the YCG year and welcome FLF participants. The event was held at the Richmond Union Bowls Club. The event attracted over 30 attendees from various companies and institutions as well as a few of the participants in Melbourne for the Future Leaders Forum. The attendees took to the greens to revel in the sport of lawn bowls and be taught the fine art by experienced club bowlers. The lesson was well received and participants took to the green with tenacity and enthusiasm. With lawn
p.20 CORROSION & MATERIALS
bowls being flung from end to end, the inevitable rain set in. The players continued to roll until it became clear that all attempts at completing any semblance of a structured game was futile. With a wet green but spirits not dampened, the attendees left the green to imbibe and eat. The dinner was a modest BBQ affair which engaged all and allowed conversation and networking to flourish. The attendees were rallied with a modest announcement made by YCG Chairman Dean Ferguson. After which the night turned into a free flowing affair with rust on the agenda and friendship on the cards.
Overall the event was a great success. “The night was a celebration of the year to come for the young rusters. It encouraged conversation and engaged members to each other and the industry as a whole. A big thanks to all those who helped make the night a success, including the Victoria Branch for funding the event and the ACA for their support, particularly Wes Fawaz and Dean Wall for their support. Finally the YCG Victoria branch would like to thank Katherine for her efforts over the past few years and wish her well on her journey.” said Luke Thompson.
THE AUSTRALASIAN CORROSION ASSOCIATION INC SEMINAR
Concrete Performance for Coastal Assets
PROUDLY PRESENTED BY:
SPONSORED BY:
12th June 2014 • Melbourne Melbourne Marriott Hotel Cnr Lonsdale & Exhibition Streets Overview The Concrete Structures & Buildings Technical Group of the ACA has produced a technical program that will investigate and discuss concrete performance for coastal assets. This event will continue to build on the success of previous year’s concrete events and forum debate at the recent Corrosion & Prevention conference in Brisbane. This event focusing on real life case studies, explores both the successes and failures of concrete performance. The presenters will share their experiences and the lessons they have learnt. We will have industry experts from each of the following industry groups; • Asset Owners • Researchers • Consultants • Contractors • Suppliers This one day event will bring together all stakeholders to discuss various corrosion issues across the concrete structures and buildings fields. The final session will engage the audience in an open forum to discuss concrete related corrosion issues with the panel of speakers.
Program Time
Session
Speaker
8.30 – 8.55
Registration
8:55 – 9:00
Welcome and Seminar Opening
9.00 – 9.40
Whole of Life Asset Management for Concrete Structures in the Local Ports of Port Phillip and Western Port
Ledene Ellis, Parks Victoria
9.40 – 10.20
Corrosion Risk at Cracks in Marine Concrete Structures
Chris Weale, GHD
10.20 – 10.50 Morning Tea 10.50 – 11.30 Ageing Coastal Assets: Balancing Durability Performance with the needs of Strength, Functionality, Sustainability and Economy
Frank Collins, Monash University
11.30 – 12.10 Cathodic Protection - The Versatile Treatment for Corrosion in Marine Concrete Structures
Alan Bird, Marine & Civil Maintenance Pty Ltd
12.10 – 12.50 A Review on the Performance of Protective Coatings and Treatments for Coastal Assets
Andrew Dickinson, Parchem
12.50 – 13.40 Lunch 13.40 – 14.20 Performance of Epoxy Coating on Columns Exposed to Aggressive Tidal Marine Fred AndrewsConditions & Use of Corrosion Sensors for Monitoring Performance Phaedonous, VicRoads 14.20 – 15.00 Case Studies of Concrete Performance of Wharves
Frederic Blin, AECOM
15.00 – 15.30 Afternoon Tea 15.30 – 16.10 The Challenges of Maintaining Structural Durability for Concrete in Marine Environments
Mike Rutherford, Freyssinet
16.10 – 16.50 Efficiency of Hydrophobic Impregnation and Migrating Corrosion Inhibitors
Pedram Mojarrad, Sika
16.50 – 17.25 Open Floor Speakers Forum and Discussion 17.25 – 17.30 Seminar Close 17.30 – 19.00 Cocktail Function
Register now at www.corrosion.com.au April 2014 www.corrosion.com.au
p.21
FUTURE LEADERS FORUM REVIEW
ACA Foundation Ltd Chairman Dean Wall has confirmed the success of the 2014 Future Leaders Forum recently conducted by The Australasian Corrosion Association (ACA) in Melbourne, Victoria. The purpose of the Forum is to assist younger members of the industries that ACA serves to develop skills which will assist in their personal and professional development. By providing support, ACA Foundation Ltd is leading the way in positively
contributing to the work and personal lives of those who are likely to advance to senior positions in the industry in the future. The Foundation provided principal funding support for what is rapidly becoming one of the leading personal and professional development events in the corrosion industry. Further support for the Forum was also received from the Victorian Branch of ACA.
The 2014 event was the third Future Leaders Forum presented by ACA. 20 young men and women listed below were successful in securing delegate spaces on the program. Competitive applications were received from all parts of Australia and New Zealand. As in 2013, the 2014 Forum was oversubscribed with substantially more applications received than there were places available.
Name
Surname
Organisation
State
Name
Surname
Organisation
State
Ain
Beruldsen
Savcor
VIC
Jason
Maiolo
Santos
SA
Rochelle
Bosworth
GHD
QLD
Jordan
May
WA
Darren
Cram
ATTAR
VIC
Quality Maritime Surveyors
Stephen
Finger
ALS Industrial
VIC
Priya
Pandarinathan
Curtin University
WA
Daniel
Frost
Jotun
QLD
Simon
Poggioli
Extrin
WA
Marius
Gray
Vector Ltd
NZ
Phil
Schmidli
Woodside Energy
WA
Vijay
Hillier
Santos
SA
Brad
Slocum
Select Solutions SP Ausnet
VIC
Bradley
Knott
McElligotts Tas
TAS
Terence
Tjandra
Savcor
NSW
Tim
Lim
WGIM
QLD
Will
Von Moger
Savcor
NZ
Simon
Little
Southern Prospect
TAS
Josh
Logan
Anode Engineering
QLD
Hannah
Watchman
Dept of Planning, Transport & Infrastructure
SA
p.22  CORROSION & MATERIALS
FUTURE LEADERS FORUM
“A great forum for meeting other like-minded people in the corrosion industry, I will definitely be recommending this event to my colleagues.”
The program for 2014’s Forum focussed on these areas:
• Leadership vs. Management & Relationship Management • Maximising associations – the benefits of association membership • Importance of networking and how to do it • Noble silence • Beyond technical knowledge – key attributes to success • Communication skills, and • Participating in presentations
• Presentation skills • Dealing with difficult personalities in the workplace
Geoffrey Witherow from Changing Organisations facilitated the Forum for the third year in a row. Geoffrey’s
Dean Wall, who participated in the program and presented on maximising associations, said “the Forum is very popular with younger members of the industry. Their employers and direct managers value the work which ACA is doing in this area with support from the Foundation”.
highly developed skills and passion for working with young people so that they fully reach their potential were well received by all Forum participants – delegates and guest presenters alike. Guest presenters for the 2014 Forum included Dean Wall from Jotun Australia, Luke Thompson from Infracorr Consulting, Sarah Furman from AECOM and Dean Ferguson, YCG Chairman.
a division of valspar
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April 2014 www.corrosion.com.au p.23
ACA STANDARDS UPDATE
ACA Standards Update Welcome to the second corrosion related Standards Update for 2014. This Standards report focuses on Coatings and Paint related corrosion for the Coatings Technical Group. In this ‘Standards Update’, Focus 1 & 2 will, summarise all relevant standards to the technical group in question. In this update Focus 3, will look at a surface profile specification issue where the following surface profile is required. Focus 1 As 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 ‘Coatings’ Technical Group. These results are shown in Focus 1 report below. Focus 2 A 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 20 January 2014 to 13 March 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 the Focus 2 report below. Focus 3 This looks at a surface profile specification issue where the following surface profile is required; Surface Preparation: Sa2½ (ISO 8501-1) with sharp edge profile corresponding to Rugotest No. 3 BN9a These results are shown in the Focus 3 report below.
p.24 CORROSION & MATERIALS
Focus 1 Report Report on SAI Global Publications at https://infostore.saiglobal.com/ store, for all current publications and standards relating to ‘coating and corrosion’ and ‘paint and ‘corrosion’ for the ‘Coatings’ Technical Group. A total of 1429 publications were returned in the search, with 23 being AS & AS/NZS publications. Summary and highlights of the search Of interest in the AS/NZS publications were: ‘ AS 1247-2004 - Metallic coatings - Rating of test specimens and manufactured articles subject to corrosion tests 'AS 1247-2004/Amdt 1-2004 Metallic coatings - Rating of test specimens and manufactured articles subject to corrosion tests 'AS/NZS 2312:2002/Amdt 1:2004 Guide to the protection of structural steel against atmospheric corrosion by use of protective coatings 'AS 2331.3.1-2001- Methods of test for metallic and related coatings Corrosion and related property tests - Neutral salt spray (NSS) test 'AS 2331.3.10-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Cracks and pores in chromium 'AS 2331.3.11-2004 - Methods of test for metallic and related coatings Corrosion and related property tests - Chemical residue tests 'AS 2331.3.12-2006 - Methods of test for metallic and related coatings - Corrosion and related property tests - Cyclic salt fog/UV exposure of organically coated metal 'AS 2331.3.13-2006 - Methods of test for metallic and related coatings Corrosion and related property tests - Wet (salt fog)/dry/humidity 'AS 2331.3.2-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Acetic acid salt spray test (ASS test) 'AS 2331.3.3-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Copper accelerated acetic acid salt spray test (CASS test) 'AS 2331.3.4-2001 - Methods of test for metallic and related coatings -
Corrosion and related property tests - Thioacetamide anti-tarnish and porosity tests 'AS 2331.3.5-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Sulfur dioxide/hydrogen sulfide porosity tests 'AS 2331.3.6-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Electrographic porosity test 'AS 2331.3.7-2004 - Methods of test for metallic and related coatings - Corrosion and related property tests - Corrodkote (Corr) test (ISO 4541:1978, MOD) 'AS 2331.3.8-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Humidity test - 24 h cycle, damp heat 'AS 2331.3.9-2001 - Methods of test for metallic and related coatings Corrosion and related property tests - Metallic coatings - Porosity tests Ferroxyl test 'AS 1580.452.2-2002 (R2013) - Paints and related materials - Methods of test - - Resistance to corrosion - Salt droplet test 'AS 1580.481.3-2002 (R2013) - Paints and related materials - Methods of test - Coatings - Exposed to weathering - Degree of corrosion of coated metal substrates 'AS/NZS 2312:2002 - Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings 'DR AS/NZS 2312.1 - Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 1: Paint coatings 'DR AS/NZS 2312.2 - Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing Focus 2 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 20 January 2014 to 13 March 2014.
ACA STANDARDS UPDATE
This produced 46 Documents as listed below. There was 1 AS on AS/NZS Standard Update - (AS 1445-2013 Hotdipped zinc-coated, aluminium/zinccoated or aluminium/zinc/magnesiumcoated steel sheet — 76 mm pitch corrugated) since 21 January 2013. Summary and highlights of the search Of possible interest were the I.S. EN standards on Non-destructive
inspection of corrosion deposits in pipes by gamma and X radiographic inspection, as shown below. I .S. EN 16407-1:2014 Non-destructive Testing - Radiographic Inspection of Corrosion and Deposits in Pipes by xand Gamma Rays - Part 1: Tangential Radiographic Inspection. I.S. EN 16407-2:2014 Non-destructive Testing - Radiographic Inspection of Corrosion and Deposits in Pipes by
x- and Gamma Rays - Part 2: Double Wall Radiographic Inspection Of further interest was that DR AS/ NZS 2312.2 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing was not picked up in this or the previous search (Standards Report No 1 2014), but was on the general search at the info store.
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 20 January 2014 to 13 March 2014 Key word search on ‘durability’.- 6 citations None from AS AS/NZS,1 possibly corrosion related ISO/DIS 19095-4
Adhesives - Evaluation of the adhesion interface performance in plastic-metal assemblies Part 4: Environmental condition for durability
Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 12 citations found; 0 from AS or AS/ASNZ ISO 15158:2014
Corrosion of metals and alloys - Method of measuring the pitting potential for stainless steels by potentiodynamic control in sodium chloride solution
ISO/FDIS 16143-1
Stainless steels for general purposes - Part 1: Corrosion-resistant flat products
I.S. EN 16407-1:2014
Non-destructive Testing - Radiographic Inspection of Corrosion and Deposits in Pipes by x- and Gamma Rays - Part 1: Tangential Radiographic Inspection
I.S. EN 16407-2:2014
Non-destructive Testing - Radiographic Inspection of Corrosion and Deposits in Pipes by x- and Gamma Rays - Part 2: Double Wall Radiographic Inspection
DIN EN 4156 (2014-03)
Aerospace series - Rod ends, with self-aligning double row ball bearings and threaded shank in steel - Inner ring and balls in corrosion resisting steel - Dimensions and loads - Inch series; German and English version DIN EN 4156:2013
DIN EN 4537-2 (2014-02)
Aerospace series - Bushes, flanged in corrosion-resisting steel with self-lubricating liner, elevated load - Part 2: Dimensions and loads - Inch series; German and English version EN 4537-2:2009
DIN 65545 (2014-03) (Draft)
Aerospace series - Nuts, hexagon, with MJ-thread - Self-locking, corrosion-resisting steel, classification: 1 100 MPa/120 C; Text in German and English
UNE EN 62716:2014
Photovoltaic (Pv) Modules - Ammonia Corrosion Testing
BS EN ISO 11997-2:2013
Paints And Varnishes - Determination Of Resistance To Cyclic Corrosion Conditions - Part 2: Wet (Salt Fog)/Dry/Humidity/Uv Light (ISO 11997-2:2013)
BS EN 16407-1:2014
Non-Destructive Testing - Radiographic Inspection Of Corrosion And Deposits In Pipes By X- And Gamma Rays - Part 1: Tangential Radiographic Inspection
BS EN 16407-2:2014
Non-Destructive Testing - Radiographic Inspection Of Corrosion And Deposits In Pipes By X- And Gamma Rays - Part 2: Double Wall Radiographic Inspection
PD ISO/TR 16208:2014
Corrosion Of Metals And Alloys - Test Method For Corrosion Of Materials By Electrochemical Impedance Measurements
Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 22 Publications found; 1 from AS. ISO 16925:2014
Paints and varnishes - Determination of the resistance of coatings to pressure water-jetting
ISO 16927:2014
Paints and varnishes - Determination of the overcoatability and recoatability of a coating
ISO/FDIS 17463
Paints and varnishes - Guidelines for the determination of anticorrosive properties of organic coatings by accelerated cyclic electrochemical technique
ISO/FDIS 4618
Paints and varnishes - Terms and definitions
ISO/DIS 8623
Tall-oil fatty acids for paints and varnishes - Test methods and characteristic values
April 2014 www.corrosion.com.au p.25
ACA STANDARDS UPDATE
I.S. EN ISO 16925:2014
Paints and Varnishes - Determination of the Resistance of Coatings to Pressure Water-jetting (ISO 16925:2014)
I.S. EN ISO 16927:2014
Paints and Varnishes - Determination of the Overcoatability and Recoatability of a Coating (ISO 16927:2014)
DIN EN 16402 (2014-02)
Paints and varnishes - Assessment of emissions of substances from coatings into indoor air Sampling, conditioning and testing
DIN EN ISO 16474-1 (2014-03)
Paints and varnishes - Methods of exposure to laboratory light sources - Part 1: General guidance (ISO 16474-1:2013)
BS EN ISO 11997-2:2013
Paints And Varnishes - Determination Of Resistance To Cyclic Corrosion Conditions - Part 2: Wet (Salt Fog)/Dry/Humidity/Uv Light (ISO 11997-2:2013)
BS EN 16402:2013
Paints And Varnishes - Assessment Of Emissions Of Substances From Coatings Into Indoor Air - Sampling, Conditioning And Testing
BS EN ISO 16474-1:2013
Paints And Varnishes - Methods Of Exposure To Laboratory Light Sources - Part 1: General Guidance
BS EN ISO 16474-2:2013
Paints And Varnishes - Methods Of Exposure To Laboratory Light Sources - Part 2: Xenon-Arc Lamps (ISO 16474-2:2013)
BS EN ISO 16474-3:2013
Paints And Varnishes - Methods Of Exposure To Laboratory Light Sources - Part 3: Fluorescent Uv Lamps (ISO 16474-3:2013)
BS EN ISO 16925:2014
Paints And Varnishes - Determination Of The Resistance Of Coatings To Pressure Water-Jetting
BS EN ISO 16927:2014
Paints And Varnishes - Determination Of The Overcoatability And Recoatability Of A Coating (ISO 16927:2014)
ISO 16691:2014
Space systems - Thermal control coatings for spacecraft - General requirements
ISO/FDIS 21809-2
Petroleum and natural gas industries - External coatings for buried or submerged pipelines used in pipeline transportation systems - Part 2: Single layer fusion-bonded epoxy coatings
ISO/DIS 27307
Evaluation of adhesion/cohesion of plasma sprayed ceramic coatings by scratch testing
A A 59300:1998 Notice 3 Validation
Insulation Tape, Nonadhering, Glass Fabric, Polytetrafluoroethylene Coated - Notice 3 Validation
13/30197535 DC Bs ISO 27307
Evaluation Of Adhesion/Cohesion Of Plasma Sprayed Ceramic Coatings By Scratch Testing
14/30291744 DC BS EN 13523-23
Coil Coated Metals - Test Methods - Part 23: Resistance To Humid Atmospheres Containing Sulfur Dioxide
Key word search on 'galvanize' or ‘galvanized’ or galvanizing’; 'galvanise' or ‘galvanised’ or galvanising’ – 0 Standard Publications found. Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ – 0 Standard Publications found Key word search on ‘cathode’ or 'cathodic' - 1 publication; 0 from AS, AS/NZS DIN EN 12496 (2014-02)
Galvanic anodes for cathodic protection in seawater and saline mud
Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 1 corrosion related Standard Publications found – None from AS/ANZS DIN EN 12496 (2014-02)
Galvanic anodes for cathodic protection in seawater and saline mud
Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 2 Standard Publications found; 0 from AS, AS/ NZS; these were also found in the “Paint” and “Corrosion” searches ISO/FDIS 17463
Paints and varnishes - Guidelines for the determination of anticorrosive properties of organic coatings by accelerated cyclic electrochemical technique
PD ISO/TR 16208:2014
Corrosion Of Metals And Alloys - Test Method For Corrosion Of Materials By Electrochemical Impedance Measurements
Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found
p.26 CORROSION & MATERIALS
ACA STANDARDS UPDATE
Focus 3 Report This report looks at a surface profile specification issue where the following surface profile is required; Surface Preparation: Sa2½ (ISO 8501-1) with sharp edge profile corresponding to Rugotest No. 3 BN9a This Rugotest No. 3 BN9a profile is not covered by AS3894.5 Site testing of protective coatings Method 5: Determination of surface profile. In this standard surface profile height is measured by replica tape, visual profile comparator or needle depth gauge. The surface profile technique is most used in Australia and it measures the
total height of a roughness profile, typically expressed in microns; it is the maximum peak-to-valley height along the assessment length.
the equivalent replica tape Ry profile would be 50 to 75µm.
The Rugotest No.3 BN9a profile can be measured using replica tape and Hempel1 provides the surface roughness comparator comparison guide picture shown below.
We ask for reader feedback and interaction on this section to enable practice to improve and corrosion to be further minimised, if not eliminated. Please send comments to Brendan Pejkovic in the ACA office on bpejkovic@corrosion.com.au
From these charts we see that the Rugotest No.3 BN9a profile is a Ra profile and is equal to 50µm Rz. As Rz is 4-6 times Ra (the Rugotest profile) then the Rugotest No.3 BN9a profile is equivalent to 8.3 to 12.5µm; therefore
Arthur Austin ACA Standards Officer
HEMPEL HEMPEL
1
http://www.hempel.co.uk/~/media/Sites/hempel-co-uk/Files/General/Brochures/Hempel_Coating%20Reference%20Handbook_GB.pdf ; under guidelines
April 2014 www.corrosion.com.au p.27
Marine & Coastal Corrosion
Overview Now in its 8th year, the ACA annual Seminar Series is back and will visit 8 locations around Australia and New Zealand. In 2014, the series will investigate and explore marine and coastal corrosion and the ways to increase assets long term protection.
PROUDLY SPONSORED BY:
Long Term Asset Protection 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
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.
Material selection and corrosion control in the marine and 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:
Who should attend?
• 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.
Program Highlights
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.
Each location’s speaker program will vary slightly depending on local contributions. The full listing of the Seminar Series programs is available from www.corrosion.com.au
PROUDLY PRESENTED BY:
Marine & Coastal Corrosion Selected Topics Include: Topic
Company Presenting
Monitoring Corrosion Protection in Off Shore Structures
Adetra
Dundas Point Walkway – Applecross Foreshore – Condition Assessment & Remedial Design
Airey Taylor Consulting
Using Stainless & Nickel Alloys in Marine Environments
ASSDA
Tape & Membrane Encapsulation Systems. Case Histories & Lessons Learnt
Denso
Reinforcing the Protection of your Assets with Hot Dip Galvanizing
Galvanizers Association of Australia
Cathodic Protection Update with Case Studies in Marine Environments
GHD
An Ocean of Galvanizing – Case Study Reviews & Lessons Learnt
Industrial Galvanizers
Long Term Protection Of Marine Piling – Are We Stuck In Our Ways, or Just Safely Stuck In The Waves
International Paint
The Development of a Long Term Maintenance System to increase the life of Grange Resources Port Latta Ship Loading Facility
Jotun Australia
Corrosion Prevention of Coastal Assets – An Applicators Perspective
McElligotts Partners
Stainless Steels & Nickel Alloys in Marine & Coastal Environments
Nickel Institute
Corrosion Management at Northport: Overview & Update on Lessons Learnt
Northport
Assessment of Weld-Zone Coating Repair Methods for Zn-alloy coated Hollow Sections
Orrcon Steel
Variations in Corrosion Rates for Marine Structures
Pacific Testing & The University Of Newcastle
Accelerated Low Water Corrosion
Port of Melbourne & Swinburne University
Impressed Current Cathodic Protection (CP) Systems in Marine Environments
Remedial Technology
Protection of Marine Assets Using CSI Technology
Rustproof Services
Corrosion History & Performance of the Nightcliff Jetty
Jacobs SKM
A Unified Approach to Wharf Structures Condition Assessment
SMEC
Corrosion Management Design Experiences of Port Structures
Vinsi Partners
Interpretation of Concretion Profiles & the Associated Corrosion Mechanisms
Western Australian Museum
How Coastal Structures will be Affected by Welding
WTIA
Registration
Proudly Sponsored by:
To register online or to download the registration form visit www.corrosion.com.au
Contact For all enquiries regarding the Seminar Series please contact: Brendan Pejkovic on +61 (0)3 9890 4833 or bpejkovic@corrosion.com.au
February 2014 www.corrosion.com.au p.29
NEW PRODUCT SHOWCASE
SHOWCASE Oxifree® Metal Protection Oxifree TM198 is the latest innovation in sprayable polymeric resin coatings for the protection of metallic objects of any size and shape. When applied by a simple heated application machine Oxifree TM 198 encapsulates the metal object. The material then becomes an air-tight protective sheath with rubber like consistency. This flexible coating contains deep penetrating organic corrosion inhibitors providing both active and passive protection against a wide range of corrosion problems, especially in hot spot areas like flanges valves and risers
Due to the barrier properties of the material, Oxifree TM198 also provides a shield against ingress of dust, sand, mud or organic matter, therefore resisting contamination in many situations. For further information or a quote please contact; Pipe Management Australia Pty Ltd Chris Gavan t 07 5573 2694 f 02 9618 0465 m 0430133100 e chris@pmaus.com.au w www.pmaus.com.au
FirstMap™ Corrosion Mapping – A new way of seeing things NDT Equipment Sales is pleased to announce the introduction of Imperium’s newest ultrasonic camera FirstMap™. The FirstMap™ Corrosion Mapping system has been designed specifically for the Petrochemical industry, offering a revolutionary view into oil and gas pipelines and storage tanks.
creating a comprehensive large area scan. By incorporating a wheel encoder into the camera head, the operator can now take continuous images, stitch them together and create a panoramic photographic image. This mapping technology also generates thickness readings identical to those from a flaw detector.
The FirstMap™ Corrosion Mapping system incorporates specialised modifications to facilitate scanning curved pipelines with greater accuracy and to quickly and easily evaluate the large surfaces of storage tank bottoms. For the first time, users can immediately see a complete picture of the area being inspected. Technicians can see corrosion problems on the spot and generate a comprehensive data and visual representation of the problem.
Imperium’s DAV technology uses a 120 row x 120 column ultrasound detector array to generate real time C-scan images which is a very different technique than used by Phased Array. The results are clear, FirstMap™ offers a better image along with thickness readings.
Imperium’s newest enhancement allows the technician to scan multiple images and stitch them together,
p.30 CORROSION & MATERIALS
For further information please contact: NDT Equipment Sales T: (02) 9524 0558 F: (02) 9524 0560 E: ndt@ndt.com.au W: www.ndt.com.au.
NEW PRODUCT SHOWCASE
SHOWCASE Olympus instrumentation for the recycling industry XRF analysers for the recycling industry and the GoldXpert benchtop analyser for the new and second hand precious metals market were displayed by Olympus at the Australian Waste and Recycling Exhibition (AWRE) in Melbourne The Delta Professional has been developed specifically for companies conducting analysis of manufactured and scrap materials such as stainless steel and a wide range of other alloy types. They can also be used by environmental consultancies in contaminated land remediation. Companies in Australia are beginning to discover the benefits XRF technology provides. Olympus IMS builds and markets leading edge instrumentation, probes,
software programs, and accessories for in-line and advanced non-destructive testing systems. 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: IBDinfo@olympus.com.au New Zealand www.olympus.co.nz Faizal Sahib Ph (+64) 9 836 9993 E-Mail: info@olympus.co.nz
MiniTest 650 Coating Thickness Gauge Designed for durability and high precision, the MiniTest 650 is the ideal tool for any measuring task in the finishing industry. The rugged and easy-to-handle thickness gauge combines extended mechanical life on the one hand and high accuracy on the other hand to meet the requirements of any professional user in the shipbuilding, automotive, bridge building, construction or other industry. According to the selected model, the MiniTest 650 is suitable to measure: ny non-magnetic coatings such A as paint, enamel, chrome and zinc on steel. ny insulating coatings on nonA ferrous metals such as paint, anodising, ceramics on aluminium, copper, zinc die-cast, brass etc. The MiniTest 650 is available in three different models: odel F: With a magnetic-induction M sensor for measurements on steel substrates.
odel N: With an eddy current M sensor for measurements on nonferrous metals. odel FN: With a dual sensor for M measuring on steel or non-ferrous metals. Its dual sensor identifies the substrate material. Upon contact with the surface, the gauge automatically switches to the suitable measuring principle based on the application. The measuring principle conforms to the DIN, ISO, BS, and ASTM norms and standards. The MiniTest 650 is supplied complete with batteries, control plate(s), calibration standards in folding case, operating manual on a CD, quick reference guide, factory certification and soft case. For further information please contact: NDT Equipment Sales T: (02) 9524 0558 F: (02) 9524 0560 E: ndt@ndt.com.au W: www.ndt.com.au.
April 2014  www.corrosion.com.au  p.31
ACA CERTIFICATION PROGRAM
ACA’s Certification Program The ACA’s Certification program for ACA Corrosion Technicians and Technologists recognises those with education and experience in the corrosion industry. A Corrosion Technician has at least 4 years work experience and has attended a number of formal training courses, whilst those awarded Corrosion Technologist have at least 10 years work experience and have obtained further training. For a more detailed explanation of the
eligibility criteria, please consult our ACA Certification Program brochure which is available on our website www.corrosion.com.au. A schedule of current ACA Corrosion Technicians and Technologists appears below and will be published in Corrosion & Materials in full each April and October and will be continuously updated on the ACA’s web site. All current ACA Technicians and Technologists have been issued a
Corrosion Technicians
wallet card with their certification number and membership details. Please note continued membership of the ACA is a requirement for certification and therefore all certified Corrosion Technicians and Technologists will have an expiry date which coincides with their ACA membership renewal date. ‘Pending’ expiry dates indicate that a membership payment is overdue.
Corrosion Technologists
Name
Cert No:
Expiry Date
Name
Cert No:
Expiry Date
Gary Barber
248
30/06/2014
Bruce Ackland
82
30/06/2014
4/05/2014
Fred Andrews-Phaedonos
153
30/06/2014
Ross Antunovich
214
30/06/2014
Arthur Austin
106
30/06/2014
Derek Avery
295
19/08/2014
Heath Boelen
306
Stephen Brown
263
4/02/2015
Dave Charters
261
21/01/2015
Craig Clarke
246
26/03/2015
Dinesh Bankar
264
23/02/2015
Rodney Clarke
206
20/12/2014
Don Bartlett
15
29/06/2014
Ross Darrigan
174
5/09/2014
Stuart Bayliss
236
7/11/2014
Glenn Dean
280
20/01/2015
Tony Betts
74
1/01/2015
Rob Billing
12
30/06/2014
Harvey Blackburn
10
1/01/2015
Michael Boardman
30
12/07/2014
Les Boulton
43
1/01/2015
Clint Doherty
298
8/05/2014
Raed El Sarraf
305
25/09/2014
David Fairfull
179
30/06/2014
Geoff Farrant
253
30/06/2014
John Bristow
107
1/01/2015
Robert Gentry
114
30/06/2014
Gary Brockett
215
30/06/2014
Haydn George
307
23/11/2014
Kingsley Brown
257
30/06/2014
Philip Bundy
209
30/06/2014
Wayne Burns
100
1/01/2015
Brian Byrne
27
1/01/2015
Bryan Cackett
70
30/06/2014
William Guest
316
15/12/2014
David Harley
291
17/12/2014
Stephen Holt
207
28/02/2015
Bradley Jones
258
18/04/2014
Neil Campbell
38
30/06/2014
Gary Martin
57
1/06/2014
Graham Carlisle
281
19/05/2014
Ian McNair
163
30/06/2014
Antonio Carnovale
203
30/06/2014
Terence Moore
125
9/06/2014
Luis Carro
260
30/06/2014
Reg Casling
11
1/01/2015
Dylan Cawley
224
29/06/2014
Pasquale Chiaravalloti
274
11/07/2014
Peter Clark
80
30/06/2014
Stan Collins
128
30/06/2014
David Morgan
234
Pending
Reg Oliver
223
19/08/2014
David Parravicini
296
2/09/2014
Sean Ryder
262
21/11/2014
Ian Saunders
251
24/06/2014
Geoff Cope
71
29/06/2014
Brendan Schapers
314
5/07/2014
Leon Cordewener
44
30/06/2014
Robert Cox
14
30/06/2014
Peter Crampton
8
29/06/2014
Kerry Dalzell
28
30/06/2014
Roman Dankiw
208
29/06/2014
Rene D'Ath
197
11/03/2015
Robert de Graaf
154
1/01/2015
Justin Tanti
238
14/02/2015
Gavin Telford
244
30/06/2014
Ben Ward
300
16/07/2014
Mark Watson
186
3/09/2014
Derek Whitcombe
123
30/06/2014
p.32 CORROSION & MATERIALS
Mike Dinon
5
30/06/2014
Michael McCoy
109
14/04/2015
Bradley Dockrill
241
15/07/2014
Bill McEwan
32
1/01/2015
Peter Dove
210
29/03/2015
Stuart McLaughlin
299
17/12/2014
Gary Doyle
294
2/08/2014
Vic McLean
237
30/06/2014
Adrian Dundas
250
1/02/2015
Jim McMonagle
56
1/01/2015
Lucas Edwards
273
11/07/2014
John Mitchell
115
30/06/2014
Bernard Egan
20
30/06/2014
Elio Monzu
159
30/06/2014
Wayne Ferguson
242
4/09/2014
Greg Moore
97
1/01/2015
Peter Ferris
195
30/06/2014
Janet Morris
256
5/07/2014
Gavin Forrester
282
10/02/2015
Robert Mumford
33
30/06/2014
Rob Francis
23
1/01/2015
Tony Murray
134
30/06/2014
Dale Franke
199
30/06/2014
David Nicholas
94
1/01/2015
Max Fraser
283
Pending
Calvin Ogilvie
17
19/01/2015
Robert Freedman
147
1/01/2015
Dean Parker
108
5/07/2014
Jim Galanos
254
17/12/2014
David Pettigrew
297
17/12/2014
Barry Gartner
2
30/06/2014
Steve Richards
110
30/06/2014
Bill Gerritsen
18
30/06/2014
Dennis Richards
180
1/01/2015
Ian Glover
129
30/06/2014
Gavin Richardson
48
30/06/2014
Frederick Gooder
141
30/06/2014
Tony Ridgers
36
30/06/2014
Graeme Gummow
318
20/09/2014
Geoff Robb
124
30/06/2014
Wade Guye
313
9/08/2014
Bernd Rose
252
1/05/2014
Chris Hargreaves
292
28/05/2014
John Rudd
243
21/06/2014
Phil Harrison
145
1/01/2015
Fred Salome
231
1/01/2015
Peter Hart
200
30/06/2014
Ron Scaddan
272
Pending
Frank Hewitt
67
1/01/2015
Philip Schembri
198
17/12/2014
Brian Hickinbottom
138
30/06/2014
David Scott
173
29/06/2014
Brett Hollis
88
30/06/2014
Mike Slade
175
7/06/2014
Marshall Holmes
293
26/08/2014
Brian Smallridge
201
30/06/2014
Peter Hosford
216
1/01/2015
Jim Steele
119
17/12/2014
Peter Hunger
301
4/08/2014
Alan Steinicke
9
1/06/2014
Paul Hunter
62
30/06/2014
Allan Sterling
191
31/03/2015
Jeffrey Hurst
202
30/06/2014
Ian Stewart
155
5/09/2014
Craig Hutchinson
249
26/10/2014
Gordon Stewart
68
1/01/2015
Luciano Ioan
228
30/06/2014
Hussain Sulaiman Abdallah
311
25/05/2014
Bruce Jewell
245
10/05/2014
Graham Sussex
136
30/06/2014
Michael Johnstone
230
18/04/2014
Tan Swee Hain
189
30/06/2014
Michael Jukes
90
3/03/2015
Yongjun Tan
194
30/06/2014
John Kalis
166
17/12/2014
Ronald Tan
308
30/06/2014
Graeme Kelly
102
1/01/2015
Peter Thorpe
144
1/01/2015
John Kilby
193
30/06/2014
Peter Tomlin
120
30/06/2014
Alireza Kouklan
317
13/11/2014
Narendra Tripathi
312
30/06/2014
Ulf Kreher
304
11/09/2014
Francesco Turco
309
11/07/2014
Boris Krizman
169
17/12/2014
Nicholas Van Styn
229
25/02/2015
John Lane
188
20/01/2015
Peter Wade
190
9/03/2015
Bill Lannen
111
1/01/2015
Stephen Wargula
310
11/07/2014
Harry Lee
19
1/01/2015
John Waters
121
30/06/2014
Keith Lichti
133
30/06/2014
John Watson
239
10/06/2014
Verne Linkhorn
39
30/06/2014
Richard Webster
69
30/06/2014
Garry Luskan
117
2/02/2015
Mark Weston
149
1/01/2015
Willie Mandeno
13
1/01/2015
Geoffrey White
182
1/07/2014
Brian Martin
60
1/01/2015
Paul Wilson
290
19/04/2014
William McCaffrey
142
30/06/2014
Rodney Wubben
46
30/06/2014
John McCallum
59
30/06/2014
Xiaoda (David) Xu
315
28/11/2014
Murry McCormick
196
28/06/2014
Morris Young
217
30/06/2014
Daryl McCormick
1
17/12/2014
Nizam Yusoff
302
9/02/2015
Brad McCoy
178
14/07/2014
NB: this list is current as at 25/3/2014
April 2014 www.corrosion.com.au p.33
TECHNICAL NOTE
The Cold Shoe Shuffle in the Heat of the Pilbara – 3D Laser Analysis In the hot and humid conditions of the Burrup Peninsula, in the Pilbara region of North West Australia, a team of rope access NDT inspectors from Sydneybased laser Inspection Company 4Z, were armed with portable handheld laser scanners and deployed to create detailed 3D surface images of the corrosion underneath 36 cold shoes (pipe supports). The process proved extremely effective, highly accurate and faster than traditional NDT methods. Laser scanning is a new and growing method of inspection within the nondestructive testing industry and forward thinking and entrepreneurial oil and gas companies in Australia are starting to reap the benefits by embracing this emerging service. The opportunity to run 3D laser analysis occurred during a scheduled maintenance shutdown on a stabiliser unit, which needed to be completed before the cyclone season got into full swing. So 36 cold shoes were removed and inspected, mapped in 3D and reports generated in ‘real time’. The entire project was delivered in less than a 2 week period. No other inspection methodologies in the market today
are capable of delivering such rich and detailed results in such a short period of time.
dimensions, volumetric loss data, cross sectional profiling and files that can be converted and infinitely queried.
The 3D data, once the scanning of a cold shoe was complete, was brought in from the field so it could be analysed and delivered in a detailed report within minutes to asset integrity engineers, who could then direct further maintenance and or coating crews to follow through with required work. The net result for the client was potential savings in the millions of dollars, through reduced down time and minimised production losses.
Like any visual inspection method, proper surface preparation is essential. Careful cleaning and removal of any coatings, rust and other visual obstructions from the surface of the asset to be inspected is required prior to laser scanning.
The high definition scanner deployed for this project produces 3D data (accurate to 0.05 mm), that is perfectly scaled to be representative of the real geometry of the asset being inspected. The realism of the 3D image generated makes for easy visualisation of any surface defects, such as corrosion features. Further post processing of the 3D data, produces colourful corrosion maps, detailing wall loss data, corrosion feature
Hand-held laser scanners create a 3D image through triangulation, a laser line is projected onto the object from the scanner and a sensor measures the distance to the surface. Data is collected in relation to an internal coordinate system. To collect data where the scanner is in motion the position of the scanner must be determined in relation to the surface. The position is determined by the scanner using reference features on the surface being scanned (retro-reflective targets). Through continual tri-angulation and the distance measurement process, a polygonal representation of the surface is formed (a polygonal mesh). Thousands of these small faceted flat surfaces are combined to give the detailed 3D model of the corrosion feature. Laser scanning is a high resolution visual inspection process, and will therefore acquire data on everything within the scanners field of view. Laser scanning should not be confused with radiography or ultrasonics, which are complimentary methods of inspection.
Figure 1. Cold shoe (pipe support) has been removed and the pipe has been cleaned and is ready for scanning.
p.34 CORROSION & MATERIALS
Figure 2. 3D data acquisition of the corroded area.
The resulting data generated by 3D laser scanning is invaluable to integrity engineers and plant operators alike, due to its flexibility, and repeatability. It is an archive that can be stored and reused, for future comparisons, and it can be changed into a myriad of formats to be imported or used for numerical modelling, and fitness for service assessments and calculations. It can therefore also be shared with consultants, colleagues and other integrity specialists anywhere and
Figure 3. Using wireless technology the scan data can be closely monitored by the technician in real time.
Figure 4. Post processing of the scan data produces deepest pit depths in full colour and 3D.
looked at and reviewed in ‘real-time’ collaboratively. The cold shoe inspection using 3D laser technology delivered in the Pilbara was the first of its kind undertaken in Australia, and is a significant development in the evolution of inspection techniques for corroded assets, and data acquisition on material performance. As costs for maintenance continue to increase, and plant operators continue to push their plants and plant materials further, the need for highly accurate data acquisition and inspection results, that only laser scanning produces, will increase. Submitted by Joel Hicks of 4Z, who are a specialised 3D NDT company, made up of highly skilled rope access NDT inspectors, able to perform inspection services in confined spaces, and difficult to access platforms, elevated areas on and offshore.
Figure 5. Further post processing can go to a level 2 assessment, detailing the geometry of the corrosion feature.
April 2014 www.corrosion.com.au p.35
PROJECT PROFILE
The World’s First Hybrid Corrosion Protection Systems for Prestressed Concrete Bridges Many reinforced concrete structures suffer from corrosion damage. Causes include salt ingress due to the application of de-icing salts during winter maintenance, exposure to marine environments and carbonation of the concrete. Corrosion is an electrochemical process and as such the use of electrochemical technology treatments has been very popular. Traditional treatments such as Impressed Current Cathodic Protection (ICCP) require the passage of a constant current through the concrete to arrest corrosion activity and hinder its future development. However, for prestressed reinforcement there are risks of hydrogen embrittlement of the steel if the applied polarisation is not strictly controlled. Standards deal with such risks by limiting the induced change in the potential of the steel reinforcement by reducing the amount of hydrogen generated as a result of water hydrolysis during the application of an electrochemical treatment such as ICCP. However the risk to the
Figure 1. Kyle of Tongue Bridge, Scotland.
p.36 CORROSION & MATERIALS
asset owner remains throughout the long-term use of an ICCP system as monitoring and adjustments are usually undertaken at annual intervals only and this may not be sufficient. An alternative approach to reduce this risk would be to apply a brief impressed current treatment delivered using an external DC power supply to re-alkalise the corrosion sites and provide longterm corrosion prevention by means of galvanic corrosion protection. This combination of electrochemical treatments is more commonly known as hybrid corrosion protection. The Kyle of Tongue Bridge in Sutherland (Figure 1), Northern Scotland opened in 1970, has an overall span of 184m consisting of 18 approximately equal spans and carries a single lane dual carriageway. Prestressed concrete beams form the deck, with reinforced concrete pilecaps supported on steel piles. The bridge was patch repaired in 1989 due to chloride induced corrosion. However, inspections from 1999 onwards reported on-going corrosion and structural deterioration (Figure 2).
A refurbishment contract was let in 2011 to extend the service life of the structure for a 30 year period by providing corrosion arrest and prevention. The Tiwai Point Bridge in Invercargill, Southland, New Zealand opened in 1969, has an overall span of 486m consisting of 27 approximately equal spans and carries a single lane dual carriageway. It is comprised of prestressed and post-tensioned concrete beams forming the deck, with reinforced concrete pilecaps supported on prestressed concrete piles. The super-structure was replaced in 2009-2010 due to severe corrosion to the reinforcement. A repair contract was let in 2013 to extend the service life of the sub-structure for a 50 year period by providing corrosion arrest and prevention. Hybrid corrosion protection was implemented on both structures. For Kyle of Tongue, it was used to arrest existing corrosion activity to the prestressed concrete beams of the super-structure and extend their service life for an additional 30 years. For Tiwai Point Bridge, it was used to provide corrosion prevention to the prestressed concrete piles within the tidal zone with a service life of 50 years. The advantages of employing hybrid corrosion protection included:
Figure 2. Typical chloride induced deterioration of the prestressed concrete beams.
PROJECT PROFILE
i) combining the power of a traditional electrochemical system to arrest corrosion activity with the simplicity and low maintenance requirements of galvanic technologies, ii) corrosion activity arrested immediately through a temporary energising phase, iii) overall lower risks of hydrogen embrittlement, iv) no need for permanent power supplies and associated annual maintenance costs, v) it reduced access requirements for installation and monitoring, vi) future re-energisation features and vii) it significantly reduced risks of electrical short-circuits. Only physically deteriorated concrete was required to be removed from the prestressed concrete elements. Hybrid anodes 18mm in diameter and typically 37mm long were installed in pre-drilled cavities at approximately 300mm centres, in-between the prestressed tendons. The pre-drilled cavities were filled with proprietary low strength putty to fully cover the anodes and provide separation from the repair concrete (Figure 3). The hybrid corrosion protection systems installed on the two structures were designed to provide an initial charge sufficient to arrest corrosion
and to provide adequate current to maintain passivity for the remainder of the service life. However, it has also been designed to enable an additional impressed current charge later during service life should monitoring data so determine that this is necessary. On this basis, the following criteria were set for assessing its performance:
Overall, hybrid corrosion protection is an attractive alternative to traditional corrosion protection treatments as it combines the power to arrest the corrosion activity with the simplicity and low maintenance requirements of galvanic technologies. It offers a temporary energising phase to arrest corrosion followed by a permanent galvanic mode phase which is particularly beneficial for prestressed concrete structures as it reduces significantly any hydrogen embrittlement risk.
minimum charge to the A reinforcement of 50 kC/m2; uring the impressed current phase D of the treatment, the potential of prestressed steel shall not be driven more negative than -900 mV with respect to Ag/AgCl/0.5M KCl (Silver/ Silver Chloride) electrode;
Following a brief impressed current treatment delivered using an external DC power supply to arrest corrosion, low density galvanic corrosion protection has been sufficient to maintain the corrosion rates below the required threshold. Monitoring of the steel potentials over a period of up to 600 days has also confirmed that the steel is passive. It has also been observed that over-time steel potentials have been moving towards more positive values which is another indication of overall steel passivity. Most importantly, passivity has been maintained despite the continuous exposure to an aggressive marine environment.
he current density, measured at T locations of high corrosion risk, after the initial impressed current phase and system depolarization should be less than 2 mA/m2; he anodes shall be installed in such a T way that there is capability for future impressed current treatment phases during the system life. Corrosion current densities can be calculated based on an applied current to the steel and the resultant steel potential shift. These can be subsequently inserted into the Butler– Volmer equation, which provides the basis for polarisation resistance theory, to calculate the corrosion current density (Figure 4).
-70
C. Christodoulou, R. Kilgour AECOM (Editor’s Note: This is an abbreviated version of the paper that was originally published with references in the Corrosion & Prevention 2013 proceedings as Paper 076.)
Applied Current = 1.8 mA/m2
System Off
-60 -50
IR drop = 21mV
Potential (mV)
-40 -30
icorr =
-20
( ( ) ( )) exp
-10 0
iappl
Pot. Shift = 55 mV
2.3∆E 2.3∆E -exp βc βa
icorr = 0.71 mA/m2
10 20 30 40 09:44
09:47
09:50
09:53
09:56
09:59
Time Figure 3. Typical hybrid anode installation on a prestressed concrete beam.
Figure 4. Example corrosion current density calculation.
April 2014 www.corrosion.com.au p.37
PROJECT PROFILE
Making ‘The Moment’ Last An intricate new crimson sculpture known as The Moment, which adorns a new apartment building in Melbourne’s premier arts precinct, benefits from a hot dip galvanizing (HDG)-based duplex system that lowers total lifecycle cost while delivering a striking aesthetic finish. The duplex system for this sculpture, consisting of a base HDG layer and two top coats, cost less than a three coat paint system to provide equivalent protection, representing a saving for the client. The result is a striking HDG and painted piece 7 metres in diameter and 2.4 metres deep, permanently installed 5 metres above ground. Predominantly created from 3mm mild steel and
p.38 CORROSION & MATERIALS
mounted on an angle frame, the installation weighs three tonnes. The sculpture was built by artist, Damian Vick and was commissioned for a new residential development comprising 220 apartments in South Melbourne; the neighbourhood home to the National Gallery of Victoria, Victorian College of the Arts, Malthouse Theatre, Melbourne Recital Centre, Art Centre and the Australian Centre for Contemporary Art. Due to its location in the centre of Melbourne’s art hub there was a Council requirement to provide an artistic feature to the building. Considered the most significant of Mr Vick’s works to date, he needed to
ensure it was developed in such a way to ensure great longevity of both the structure and the finish. Due to the complexity of the design, the structure was created from 49 individual sections with every piece hot dip galvanized, the finish primarily chosen over a paint-only application to ensure longevity. The HDG coating under the aesthetic paint means the steel substrate will not corrode and taint the work with unsightly rust staining for a long time. The extremely odd shapes that make up the piece required precise jigging to ensure no build-up of zinc on the inside and outside surfaces. The dipping technique employed by the galvanizer
PROJECT PROFILE
in accordance with AS/NZS 4680 ensured no runs, dribbles or pimpling on the outside surfaces and sufficient coating thickness. Wire and touch marks were not allowed as any defect would show up due to the duplex coating. Consultation at the initial design stage allowed for adequate venting/draining to be placed and not to detract from the overall façade. Due to the thin gauge of steel used, care with quenching was critical to ensure no distortion as any deformation at all would have made assembly of the work virtually impossible. After the duplex paint coating had been applied and cured, the
galvanizer had to ensure no damage to the top coat through handling or transporting, which was exacerbated by the tight time schedule for transporting and installing onsite, and the safety issues associated with the prominent public location. Transporting the sculpture to site required that every single item was individually wrapped and shipped to ensure no damage to the final surface finish.
Project team Developer/Owner: PGS Management/LAS Group
The paint work component involved whip blasting surface preparation, before applying an epoxy prime coat of DUREMAX® GPE at 75 microns and a polyurethane topcoat of WEATHERMAX® HBR of 50 microns thickness.
Paint System: Geelong Galvanizing
Architecture: Peddle Thorp Architects. Project Manager: Damian Vick Hot Dip Galvanizer: Geelong Galvanizing
Photos: Courtesy of Damian Vick & Geelong Galvanizing
April 2014 www.corrosion.com.au p.39
COATINGS GROUP MEMBER PROFILE
Mattioli Bros. Q: In what year was your company established?
gas, marine, chemical process, general fabrication, tank lining, offshore etc.
A: 1968.
A: Our business divisions enable Mattioli Bros to cover most markets –
Q: How many employees did you employ when you first started the business? A: The business was started by the 2 founding brothers and 1 employee. Q: How many do you currently employ? A: The numbers can fluctuate considerably depending on projects at any given time. We generally operate in excess of 80. Q: Do you operate from a number of locations in Australia? A: We are Melbourne based company with contracts and projects around Australia. Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.) A: Coating Management is our core business. Our 4 key business divisions enable us to provide complete coating solutions to our diverse client base. ong Term Asset Protection L Commercial Painting & Restoration Floor Coating Systems Industrial Protective Coatings Q: What markets do you cover with your products or services? eg: oil &
p.40 CORROSION & MATERIALS
Industrial Oil & Gas Chemical Tank linings Power Stations, etc Road & Rail Commercial Buildings & Factories Structures Body Corporate Heritage Universities New Construction Flooring Food & Beverage Manufacturing Pharmaceutical, just to name a few.
Q: Is the business yard based, site based or both? A: We are predominantly a site services based business, however our new facility allows for both. Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.)
divisions. It also highlighted qualified and experienced personnel and displayed the company’s organisational and managerial skills. Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job? A: The best advice for a great outcome on any project including the Victorian Desalination Project is to have a close working relationship with your client and understand their expectations, plan well, provide qualified and experienced personnel and execute works precisely as specified. The Victorian Desalination Project is a testament to these principals. Q: Do you have an internal training scheme or do you outsource training for your employees? A: We have several internal training schemes for our employees, we specifically tailor training schemes for Project Managers, General Site Personnel and Apprentices. We also utilise external services such as the ACA, NACE, PCCP and ISO Global.
A: Yes we do. We offer consultancy services, overall project management and specification development. Q: What is the most satisfying project that you have completed in the past two years and why? A: Victorian Desalination Project – this project allowed Mattioli Bros. to showcase our core strengths from all
Mattioli Bros. Coating Management Systems 42-48 Ricketts Road Mount Waverley, VIC 3149 Phone: (03) 9544 9555 Facsimile: (03) 9544 3755 www.mattiolibros.com.au
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April 2014 www.corrosion.com.au p.41
INDUSTRY INSIGHT
Protecting Pipelines from Corrosion Under Insulation In the petrochemical industry Corrosion Under Insulation (CUI) in pipeline systems consumes a significant percentage of the maintenance budget. A large portion of this money is spent on expensive items such as external piping inspection, insulation removal and re-installation, painting and pipe replacements. CUI prevention strategies provide long term and reliable prevention of CUI that move towards reduced inspection and maintenance piping systems and significant maintenance cost reductions. Coating with TSA (Thermal Sprayed Aluminium), using flamespray equipment is one method that a number of operators within the petrochemical industry have adopted. TSA is found to be a cost effective solution compared to other systems when reviewed over the lifetime of the facility. One of our customers has an ongoing programme for applying TSA at a petrochemical plant, as a solution for the long term protection against atmospheric corrosion and CUI. One specific project is a three quarter mile long marine jetty pipeline that is used for the transportation of lube oil and is exposed to the harsh marine environment. Other TSA projects on this site have included a full range of pipes and vessels, including work on live operating plant. To ensure the success of the thermal spraying process, the preparation of the pipeline surfaces is critical. For this project the pipeline surface was prepared by grit blasting with garnet to give a sharp angular profile for the TSA to bond to. As part of the QA/QC process, the blast profile was regularly checked using Testex tape to ensure it meets the required 75-125 micron specification. The grit blasted surface
p.42 CORROSION & MATERIALS
was then given a visual inspection, using 10 x magnification, to check the surface cleanliness and finish. The pipes are also given a ‘tape test’, which checks for dust contamination of the blasted surface. The tape sample is then visually inspected against white and black backgrounds for signs of dust particles. The final quality test is a salt contamination test. Using a small flexible container a minimal amount of testing solution is applied and agitated on the surface of the blasted pipe. This solution is then checked for the presence of salt using a test kit pipette. Once all of these tests have been passed the pipelines are ready to be thermal sprayed with aluminium. In this project the gas bottles and compressor were situated in a remote supply area, which gave easy access to the gas cylinders and enabled manifolding for fewer cylinder changes. In elevated applications such as vessels and towers, the cylinders can remain on the floor while the spray system is elevated tens of metres. This situation therefore requires less complex scaffolding as the heavy bottles are not scaffold mounted. The 30 metre supply package, consisting of gas, oxygen and air, was fed from
the overhead supply area down to the control panel. The spray pistol is then a further 10m away from the control panel. This setup allows around a 60m length of piping to be sprayed without having to move the cylinders and air compressor, giving significant productivity benefits in a very difficult environment. The contractor on this specific jobsite is using two Metallisation MK73 flamespray systems in different spray locations. Once the blasting and inspection is completed, the TSA application starts. Typically, blasting and inspection is completed in the morning taking approximately four hours. The TSA is applied in the early afternoon for around three hours and the final sealant application at the end of the day. The TSA is applied with a methodical work pattern with the pipe topside coated first, then the underside. The long supplies package allows the sprayer and wireman to move freely around the worksite in the most efficient manner to suit the specific area. The MK73 deflected extension is perfect for those difficult to access areas commonly found
INDUSTRY INSIGHT
at petrochemical sites and has been designed specifically for this application area. It comes in three lengths, 150mm, 300mm and 450mm. The extension unit can spray directly forward or at a deflected angle up to 90º by varying the deflector air
pressure. The deflection nozzle can also be rotated through 180° to allow spraying in a 360° arc around the pistol. The long supplies system provides flexible working conditions, particularly useful when spraying the underside of the pipes.
Following the application of the TSA, the pipelines in this specific application were sealed with an aluminium pigmented silicone (‘Intertherm 50’) sealer, which was applied until full penetration was achieved. In some CUI related environments, no sealer is applied, especially where the spray area is operational and hot. During the application of the TSA the operators periodically checked the coating thickness using a DFT gauge and made appropriate corrections along the way. The specification for this particular job was 250-500 microns. The QA/QC Inspector for the project also checked and recorded the coating thickness throughout the process. To support the QA/QC process the spray operators produced witness plates on a daily basis, which were then tested for adhesion to ensure it met the minimum 1000 psi – 6.9MPa coating thickness. Audit bond strength testing was also carried out periodically on the actual sprayed pipe sections. Thermal spraying involves the projection of small molten metal particles onto a blast prepared surface. Upon contact, the particles flatten onto the surface, freeze and mechanically bond, firstly onto the blasted substrate and then onto each other, as the coating thickness is increased. To create the molten particles, a heat source, a spray material and an atomisation/ projection method are required, in this instance the customer opted for the flamespray process. Article supplied by Keven Healey, Metal Spray Supplies Australia
April 2014 www.corrosion.com.au p.43
Corrosion of Concrete Structures Corrosion & CP of Concrete Structures Sydney 21-22 May 2014
ACA/ACRA Corrosion & Protection of Concrete Structures
Brisbane 7-8 August 2014
Sydney 19-20 June 2014
This course covers the background theory on corrosion and cathodic protection.
Brisbane 27-28 November 2014
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 Cost: • Members $1060 • Non Members $1330
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 Cost: • Members $1060 • Non Members $1330
Register now at www.corrosion.com.au p.44 CORROSION & MATERIALS
UNIVERSITY PROFILE
Curtin Corrosion Engineering Industry Centre The Corrosion Centre is focused on education, high quality research services, and corrosion testing. Its diverse testing facilities offer several opportunities to investigate a broad range of corrosion issues. Combined with industry support, dedicated researchers and students are able to offer solutions and insights into real industry problems. Some of Curtin’s current research efforts are outlined below. Research Areas Microbiologically Induced Corrosion (MIC): MIC is an electrochemical process in which microorganisms influence the corrosion reactions. Research has been conducted on the preservation of wet-parked pipelines, the assessment and control of microorganisms in oilfield systems and MIC of offshore construction alloys.
Corrosion Under Insulation (CUI): CUI is a severe form of external corrosion that occurs in carbon and stainless steel equipment that has been insulated. The centre is currently developing a test rig which can improve the understanding of CUI and its contributing factors. The research aims to develop strategies to reduce the CUI rate.
Top-of-the-Line Corrosion (TLC): TLC occurs in wet gas pipelines. It can lead to localized corrosion failures due to the lack of conventional corrosion inhibitors reaching the top-of-theline. Research has been performed to enhance the efficiency of volatile corrosion inhibitors to increase pigging intervals and minimize maintenance costs.
Under-Deposit Corrosion (UDC): UDC research involves development of test methods for determining the extent of corrosion, particularly localized corrosion and investigating UDC mechanisms in CO2 media. The UDC research team at Curtin University have applied electrochemical and advanced analytical methods, such as in-situ atomic force microscopy and synchrotron-sourced infrared spectroscopy (Australian Synchrotron). More recently, the team studied the effect of various mineral deposits on CO2 corrosion of carbon steel, identified corrosion inhibitors with low adsorption affinity to sand and determined the relationship between corrosion rates and the structures of adsorbed inhibitor films.
Monoethylene Glycol (MEG) Corrosion and Testing: MEG is an intrinsic component used for addressing hydrate and corrosion management issues in multiphase gas pipelines. Curtin Corrosion Engineering Centre has been involved in extensive research and testing of effects of MEG on corrosion, and assessing operational issues associated with various chemical additives. The Corrosion Centre is currently working towards building a MEG pilot plant as part of Joint Industry Program on Exploration and Production Sound and Marine Life (JIP).
In-situ AFM images of carbon steel surface with corrosion products after exposure to CO2 conditions.
3D optical image of pits on carbon steel exposed to seawater.
Research & Testing Capabilities Coating test services Cyclic corrosion testing Coating evaluation Flow-coating evaluation MIC services Microbial Diversity profiling. Gene expression studies Biocide qualification Metabolic activity levels
hemical evaluation and C qualification testing Materials qualifications Electrochemical testing
Surface analysis 3D imaging Electron microscopy Atomic force microscopy Failure Analysis Dissolved oxygen in complex matrices Hydrogen sulphide (H2S) corrosion testing Fit for purpose testing op-of-the-line corrosion testing T using high pressure, high temperature autoclaves aterials and inhibitor testing at high M temperature, pressure and shear stress using jet impingement cells
Jet impingement cell setup. Contact Information Director: Professor Moses Tade, (M.O.Tade@curtin.edu.au) Corrosion Research and Testing Services: Professor Brian Kinsella (b.kinsella@exchange.curtin.edu.au) Advanced Corrosion Learning: Professor Rolf Gubner (r.gubner@curtin.edu.au)
April 2014 www.corrosion.com.au p.45
SUPPLIERS & CONSULTANTS
David Pocock MANAGER
HEMPEL A/S 1 Garston Way North Coogee WA 6163 Australia www.hempel.com
For Advertising details, please contact:
Tracey Winn Marketing & Communications Manager The Australasian Corrosion Association Inc Phone: +61 (0)3 9890 4833 Ext. 238 Fax: +61 (0)3 9890 7866 Email: twinn@corrosion.com.au Web: www.corrosion.com.au
22 Irvine Street Bayswater WA 6053 T: 08 9721 2265 F: 08 9271 2235 M: 0409 112 010 E: david@tfgpumpline.com.au www.pumpline.com.au
Phone: Mobile: Fax: Email:
+61 8 9431 7377 +61 447 600 027 +61 8 9431 7388 phma@hempel.com
PHILIP MATHEW Global Business Development Manager Group Marketing
Australia
Russell Fraser Sales Pty Ltd
David Dawson
Phone: 1800-RENT-DH (736 834) Mobile: 0450 008 259 Office: 02 9833 0777 Fax: 02 9833 0700 Email: ddawson@rentdh.com www.rentdh.com
National Sales & Operations Manager
DeHumidification Technologies PTY LTD 6 Warrior Place St Marys NSW 2760 Australia
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3C Corrosion Control Company AB Billeberga Station 3C Corrosion Control Company AB P.O Box 72 Station Billeberga SE-268 03 72 Billeberga P.O Box SWEDEN SE-268 03 Billeberga
SWEDEN
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TECHNOLOGY
Corrosion Control Solutions for Concrete Structures Phone: +46Phone: 418 411 900 E-mail: +46 418 411 900 info@3ccc.net E-mail: www.3ccc.net info@3ccc.net www.3ccc.net
Gianni Mattioli
Operations Manager
1-3 Commercial Road Notting Hill Victoria 3168 Australia Mobile: 0412 360 378 Phone: (03) 9544 9555 Facsimile: (03) 9544 3755 Email: gmattioli@mattiolibros.com.au Web: www.mattiolibros.com.au
TRISTAR AUSTRALIA PTY LTD T:+61 894942151 F:+61 894349206 Website: www.tristar-au.com Email: sales@tristar-au.com
Sales Manager
Abrasive Blast Media Supplier
SUPER GARNET & GEO-BLASTER® Exclusive Distributor for Australia & New Zealand AU Free Phone 1800 309 734
sales@industrial-minerals.co.nz NZ Free Phone 0800 646 372
p.54 CORROSION & MATERIALS
Phone: 02 8097 7004 www.remedialtechnology.com.au Contact: Atef Cheaitani on 0412 477 773 atef.cheaitani@remedialtechnology.com.au
Contact Dr ANTHEA AIREY BSc(Hons) PhD MBA MRACI CChem email: anthea@atconsulting.com.au ph: 08 92650400 12/18 Harvest Terrace, West Perth WA 6005
Toll free: 1800 008 379 Fax: (02) 88431589 Email: dh.info@munters.com.au www.munters.com.au
KURT RUSSELL
Condition Assessment Repair Specification Galvanic Protection Desalination Realkalisation Corrosion Prevention Cathodic Protection Strata & Remedial
Corrosion, Materials Failure & Mould Investigations Remediation Specification, Contract Administration Industrial and Environmental Chemistry Structural and Civil Design for Durability
For Applications in: • Surface preparation and coating • Condensation and corrosion prevention
www.mineralscorp.com
SYDNEY Tel: 02 9545 4433 Fax: 02 9545 4218 rfs@rfsales.com.au www.rfsales.com.au
REMEDIAL
Manufacturers and Suppliers of: • Dessicant Dehumidifiers • HCU- Humidity Control Units • Temporary Humidity Control Systems
Munters Pty. Limited Sydney – Brisbane – Melbourne
InSPectIon & teStIng equIPment
Sydney | BriSBane | MelBourne | Perth
Manufacturer of: • DIMET Sacrificial Anodes. Design, survey, installation and commissioning of ICCP by NACE certified CP Engineers • MASTERCOTE PTFE Coated, and high grade alloy/ stainless/ high nickel/ super duplex special fasteners (e.g. anchor/stud/hex bolt). A Division of TRI-STAR Industries (Singapore) Website: www.tristar.com.sg Email: sales@tristar.com.sg T: +65 62663636 F: +65 62653635 / 2801
SUPPLIERS & CONSULTANTS
Leading Suppliers of NDT Equipment for the Corrosion Industry
Cathodic Anodes Australasia
Head Office T +61 7 5476 9788 sales@cathodicanodes.com.au www.cathodicanodes.com.au
Unit 23, 58 Box Rd Taren Point NSW 2229 Tel: 02 9524-0558 • Fax: 02 9524-0560 Email: ndt@ndt.com.au • Web: www.ndt.com.au
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Technical Note: Pipelines and Polyurethane Coatings: A Winning Combination Industry Insight: Overcoming Corrosion Challenges Faced in Alumina Processing Project Profile: Sydney Desalination Pipeline Cathodic Performance Review after Protection System 3 Years Project Profile: Don’t Gamble on Your Coating Selection Research Profile: CSIRO’s Environmental Surface Design Team Professional Practice Paper: Stainless Steel in Bridges: A New Zealand Perspective
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