Corrosion & Materials April 2014

Official

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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

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Proudly presented by:

21–24 September 2014

Major Sponsor:

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Total prize value $3000 (AUS).

For full competition terms and conditions please refer to www.acaconference.com.au

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.

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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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SWEDEN

Original Bumax® Stainless Fasteners: » Bumax® 88 tensile strength to Class 8.8 » Unmatched Corrosion resistance Tel: (02) 8818 0222

www.hobson.com.au

- 3D Laser Scanning - Ultrasonic Thickness Gauges - Holiday Detectors - Coating Thickness Gauges - Pit Gauges, Borescopes, Magnifiers - Surface Replication & much more…

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

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Dr David Tawfik — Principal Materials Engineer

Dr David Tawfik — Principal Materials Engineer

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2012: Review and Photos ACA 2013 Training Calendar

Technical Introduction: Galvanic Corrosion and Dissimilar Metals Project Profile: Corrosion Management at the Port of Newcastle Project Profile: High Grade Coatings Keep Coastal Stadium Gleaming Technical Note: GPR Array for the Condition Assessment & Pavements of Concrete Slabs

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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Project Profile: Engineered Maintenance of Newcastle Port Wharf Structures Technical Note: Energy Savings in the HVAC Environment Technical Note: Salt Fog Testing University Profile: RMIT University Professional Practice Paper: Cathodic Prevention of Reinforced Concrete Seawater Cooling Towers

University Profile: Ian Wark Research Institute University of South Australia Professional Practice Paper: Thermal Metal Spray: Successes, Failures Lessons Learned and

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Project Profile: CityLink Gateway Red Restored Project Profile: New Systems Open Opportunities for Protection in Concrete Cathodic Repair University Profile: Swinburne University of Technology Professional Practice Paper: The Application of Plasma Electrolytic Oxidation (PEO) to the Production of Corrosion Coatings on Magnesium Resistant Alloys: a Review

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Corrosion & Prevention 2013: Call for Papers ACA 2013 Training Calendar Technical Introduction: Designing For Corrosion Protection – Part 2 Project Profile: Restoring the Pride of an Australian Icon champions ACFM in Australia

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Project Profile: Neptune

University Profile: The

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Dr David Tawfik — Principal Materials Engineer

Dr David Tawfik — Principal Materials Engineer

April 2014 www.corrosion.com.au p.55

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