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Vol 39 No 6, December 2014 ISSN 1326 -1932
Inside this Issue: Project Profile: Attraction – The Melbourne Star Observation Wheel Corrosion History: Corrosion Engineering – an Historical View C&P2014: Full Review University Profile: RMIT University Professional Practice Paper: Performance of Hot Dip Galvanizing in Coastal Environments: A Review
Proudly presented by:
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Major Sponsor:
Adelaide Convention Centre • Adelaide, South Australia, Australia • 15 - 18 November 2015 Jotun blue
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Corrosion and Prevention is the annual conference of the Australasian Corrosion Association, it’s a 4 day gathering of world experts on corrosion mitigation. This will be a premium networking event as well as a source for the latest information concerning corrosion mitigation. Entitled Corrosion & Prevention 2015, the conference will feature a program of keynote speakers and presentations under a range of industry streams and is expected to attract approximately 450 - 550 delegates. In 2015 we invite you to the vibrant city of Adelaide, which is internationally regarded as a wine and food mecca, add in a temperate Mediterranean climate and Adelaide is the ideal place for mixing business with pleasure. All in all, this promises to be an enlightening, exciting and highly enjoyable conference.
Call for Papers Submissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2015. Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are: Close of Abstracts: 13 March 2015 Acceptance of Abstracts: 3 April 2015 Receipt of Papers: 5 June 2015
Submit an Abstract Please refer to www.acaconference.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (13 March 2015). Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process.
p.2 CORROSION & MATERIALS
Guide to Submission Papers submitted to the Corrosion & Prevention 2015 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/permission from their organisation. Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary. All authors whose papers are accepted are required to attend the conference to present.
The Destination Nestled between the beautiful Adelaide Hills and the long white beaches of the Gulf of St Vincent, Adelaide is a picturesque city featuring wide boulevards surrounded by parklands around the city centre. Its position on the banks of the Torrens River amongst superb gardens also gives the city a relaxed atmosphere and a lifestyle that is the envy of all who visit. Adelaide is internationally regarded as a wine and food ‘destination’ - offering locally produced world-class wines matched with fresh local produce; resulting in amazing dining experiences that are unforgettable. South Australia is made up of spectacular regions, all of which offer a unique and exhilarating experience waiting to be discovered. Amongst the many reasons people visit South Australia are the spectacular scenery, fishing, fauna and national parks - wine and food are often at the top of the list. South Australia’s wineries are legendary - the Barossa Valley, McLaren Vale, Clare Valley, Coonawarra and Adelaide Hills are sought out by many visitors.
www.southaustralia.com
Proudly presented by:
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Major Sponsor:
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Technical Streams
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Corrosion and Prevention 2015 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion on a daily basis. Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application. Submissions may include research papers, posters, review papers and case studies related to the industry sectors and technical streams listed below. • Advances in Sensing & Monitoring • Asset & Integrity Management • Cathodic/Anodic Protection • Concrete Corrosion & Repair • Corrosion Mechanisms, Modelling and Prediction • Materials Selection & Design • Marine Corrosion • Mining • Non-Destructive Evaluation (NDE) • Novel Materials and Their Application • Oil & Gas • Power & Energy • Protective Coatings • Water & Wastewater
Industry Sectors Attracting approximately 450–550 delegates, this conference will have material of value to: Consultants, Asset Owners, Contractors, Suppliers and Academics within the following industries • Buildings & Construction • Consulting Engineering and Technical Services • Cultural & Historical Materials Preservation • Defence, Aviation, Maritime • Education & Research • Marine Transport & Infrastructure • Mining & Resources • Oil & Gas • Power & Energy • Water & Wastewater
Conference Committee Conference Convenor Alan Bird Technical Chair Erwin Gamboa Conference Committee • Mohammad Ali • Brian Hickinbottom • Peter Hosford • Raman Singh • Dean Wall
Sponsorship and Exhibition Corrosion & Prevention 2015 offers strong branding and exposure in a focussed and professional environment. As with every Corrosion & Prevention Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services. For further information, please contact the Australasian Corrosion Association on +61 (0)3 9890 4833 or email conference@corrosion.com.au
Your Hosts The Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, industry association, established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion. The vision of the ACA is to be leaders throughout Australasia in disseminating knowledge to enable best practice in corrosion management, thereby ensuring the environment is protected, public safety enhanced and economies improved.
The Australasian Corrosion Association Inc PO Box 112 Kerrimuir, Victoria, Australia, 3129 Ph: +61 (0)3 9890 4833, Fax: +61 (0)3 9890 7866 Email: conference@corrosion.com.au Website: www.acaconference.com.au
December 2014 www.corrosion.com.au p.3
CONTENTS
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 short article to Brendan Pejkovic at bpejkovic@corrosion.com.au The Australasian Corrosion Association Inc The ACA is a not-for-profit, membership Association which disseminates information on corrosion and its prevention or control by providing training, seminars, conferences, publications and other activities. Vision Statement To be leaders throughout Australasia in disseminating knowledge to enable best practice in corrosion management, thereby ensuring the environment is protected, public safety enhanced and economies improved.
Front Cover Photo:
The Melbourne Star at the new Docklands home. (Image Courtesy of AkzoNobel).
The ACA is a founder member of the World Corrosion Organization
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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$77.00, 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 E-mail: aca@corrosion.com.au Internet: www.corrosion.com.au ACA Board Paul Vince (Chair) Kingsley Brown Graham Carlisle Peter Dove Allan Sterling Dean Wall ACA President: Mohammad Ali ACA Senior Vice President : John Duncan ACA Junior Vice President: Matthew Dafter ACA Executive Officer: Wesley Fawaz
ACA Branches & Divisions Auckland Division: Grant Chamberlain
64 21 245 9038
Newcastle: Nathan Spencer
61 439 511 836
New South Wales: Jim Galanos
61 2 9763 5611
Queensland: Cathy Sterling
61 7 3821 0202
South Australia: Dennis Richards
61 0 419 860 514
Tasmania: Grant Weatherburn
61 0 418 120 550
Taranaki Division: Ron Berry
64 27 671 2278
Victoria: John Tanti
61 3 9885 5305
Wellington Division: Monika Ko
64 4 978 6630
Western Australia: Phil Schmidli
61 4 5148 0090
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
Petroleum & Chemical Processing Industry: Fikry Barouky
61 402 684 165
Research: TBA Water & Water Teatment: Matthew Dafter Young Corrosion Group: Dean Ferguson
61 419 816 783 61 0 425 784 932
* all the above information is accurate at the time of this issue going to press.
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Vol 39 No 6, December 2014
6 | Chairman’s Message 7 | ACA 2015 Calendar of Events 8 | Executive Officer’s Message 9 | ACA Training Calendar 2015 10 | News 16 | Branch & YCG News 18 | ACA Standards Update
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22 | ACA Corporate Members 26 | C&P2014: Review 28 | C&P2014: Photos 31 | C&P2014: Exhibitors 34 | C&P2014: Early Bird Competition 35 | C&P2014: Awards 38 | C&P2014: Partner Program 39
| Coatings Group Member Profile
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41 | University Profile: RMIT University
42 | New Product Showcase 44 | Project Profile:
Attraction – The Melbourne Star Observation Wheel
46 | Corrosion History:
Corrosion Engineering – an Historical View
49| ACA Foundation Centurion 50 | Research Paper:
Performance of Hot Dip Galvanizing in Coastal Environments: A Review
58 | Suppliers and Consultants
46 December 2014 www.corrosion.com.au p.5
CHAIRMAN’S MESSAGE
Congratulations to Warren Green for his excellent P.F.Thompson Lecture entitled ‘Electrochemistry and its Relevance to Reinforced Concrete Durability, Repair and Protection.’ The paper provides a comprehensive coverage of the topic and I encourage all those involved in the concrete industry to take the time to read the paper. In particular, I found Warren’s considerations on the formation of the passive film on the surface of steel reinforcement in the highly alkaline conditions of concrete to be fascinating. This complex film is only nanometres thick and is readily impacted by chlorides and changes in pH. Electrochemical protection is important to counteract these factors! Paul Vince Chairman
Welcome to the final edition of Corrosion and Materials for 2014. Merry Christmas to you all and I hope you enjoy a happy holiday season with your families and loved ones. Congratulations to all those involved with Corrosion and Prevention 2014 ‘Get on Top of Corrosion’ in Darwin in September. It was a big success. Thanks to all those who made a contribution including Major Sponsor, Dulux, all other sponsors, all exhibitors, all presenters and all ACA staff (who put in a mammoth effort). Everyone worked together to put on a great event and advance the cause against corrosion in Australia and New Zealand.
At the end of his presentation Warren thanked many people for their encouragement and mentoring during his career. Many of these people were members of the ACA. I have found the ACA to be a supportive environment that often works together to achieve positive results against corrosion. A strong network exists between ACA members in the common goal of asset protection and maintenance. I encourage members to build your industry links, attend ACA events, get to know your corrosion colleagues and use the many resources available to you; so much can be achieved when we work together. I attended my first ACA conference in 2002 in Adelaide. My mind was opened to the breadth and depth of the corrosion industry in Australia
and New Zealand; I still marvel at some of the projects and research presented at each conference. After one of the presentations I was talking with Rob Francis, an ACA Life Member specialising in coatings. I was reflecting on the excellent presentation that we had both just enjoyed. At the time he said to me ‘You could give a presentation at an ACA conference.’ I didn’t think that would be possible and discounted the idea completely. But Rob had planted a seed. Two years later at the conference in Perth I gave my first presentation at an ACA conference. The same is true for you; ‘You could present a paper at an ACA conference.’ Why not next year in Adelaide? The call for abstracts is open now for the 2015 ACA conference in Adelaide. Details are on the great new ACA website. If you have had a successful project, completed some informative testing, released a new product or finalised some detailed research why not write a paper and expand everyone’s knowledge! I look forward to seeing your abstract. If you have found ACA activities valuable, I encourage you to tell a colleague. It could help us all. All the best Paul Vince ACA Chairman
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p.6 CORROSION & MATERIALS
ACA CALENDAR OF EVENTS
ACA 2015 Events Calendar 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. 2015 will be no different, with the events listed below scheduled in our Calendar of Events. Event Title
Event Date
Event Location
Protective Coatings
19 March 2015
Adelaide
Water & Water Treatment
26 March 2015
Melbourne
Durability Planning
14 May 2015
Auckland
Corrosion in the Oil & Gas Industries
21 May 2015
Melbourne
Concrete Corrosion
25 June 2015
Perth
APIA/ACA - Pipeline Corrosion Management
23 July 2015
Brisbane
Introduction to Corrosion
30 July 2015
Melbourne
Introduction to Corrosion
30 July 2015
Sydney
Protective Coatings
13 August 2015
Perth
Corrosion in the Oil & Gas Industries
27 August 2015
New Plymouth
Corrosion in the Power & Energy Industry
3 September 2015
Brisbane
Concrete Corrosion
17 September 2015
Sydney
Corrosion & Prevention 2015 Conference
15 – 18 November 2015
Adelaide
ACA members will receive further details on each event as appropriate throughout the year, but for now, please include these in your 2015 diary. For further information on these events for 2015 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 8 ACA Branches will conduct regular technical events throughout 2015. 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.
December 2014 www.corrosion.com.au p.7
EXECUTIVE OFFICER’S MESSAGE
Corrosion Group which combined attracted over 900 delegates.
thereby ensuring the environment is protected, public safety enhanced and economies improved.’
We conducted over 50 training courses both publicly and in-house for over 750 students.
The strategic plan set out some ambitious targets and we have made progress towards our goals in several areas. This year we embarked on a governance review and members voted in the new Constitution and Bylaws in September. A new website was recently launched with a fresh new look, some brand new features and additional functionality.
Wesley Fawaz Executive Officer This time of the year is when organisations look back on everything that it has achieved over the past year and for the ACA, it has been yet another busy year full of activity on behalf of its members. It was the first year of a new three year strategic plan which amended the Associations ‘ vision as ‘Leaders throughout Australasia in disseminating knowledge to enable best practice in corrosion management,
The annual conference was held in Darwin for the first time in ACA’s history with further details and photos outlined in this issue of C&M. The ACA continued to financially support the ACA Foundation which provided 25 scholarships to members. We continued to see a growth in membership which is now over 2,150. ACA Branches conducted close to 60 local events with regular activity now also in Christchurch and New Plymouth. Over 20 events were conducted by the roadshow, technical groups and Young
In 2014 our most important financial goal was to achieve the organisational budget target. We are on track to perform better than budget, and this is an important step in returning the ACA to regular breakeven and surplus budgets to ensure that the ACA remains in a strong financial position. There was plenty of action on other fronts as well. Thanks to the cooperative efforts of all volunteers, members, staff and corporate supporters, 2014 has been a year of achievements for the Association that I hope every member is proud of. In 2015, the ACA turns 60 years and will no doubt bring another year of challenges. I know the ACA with the continued support and energy from its members will continue to grow for another 60 years. I wish all the ACA members, staff, friends and their families a very Merry Christmas and Happy New Year.
CATHODIC PROTECTION PERSONNEL Are you interested in travel and working in a wide variety of industries? Corrosion Control Engineering is a leader in the field of cathodic protection and corrosion engineering with an expanding client base. Positions are currently available in our Sydney office for:
EXPERIENCED CORROSION ENGINEERS AND TECHNICIANS Please forward applications by the 12th January 2015 to: Corrosion Control Engineering email: employment@cceng.com.au
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TRAINING
ACA/ACRA Corrosion and Protection of Concrete Structures
Corrosion and CP of Concrete Structures
Member $1060 Non-member $1330
Member $1060 Non-member $1330
Melbourne April 28 – 29
Sydney June 10 – 11
Adelaide August 20 – 21 Perth September 1 – 2
Corrosion Technology Certificate ACA Coating Inspection Refresher Member $605
Non-member $740
ACA Training Calendar
Member $2220 Non-member $2600 Perth February 16 – 20 Brisbane May 18 – 22
Adelaide November 14
New Zealand June 22 – 26
New Zealand December 4
Melbourne September 21 – 25 Sydney November 23 – 27
NACE CIP Level 2 Member $3740 Non-member $4275
Cathodic Protection Monitoring Member $1485 Non-member $1810
Home Study
Sydney February 9 – 14 Perth March 16 – 21
Brisbane March 16 – 18
Member $2220 Non-member $2600
Melbourne May 11 – 16
New Zealand April 27 – 29
Start at anytime
Sydney June 22 – 27
Sydney August 3 – 5
New Zealand July 13 – 18
Adelaide August 31 – September 2
Brisbane July 27 – August 1
Perth October 5 – 7
Perth August 24 – 29
Melbourne October 26 – 28
NACE CIP Level 1
Melbourne October 19 – 24
Member $3740 Non-member $4275
Adelaide November 9 – 14
Sydney February 2 – 7 Brisbane February 23 – 28
Cathodic Protection Advanced
Perth March 9 – 14
Member $2220 Non-member $2600
Adelaide April 13 – 18
NACE CIP Level 3 Peer Review
Brisbane March 23 – 27
Melbourne May 4 – 9
Member $1470 Non-member $1725
Melbourne May 25 – 29
Sydney June 15 – 20
Adelaide November 9 – 13
Perth November 30 – December 4
New Zealand July 6 – 11 Brisbane July 20 – 25 Perth August 17 – 22 Sydney September 7 – 12
Coating Selection and Specification Member $1485 Non-member $1810 Melbourne March 2 – 4 Perth August 10 – 12
Melbourne October 12 – 17 Adelaide November 2 – 7
All prices are in $AUD. All courses listed include GST. For NZ courses deduct 10%
Protective Coatings Quality Control Member $1485 Non-member $1810 Melbourne March 23 – 25 Sydney July 1 – 3 Perth September 14 – 16
December 2014 www.corrosion.com.au p.9
NEWS
Microbial Pipeline Corrosion JIP Underway Pipeline corrosion caused by microbes in the soil is a serious threat for onshore oil and natural gas systems—accounting for up to 20 percent of pipeline problems in the U.S. Despite advances in understanding, there is limited knowledge to accurately predict its location and the rate of corrosion. Global maritime and oil/ gas safety consulting and accreditation organization DNV GL is calling for partners to collaborate in a Joint Industry Project (JIP) to develop a Recommended Practice for the detection and mitigation of MIC. Microorganisms may adhere to metal surfaces and form biofilms (complex microbial ecosystems) that can alter the electrochemical conditions on the metal surface in such a way that corrosion can be induced locally, most commonly occurring as pitting. MIC Detection & Mitigation It is difficult to prevent this type of rapid corrosion, since it is not possible
Indications of MIC can be found through detecting either coating degradation using DCVG (Direct Current Voltage Gradient) or the pipeline's metal loss using ILI (In-line Inspection).
of coating condition and cathodic protection in the occurrence and prevention of MIC, and identify practical means to support pipeline operators in detecting possible MIC sites by testing and selecting the best measurement techniques. The project will also develop a decision-support tool to rank the risk of MIC-sensitive areas along a pipeline.
“Tiny microorganisms can cause big headaches for onshore pipeline operators, since MIC leads to high corrosion rates at unpredictable locations along a pipeline. Even with well-functioning, long-running cathodic protection systems in place, MIC can still occur,” said Mirjam van Burgel, JIP project manager.
The final outcome of the JIP will be an industry-wide Recommended Practice (RP) establishing industry guidelines and recommendations to predict, detect and mitigate the occurrence of MIC. DNV GL established an MIC Technical Exchange Group earlier this year, and has a number of other pipeline-related Joint Industry Projects underway.
“Though corrosion rates can be reduced, microbiological colonies responsible for MIC do not disappear completely,” she added.
Story by DNV GL
to prove the presence of MIC directly without excavating the suspected site to run tests.
The JIP will focus on preventing or alleviating MIC by exploring the role
Foul-Release Coatings Testing Quagga and Zebra mussels are a continual curse for water and hydropower facilities, attaching to underwater equipment surfaces, clogging small diameter piping, and reducing flow in larger pipes. Flowing water creates a perfect environment for mussels to thrive. U.S. Department of the Interior’s Bureau of Reclamation has released a report on a six-year study of antifouling and foulrelease coatings and materials tested for Quagga and Zebra mussel control. Since 2008, Materials Engineering and Research Laboratory (MERL) researchers have evaluated over 100 coatings and materials at Parker Dam on the Colorado River. Invasive mussels at this location reproduce year-round and have a high growth rate. Each coating system was tested in static and flowing water conditions at the dam. Each coating system was evaluated approximately every six months, about every May and November.
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Three Formulations Top the List Reclamation tested coatings and metal alloys across six broad categories: onventional epoxies C (no fouling control) Foul release coatings Antifouling coatings Fluorinated powdered coatings Metallic coatings Metal alloys The coatings were tested in still water and flowing water. "Though we have tested many different coatings, three durable foul-release coatings are showing promise in managing mussels," principal researcher Allen Skaja said. Silicon epoxy allowed mussels to attach but were easily cleaned for the first 12 months of exposure. Two experimental formulations prevented mussel attachment for the first 18 months. These three durable foul release coatings will be tested further.
Silicone foul release coatings are the most promising for deterring mussel attachment in flowing and static water. Though aquatic vegetation and algae may provide a surface for attachment, the coatings can be easily cleaned with no measurable force. Unfortunately, silicone foul release coatings are soft and are easily damaged. The research was funded by Reclamation's Research and Development Office where research is conducted to develop and deploy successful solutions to improve water management practices, increase water supply, and ensure cost-effective power generation operations. Source: Bureau of Reclamation.
NEWS
AICIP News The Australian Institute for the Certification of Inspection Personnel (AICIP), formed by, and for, the Australian Pressure Equipment industry, supports the regulatory needs of industry through the on-going certification of inspection personnel, and the promotion of quality plant inspection and maintenance.
global qualification and certification programs, including International Welding Inspection Personnel (IWI P). The IIW harmonised Triple-I scheme will provide benchmarking of in-service inspection competencies for companies operating anywhere in the world, and enhance the job opportunities for the qualified personnel.
Since formation in 1997, AICIP has certified the competence of over 600 inservice inspectors of pressure equipment supporting a vast range of industries Australia-wide.
The IIW Triple-I qualification will be available at two levels in each of three fields of application – Pressure Equipment, Constructions, and Railway Components. Personnel qualified to this guideline will possess knowledge in inspection of both new components fabricated by welding and in maintenance of servicing components (welded and non-welded). Therefore personnel seeking training and examination as an IIW Triple-I must already hold appropriate IWI P diploma.
The ACA has a seat on the AICIP Committee of Management. In-service inspection: The global scene The International Institute of Welding (IIW) is developing a globally harmonised qualification scheme for International In-service Inspectors (‘III’ or ‘Triple-I’). This follows from the outstanding success of the other IIW
Simon England, WA
IN-SERVICE INSPECTORS (ISI)
Joshua Higgins, WA
Ajay Karan, NSW Paul Mainey, NSW David Ross, NSW Harry Burden, Qld Dale Cram, Qld Jason Griffin, Qld Patrick Hunter, Qld Kevin Swinney, Qld Darren Williams, Qld Craig Hepburn, SA
Already, many nations around the world operate certification schemes of in-service inspection personnel, supporting the regulatory environment and industry needs in that country, and the manufacturing codes emanating from that country. AICIP is one example of such a scheme, and others run in the Republic of South Africa (RSA), the USA such as the National Board of Boiler and Pressure Vessel Inspectors, and in New Zealand. The harmonised IIW global program will complement the best elements of these IIW Member schemes and facilitate international benchmarking to serve the needs of the global industry.
A qualified IIW Triple-I will have an intimate knowledge of inspection in the field of servicing assets e.g. pressure
Latest certified personnel
Kirk Harding, NSW
equipment, piping, structures, etc. as well as NDT, damage mechanisms, repair and documentation of inspected components. In-service inspectors may also play an important role in risk and lifetime assessment.
Richard Houbart, WA Andrew Johnson, WA Steven Langley, WA Kevin Lathbury, WA Alexander Martin, WA Keith Newman, WA Suresh Ramar, WA Hongbin Shan, WA Pieter Strydom, WA Joji Uppan, WA Michael Houghton, UK
RENEWAL OF CERTIFICATION
Colin Roads, Vic
5-YEAR RENEWAL SISI Danny London, SA 5-YEAR RENEWAL ISI Patrick Coleman, NSW Vikram Malhotra, NSW Mark Purcell, NSW
Christopher Green, Qld
RE-CERTIFICATION OF SISI
Wayne Parsons, Qld
Kurt Krassnitzer, SA
Lindsay Parcell, Qld
David Hughes, SA
Jordan May, SA
RE-CERTIFICATION OF ISI
Ashley Johns, SA
Brendan Moore, SA
David Parker, SA
Robert Kirkham, SA
Philip Walker, SA
Shaun Rolevink, SA
David Ritchie, SA
Stephen Challis, Vic
Konstantin Stachovic, SA
Haydyn Wood, SA
Xavier Fernandes, Vic
Rodney McFadden, Vic
Mark Diehm, Vic
Cameron McDonald, Vic
Peter Brealey, WA
Andrew Joiner, Vic
Samuel Nelson, Vic
Donald Simpson, WA
Nicholas Kriesl, Vic
Tye Edgeloe, WA Graeme Fox, WA Tristan Hodges, WA Marc Phillips, WA
Anthony Bass, Qld
Benjamin Kennedy, SA
Albert Brown, WA
Andrew McGregor, WA
Stephen Sharman, NT
Anthony Major, Qld
Alfred Baldacci, WA Ryan Benbow, WA
David Mavros, SA
Shaun Langdon, Qld
Stephen Waters, Vic
Theo Socratous, WA Donald Fraser, New Zealand Joanna Wilce, New Zealand I5-YEAR RENEWAL ISI Phillip Walker, NSW Roman Dankiw, SA Derrick Grant, Vic Mark Holmes, Vic Stanley Thomas, Vic Vijendra Rai, WA For further information please go to the AICIP website www.aicip.org.au
December 2014 www.corrosion.com.au p.11
NEWS
Vale: Charlie dal Pozzo Charlie arrived in Australia aged 8 where his family settled down and nested in Traralgon Victoria. He started off his school years at St. Michaels primary school followed by attendance at St Paul’s Secondary College in Traralgon. Once completing his school years Charlie took on an apprenticeship with the country roads board as a painter and decorator followed up with sign writing. During this time he also was strongly involved in the C.M.F where he became a Sergeant who trained in arms, combat and warfare and was a real challenge for his senior officers. Charlie then went on to work for Corser paints and then Dasma where he then decided to take on his new venture of starting up and running his own sand blasting and spray painting business in 1980 (just a small backyard one). So he studied a business course by correspondence which he passed with flying colours. Charlie started up his business in Swan road Morwell with only a couple workers and his sons helping out on weekends and school holidays.
our best professional assistance and outstanding service, high quality and fair and honest value at all times”. It was these strong morals of high quality workmanship and work practices that enabled his staff and himself to complete jobs ranging from the handy man’s trailer to power stations and offshore oil rigs. He continually expanded and improved Valicote’s facilities, trained staff both formally and on the job, therefore enabling Valicote to gain the reputation of being a professional, well known and reputable business throughout Australia, and Charlie as an honest and caring colleague. Charlie was a gifted man of many talents & intellects. He was a very
knowledgeable and thoughtful man and it often seemed that he could foresee the future. He was unchanged by success with his favorite motto being “If it wasn’t for the workers there would be no business”. With the loss of Charlie Dal Pozzo we have all lost a honest, hardworking man, that was a mentor to many people that had the privilege of working alongside of him. It is not just what we have lost but also what the industry has lost that he tirelessly worked so hard to improve. He will be missed by all but his legacy will never be forgotten.
Because of his high quality of workmanship at the other companies, his reputation followed him, and so did the customers, allowing him to expand and eventually buying property in Jones road, Morwell… from little things big things grow. It was here where Charlie worked from a shipping container and a garden shed. Charlie’s mission statement for Valicote was “To give each customer
In-House Training Throughout the year the ACA delivers multiple in-house training courses to its members and the wider industry throughout Australia and New Zealand. The ACA can present any one of its courses exclusively for a member: we can also tailor any course to your organisation’s specific needs. If your organisation would like the convenience of the ACA delivering a training program at your job site or facility, at a time that suits your schedule, contact Renata Fularczyk at the ACA on 614 (0)3 9890 4833 or email rfularczyk@corrosion.com.au
p.12 CORROSION & MATERIALS
NEWS
Vale: Professor Ian McKay Ritchie,
AO, DSc, FAA, FTSE
Australia recently lost one of its brightest stars with the death of Ian Ritchie, a most gifted and delightful human being. For the ACA this represents a huge loss of critical analysis and understanding of interfacial phenomena. Ian gained his first degrees at Cambridge University in 1958 before travelling to the USA and working on semiconductor research. He moved to Melbourne in 1962 where he completed his Ph D on tarnishing reactions of metals. His knowledge of solid-state chemistry, talent for elegant experimentation and practical problem-solving skills led him to become a leading expert in corrosion science. His 1981 paper in Corrosion Australia on the reaction of nitrite with aluminium demonstrated that it was the “inhibitors” that caused failure of alloy engines in Perth’s brand new fleet of Mercedes buses. He became an Associate Professor at the University of Western Australia in
1972, and subsequently Professor of Chemistry and Pro-Vice Chancellor (Research) at Murdoch University. He saved the emerging AJ Parker CRC from collapse following the premature death of Professor Jim Parker. Under his leadership the centre became the most productive, profitable and prolific CRC in Australia. He was an inaugural member of the Premier's Science Council and served the WA Clean Air Committee for 20 years which resulted massive emissions reduction in the strategically important Kwinana industrial strip. Ian conducted the first of many reviews of the Chemistry Centre of WA (now “ChemCentre”) in 1982 that ultimately saved the government laboratories from privatisation. The relocated laboratories are called “The Ritchie Wing”. He received the Corrosion Medal (1979), the Stokes Medal for Electrochemistry and the West Australian Citizen of the Year (Professions) in 1997. He was a Fellow of the RACI, the Australian Academy of Science and the Australian
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Academy of Technological Science and Engineering. In 2014 he was made an Officer of the Order of Australia (AO) but cancer returned and claimed him on August 12. He is survived by Ann, their daughter Katherine Olsen, sons Andrew and Alex, and five grandsons. Greg Power & Ian MacLeod
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NEWS
ACA Welcomes New Members Corporate Platinum Trucoat Industrial Coating (www.trucoat.com.au) Trucoat is a proven leader in the blasting, painting and industrial coating industry and has set a new benchmark to ensure the highest possible quality product, attention to detail and adhere to client requirements. Trucoat brings together over 50 years’ experience in this industry and provides expert technical knowledge that varies from
basic coating systems to the most complex multi-coat systems available, including intumescent fire rated products. Trucoat’s state-of-the art facility contains both conventional & high volume / quality CNC automated blasting along with extensive final coating capacity. Savcor Products Australia Pty Ltd (www.savcorproducts.com.au)
name corrosion products in Australia. The company provides expert technical support for its wide range of products including cathodic protection materials. It also focuses on fast response to enquiries, and can often deliver various products directly from stockpiles, substantially cutting the waiting time for its customers.
Savcor Products Australia Pty Ltd is one of the leading distributors of brand
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p.14 CORROSION & MATERIALS
Company
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QLD
D N A R B A S ACA HA ! E T I S B E W NEW The ACA website has a fresh new look, some brand new features and additional functionality.
Logging In Existing Members Members who have used the previous website can login using their existing User Id’s i.e. AC1xxxxx. They will also be able to change their User ID in the Member Self Service area. The Members login buttons are at the top of every screen, and once logged in they can go to their Member’s Area.
New Members Members logging in for the first time will be able to select their own User ID.
Conference Proceedings To see Conference Proceedings in full, a member needs to be logged in. Non members can ONLY see the Paper Abstracts. If you wish to see the full Papers – Join Now ( www.corrosion.com.au)
December 2014 www.corrosion.com.au p.15
BRANCH AND YCG EVENTS
ACA Auckland Meeting Report Doug Ashby from Maskell Productions Ltd, Auckland, was the guest speaker at the ACA Auckland October meeting. Maskell Productions produce fibreglass products resistant to corrosion. Doug is a composites engineer based at the Maskell Auckland plant. Maskell also have an office and manufacture products in Melbourne. Doug's talk began with a history and background of thermoset resins. Polyester, patented in 1936, proved to be an economical solution as a glass fibre binder. Vinyl esters are a hybrid product invented in the 1970's found to have improved chemical and heat resistance. Epoxy resins were found to have a high strength and high adhesive strength and also able to cure under water. Doug explained how glass fibres were manufactured, around 50% of global supply comes from the USA. The glass fibres are coated with a sizing compound which reduces surface tension to enhance resin adhesion.
With the components explained Doug then went on to discuss products manufactured from these. The first products manufactured were for aeroplane nose cones in WW2. Examples of the advantages of Glass Reinforced Polyester (GRP) are the construction of yachts and boat hulls which largely commenced in the 1960's. It has several advantages over steel namely, corrosion resistance, weight, ease of fabrication and a low embodied energy. Ultra Violet (UV) resistance is important especially in Australia and New Zealand. UV inhibitors are added to the resin to counteract this.
and AS2634. Other standards are considered for various reasons, such as ISO, ASTM and EN standards. Doug then took a variety of questions relating to GRP products and systems. These included the use of GRP for saline pipelines at power stations, flexural performance underground in earthquake zones and several others. Doug was then thanked for his talk by Wayne Thomson, leaving the audience far more knowledgeable about GRP products and their use in corrosion resistant systems.
Doug then took the audience through some case studies with unusual requirements such as sewerage pond covers where a high build up of HCl occurs. Testing regimes applied in Maskell's laboratory ensure that the strength characteristics of GRP are well understood. Products are manufactured to a variety of standards namely BS4994
YCG SA PMB visit The SA YCG organised a tour of PMB Defence facilities. 15 people were taken on the tour to observe the process of manufacturing and commissioning the Lead Acid batteries for the Collins Class Submarines. The tour was followed by morning tea and networking.
Lead Acid continues to be cheaper and more reliable than the more modern alternatives. PMB Defence must ensure that the battery will perform reliably for as long as possible until the submarine returns for a new batch of batteries. A battery is expected to operate for 6 years.
PMB Defence was formed in 1989 and has state-of-the art production, research and development and engineering facilities. They employ about 40 people including 2 chemists and 13 engineers.
The batteries power the submarine while submerged and also act as ballast to assist with stability. Being the size of a four draw filing cabinet it is an impressive battery. The acid
p.16  CORROSION & MATERIALS
inside the battery creates an extremely harsh environment so PMB Defence pride themselves on a high level of quality control. The ACA would like to thank PMB Defence for opening their doors and allowing new and young corrosionists to get a better understanding of the main storage battery of the Collins Class Submarines.
BRANCH AND YCG EVENTS
Korvest Galvanisers visit On the 9th of September, Dr Erwin Gamboa’s Corrosion class from the University of Adelaide went on a site tour to Korvest Galvanisers. Many of these students are ACA student members.The day was a great success, with the theory and technical talks
being delivered in the morning and the afternoon was a tour of the plant, where students could see the intricacies of designing for hot tip galvanizing. Korvest Galvanisers ran a smooth and safe tour, and included a few soft drinks and nibbles after the tour.
This tour was the sixth time it has run for the University, and Korvest commented that they have started to see graduates producing designs with galvanizing in mind, helping everyone reduce time and cost of applying this corrosion protection system.
University of Adelaide Corrosion students inspecting the kettle with molten zinc prior to a dip.
Dr Erwin Gamboa discussing surface finish of hot dip galvanized steel with his students.
University of Adelaide Corrosion students inspecting the finished product after galvanizing.
YCG WA Talison Lithium Plant Tour The YCG (Young Corrosion Group) WA was invited by Talison for a tour of the Greenbushes Lithium Plant in the South Western Australia on the 5 September, 2014. The day started with a bus trip down to Australind, with a breakfast by the ocean to give the group a chance to introduce themselves. This was followed by a drive to the Greenbushes plant. The Greenbushes Lithium Operation has been producing lithium for over 25 years. The mine is located 250 kilometers (km) south of Perth/ Fremantle - a major container shipping port - and 90 km south east of the Port of Bunbury - a major bulk handling port - in Western Australia. The mining and processing plant exports over 350,000 tonnes of lithium products annually to a global customer base,
supplying of one third of the world’s lithium demand! A dozen young corrosion enthusiasts were given a brief introduction about the mine's background, followed by a tour of the large open pit mines that are within the confines of the plant. It was explained by the plant personnel during the visit that the Greenbushes ore body is a highly mineralized zoned pegmatite with a strike length of more than three km. Greenbushes mineral reserve is unique, it grades 50% spodumene. This makes Greenbushes the highest grade lithium mineral resource in the world at 3.9% Li2O mineral reserves and 3.5% Li2O mineral resources versus 1.0 – 2.0% Li2O for other known hard rock deposits. Talison’s Greenbushes lithium mineral resource is open along strike and at
depth so there is significant potential to increase lithium mineral reserves and mineral resources extending the life of mine (LOM) while at the same time increasing production rates. After the tour, the group drove to a country style pub for a catch up and some drinks, discussing the interesting facts found during the site visit. The plant visit was successful, bringing several people from different industries together to learn about ongoing corrosion problems. With support from the ACA, the YCG can continue to inform and inspire young engineers. A thankyou to Dr. Mandar Risbud for helping to organise the site visit. Simon Poggioli YCG WA Event Coordinator
December 2014 www.corrosion.com.au p.17
ACA STANDARDS UPDATE
ACA Standards Update Welcome to the sixth corrosion related Standards Update for 2014. This Standards report focuses on corrosion issues related to the Water & Wastewater Technical Group. As previously this is in two stages, namely: Stage 1 A global standards and publication focus at 24 October 2014, searching through SAIGLOBAL 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 “Water & Waste Water” Technical Group. Stage 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 4 September 2014 to 24 October 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’. Summary of Stages Stage 1 Through SAIGLOBAL Publications at https://infostore.saiglobal.com/store there were for a search on: a. “Water and Wastewater and Corrosion”, 3 Citations, 2 from Australian Standards as shown in Table 1 below.
b. “Water Corrosion”, 287 Citations, 0 from Australian Standards, a sampling is shown in Table 2 below. c. “Wastewater and Corrosion”, 6 Citations, 2 from Australian Standards as shown in Table 3 below. Stage 2 Across SAIGLOBAL online Standards Publications there was a total of 29 listings of new standards, Drafts and Amendments, found issued from to 4 September 2014 to 24 October 2014; 0 from ASNZS relating to corrosion but one AS standard relating to testing for potential alkali-silica potential in aggregates; AS 1141 .60.2:2014
Methods for sampling and testing aggregates - Potential alkali-silica reactivity - Concrete prism method
These results are shown in Table 4 below.
Stage 1 Report on SAIGLOBAL Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “Water & Wastewater” Technical Group. Table 1 For Titles search on https://infostore.saiglobal.com/store on 24 October 2014 for “Water and Wastewater and Corrosion” there were 3 citations, with 2 from Australian Standards ONORM B 5013-1:2013
Corrosion Protection By Organic Coatings For Water And Wastewater Engineering In Residential Areas - Part 1: Assessment Of Corrosion Probability And Protection Of Unalloyed And Low Alloyed Ferrous Materials
AS 3688-2005/Amdt 1-2006
Water supply - Metallic fittings and end connectors
ATS 5200.042-2004
Technical Specification for plumbing and drainage products - Roll-grooved jointing systems
p.18 CORROSION & MATERIALS
ACA STANDARDS UPDATE
Table 2 For Titles search on https://infostore.saiglobal.com/store on 24 October 2014 for “Water and Corrosion” there were 287 citations, none from Australian Standards; a sample is shown below. ASTM STP1300-97
Corrosion Testing In Natural Waters: 2nd Volume
NACE 34108:2008
Review And Survey Of Alkaline Carbonate Stress Corrosion Cracking In Refinery Sour Waters
PN 76/H-04621:1976
Corrosion Of Metals - Outdoor Test In Inland Waters
PN 76/H-04622:1976
Corrosion Of Metals - Copper Index Aggressiveness Of Natural Waters - Test Method
ASTM STP1086-90
Corrosion In Natural Waters
GOST R ISO/TR 10217:2010
Solar Energy - Water Heating Systems - Guide To Material Selection With Regard To Internal Corrosion
BIS IS 1154:2000 (R2005)
Temporary Corrosion Preventive Fluid, Soft Film, Solvent Deposited, Water Displacing Specification
GOST 18597:1973
Motor Fuel - Corrosion Testing Under Water Condensation Conditions
SAE AMS 3066:2001 (R2010) Compound, Corrosion-inhibiting, Water-displacing, Soft Film, Aerosol Canned NACE 46107:2007
Control Of Corrosion, Deposition, And Microbiological Growth In Recirculating Water Systems In Buildings
DEFSTAN 68-10/5:2003
Corrosion Preventive: Water Displacing Nato Code: C-634 Joint Service Designation: Px-24
QPL 81309 Revision 22 Notice 1
Corrosion Preventive Compound, Water Displacing, Ultra Thin Film - Revision 22 Notice 1
MIL C 40084 Revision C Notice 1 Cancellation
Corrosion Preventive Compound, Water Emulsifiable, Oil Type - Revision C Notice 1 Cancellation
Table 3 For Titles search on https://infostore.saiglobal.com/store on 24 October 2014 for “Wastewater and Corrosion” there were 6 citations, two from Australian Standards; the same 2 as in Table 1 DWA-M 168:2010
Corrosion Of Wastewater Systems - Wastewater Discharge
NACE 08113:2013
Corrosion Problems And Renewal Technologies In Municipal Wastewater Systems
ONORM B 5013-1:2013
Corrosion Protection By Organic Coatings For Water And Wastewater Engineering In Residential Areas - Part 1: Assessment Of Corrosion Probability And Protection Of Unalloyed And Low Alloyed Ferrous Materials
UNI EN 12566-7:2013
Small Wastewater Treatment Systems For Up To 50 Pt - Part 7: Prefabricated Tertiary Treatment Units
AS 3688-2005/Amdt 1-2006
Water supply - Metallic fittings and end connectors
ATS 5200.042-2004
Technical Specification for plumbing and drainage products - Roll-grooved jointing systems
Stage 2 Table 4 Standards for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards and Amendments for ISO & IEC PUBLISHED from 4 September 2014 to 24 October 2014 for: 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 4 September 2014 to 24 October 2014 Key word search on ‘durability’- 0 corrosion related citations found; 2 ISO Standards were found for furniture durability. Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 5 citations found; 0 from AS/NZS ISO 630-5:2014
Structural steels - Part 5: Technical delivery conditions for structural steels with improved atmospheric corrosion resistance
ISO/DIS 11997-1
Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 1: Wet (salt fog)/dry/humidity
ISO/DIS 3160-2
Watch-cases and accessories - Gold alloy coverings - Part 2: Determination of fineness, thickness, corrosion resistance and adhesion
DIN EN 4538-2 (2014-10)
Aerospace series - Bearings, spherical plain, in corrosion resisting steel with self-lubricating liner elevated load under low oscillations - Narrow series - Dimensions and loads - Part 2: Inch series; German and English version EN 4538-2:2014
DIN 65342 (2014-10) (Draft)
Aerospace series - Anchor nuts with MJ thread, deep counterbore, self-locking, two lug, reduced, corrosion-resisting steel, classification: 1100 MPa/315 øC/425 øC; Text in German and English
December 2014 www.corrosion.com.au p.19
ACA STANDARDS UPDATE
Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 21 Publications found; 0 for As AS/NZS ISO 13803:2014
Paints and varnishes - Determination of haze on paint films at 20 degrees
ISO 2813:2014
Paints and varnishes - Determination of gloss value at 20 degrees, 60 degrees and 85 degrees
ISO 4618:2014
Paints and varnishes - Terms and definitions
ISO/DIS 11997-1
Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 1: Wet (salt fog)/dry/humidity
ISO/DIS 1514
Paints and varnishes - Standard panels for testing
ISO/DIS 20567-1
Paints and varnishes - Determination of stone-chip resistance of coatings - Part 1: Multi-impact testing
ISO/DIS 20567-2
Paints and varnishes - Determination of stone-chip resistance of coatings - Part 2: Single-impact test with a guided impact body
ISO/DIS 2811-1
Paints and varnishes - Determination of density - Part 1: Pycnometer
ISO/DIS 8503-5
Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 5: Replica tape method for the determination of the surface profile
I.S. EN 15457:2014
Paints and Varnishes - Laboratory Method for Testing the Efficacy of Film Preservatives in a Coating Against Fungi
I.S. EN 15458:2014
Paints and Varnishes - Laboratory Method for Testing the Efficacy of Film Preservatives in a Coating Against Algae
SR CEN/TS 16700:2014
Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Assessment of Resistance to Impact of a Coating on a Wooden Substrate
I.S. EN 927-2:2014
Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Part 2: Performance Specification
BS EN 927-2:2014
Paints And Varnishes - Coating Materials And Coating Systems For Exterior Wood - Part 2: Performance Specification
ISO 1891-2:2014
Fasteners - Terminology - Part 2: Vocabulary and definitions for coatings
DIN EN ISO 10683 (2014-10)
Fasteners - Non-electrolytically applied zinc flake coatings (ISO 10683:2014)
DIN 58197-1 (2014-10) (Draft)
Optical coatings - Part 1: Minimum requirements for antireflecting coatings; Text in German and English
DIN 58197-2 (2014-10) (Draft)
Optical coatings - Part 2: Minimum requirements for reflecting coatings; Text in German and English
DIN 58197-3 (2014-10) (Draft)
Optical coatings - Part 3: Minimum requirements for neutral beam splitting coatings; Text in German and English
DIN 58197-4 (2014-10) (Draft)
Optical coatings - Part 4: Minimum requirements for coatings used for laser optics; Text in German and English
14/30304101 DC Bs En 16784
Timber Structures - Test Methods - Determination Of The Long Term Behaviour Of Coated And Uncoated Dowel-Type Fasteners
Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ –0 Standard Publications found. Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ – 0 corrosion related Standard Publications found but there was a new AS one on testing for potential alkali-silica reactivity in aggregates AS 1141.60.2:2014
Methods for sampling and testing aggregates - Potential alkali-silica reactivity - Concrete prism method
Key word search on ‘cathode’ or 'cathodic' -2 publications found, 0 from AS of AS/NZS ISO/DIS 15257
Cathodic protection - Competence levels of cathodic protection persons - Basis for certification scheme
ISO/FDIS 15589-1
Petroleum, petrochemical and natural gas industries - Cathodic protection of pipeline systems Part 1: On-land pipelines
Key word search on 'anode' or ‘anodes’ or ‘anodic’ –0 Standard Publications found Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 Standard Publications found. Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found Arthur Austin ACA Standards Officer
p.20 CORROSION & MATERIALS
ACA STANDARDS UPDATE
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ACA CORPORATE MEMBERS
ACA Corporate Members PLATINUM MEMBERS GOLD MEMBERS p.22 CORROSION & MATERIALS
Standard
Jotun blue
Black and white
ACA CORPORATE MEMBERS
Corporate Silver A S Harrison & Co Pty Limited
Galvanizers Association of Australia
Rhino Linings Australasia Pty Ltd
Action Alliance Group
Grange Resources (Tasmania) Pty Ltd
RKF Engineering Services
ALS Industrial - Power Services
Industrial Minerals (NZ) Ltd
Rosen Australia Pty Ltd
Applus RTD Pty Ltd
Kaefer Novacoat (WA) Pty Ltd
Rotafab Pty Ltd
Arup Pty Ltd
M Brodribb Pty Ltd
Scientific Solutions Pty Ltd
Atteris Pty Ltd
Melbourne Water
South Coast Surface Protection
Aurecon Australasia Pty Ltd
NSW Ports
Supreme Steel Products Ltd
Australian Maritime Systems Ltd
Oliver Technologies Pty Ltd
SVT Engineering Consultants
Core Group Ltd
Olympus Australia
Transpacific Industrial Solutions
CTI Consultants Pty Ltd
Opus International Consultants Ltd
Veolia Environmental Services
E&A Contractors
Origin Energy
VicRoads Technical Services
Elite Concrete Protection & Repair
Orrcon Operations Pty Ltd
Water Corporation of Western Australia
Engineered Surface Preparation
Petro Coating Systems Pty Ltd
Worley Parsons Ltd
Extrin Consultants
Plant & Platform Consultants Ltd
Favcote Pty Ltd
Port of Newcastle
Corporate Bronze A W Bell Pty Ltd AB and P Abrasive Blasting & Painting ABSAFE Pty Ltd Acacia Corrosion Control ACTEW Corporation Limited Adflex Protective Coatings Adtech FRP Pty Ltd Advanced Aqua Blasting AFL Services Airservices Australia Akron Group NT Pty Ltd Albany Port Authority Allunga Exposure Laboratory AMAC Corrosion Protection Pty Ltd Amog Pty Ltd Andersal Pty Ltd Anti Corrosion Technology APD Power ARC West Group Pty Ltd ArmorGalv (Aust) Pty Limited ASC Pty Ltd AsClear Pty Ltd Asset Alignment Pty Ltd Asset Integrity Australasia Pty Ltd ATCO Gas Australia Auscor Pty Ltd Austral Wright Metals Ausvic Pty Ltd Aztec Analysis BASF Australia Ltd Bayer Material Science Pty Ltd BCMG Pty Ltd BGI Group Bianco Construction & Industrial Supplies Bluey Technologies
BP Refinery (Bulwer Island) BP Refinery (Kwinana) Pty Ltd BRANZ Limited Bridgewater Solutions Pty Ltd Brisbane Abrasive Blasting Buel Pty Ltd Bundaberg Sandblasting Pty Ltd C. P. Plating Pty Ltd Caltex Refineries (QLD) Ltd Cameleon Paints Cathodic Anodes Australasia CCM Group Australia CEM International Pty Ltd Centreport Limited Champion Technologies Chevron Australia Pty Ltd Chiron Chemicals City West Water Civil & Pipeline Contractors Pty Ltd Clarkes Painting Services Clavon Pte Ltd Coating Industries Australia Pty Ltd Commercial Industrial Painting Services Pty Ltd Contract Resources Pty Ltd CORE Water Management Solutions Pty Ltd Corrosion Electronics Pty Ltd Costin Roe Consulting Couplertec Electronic Rustproofing CSIRO CMSE Dapcor Building Services Pty Ltd DBP Transmission Decora Group Ltd Department of Transport and Main Roads Dept for Manufacturing, Innovation, Trade, Resources and Energy
Dept of Infrastructure, Energy & Resources Dept of Transport Diagnostech Pty Ltd Doito Pty Ltd Doogood Specialised Coatings P/L DSTO Dulux NZ Ltd Eddy Batur Industrial Painting EM&I (Australia) Pty Ltd Energy Safe Victoria Energyworks Ltd Esso Australia Ltd Firma Industries Fremantle Ports Fremantle Sailing Club Germanischer Lloyd (Australia) Pty Limited GF Engineering Giovenco Industries (Aust) Pty Ltd Gippsland Cathodic Protection Gippsland Water Gisborne Abrasive Blast & Coatings 2000 Ltd Gladstone Ports Corporation Ltd Gladstone Regional Council GORODOK Pty Ltd GPR Electrical (WA) Pty Ltd Greater Wellington Regional Council Gummow Pty Ltd (T/A G Squared Solutions) Halcrow Group Limited HERA Hispec Industrial Coatings Pty Ltd Holmes Consulting Group Horiso Pty Ltd Hunter Water Australia Pty Ltd
December 2014 www.corrosion.com.au p.23
ACA CORPORATE MEMBERS
Hydro Flow Pty Ltd Hydro Tasmania IDEAL Machinery idec Protective Coatings Pty Ltd Inductabend Pty Ltd Industrial Composite Contractors Innovative Corrosion Management Pty Ltd Inspec Consulting Pty Ltd Inspection & Consultancy Services Ltd Intercept Australia Pty Ltd International Corrosion Services Pty Ltd Intertek Technical Services Pty Ltd Ionode Pty Ltd IPCQ ITW Buildex Jeff Hort Engineering Keppel Prince Engineering Pty Ltd KGB Protective Coatings Korvest Ltd - Galvanising Division Kulin Group Pty Ltd Linetech Consulting Liquigas Ltd Longmont Engineering Loy Yang Power Ltd Lyttelton Port of Christchurch
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M. Waters Abrasive Blasting Services Mac Coatings Pty Ltd Magnatex Marden Corrosion Services P/L Mattioli Bros Pty Ltd Maxcon Industries Pty Ltd McBerns Pty Ltd McCoy Engineering Pty Ltd McElligott Partners Pty Ltd McElligotts (QLD) Pty Ltd McElligotts (Tas) Pty Ltd Metal Spray Suppliers (NZ) Ltd Metal Spray Supplies Australia Methanex New Zealand Ltd Metrocorp Technologies Metz Specialty Materials Pty Ltd Mills Sign & Painting Service Mobil Refining Australia Pty Ltd (Altona Refinery) Monadelphous Engineering Associates Pty Ltd MTK Consulting Multicoat Pty Ltd Murphy Pipe & Civil Constructions P/L Nalco Australia Pty Ltd NDT Equipment Sales Pty Ltd
New Zealand Aluminium Smelters New Zealand Steel Ltd Newcastle City Council NMT Electrodes (Australia) Pty Ltd Norblast Industrial Solutions Pty Ltd Northport Ltd NPC Industries Pty Ltd NZ Refining Co Ltd Osborne Cogeneration Outokumpu Pty Ltd Pacific Quality Corrosion Control Pacific Remedial Solutions Pacific Resins Pty Ltd Paint N Colour PCWI International Pty Ltd Pentair Water Solutions Phillro Industries Pty Ltd Phoenix Australasia Pty Ltd Polymer Group Ltd Poly-Tech Industrial Services Port of Portland Prendos New Zealand Ltd Preservation Technologies ProDigital Pty Limited Prokote Pty Ltd
ACA CORPORATE MEMBERS
Pumpline Pty Ltd Pumpspec Ltd QLD Painters & Maintenance Services Pty Ltd Quality Maritime Surveyors Pty Ltd Queensland Bulk Water Supply Authority t/a Seqwater Queensland Rail Queensland Sugar Limited Reinforced Earth Pty Ltd Remedial Technologies Australia Pty Ltd Renfay Projects Reno Blast Resene Paints Ltd Rheem Australia Pty Ltd Rightway Industrial Pty Ltd RM Watson Pty Ltd Roads and Maritime Services Rolls Royce Australia Services Rust Bullet Australasia Rust-oleum Industrial Coatings Rustproof Coatings Ltd Schmidts Pty Ltd SGS NZ Ltd SICC SERVICES Pty Ltd
Siemens Rail Automation Sika (NZ) Ltd Silver Raven Pty Ltd SLH Contracting (2008) Ltd South East Water Limited Southern Cross Building Products Steelpipe Limited STR Inspection Services Structural Systems (Remedial) Pty Ltd Style Maintenance Services Sulco Limited Summit Fertilizers SunWater Limited Sydney Trains Syntech Distributors Ltd Tas Gas Networks Tasmanian Ports Corporation Pty Ltd TasNetworks TasWater Thomas Contracting Pty Ltd Tincone Pty Ltd Titanium Electrode Products (Australia) Pty Ltd TOD Consulting Total Corrosion Control Pty Ltd
Total Paint Protection Total Surface Protection Townsville Port Authority Transfield Services Transpower New Zealand Ltd Tristar Australia Pty Ltd Tropical Reef Shipyard Pty Ltd Undersea Construction Ltd Underwood Offshore Consulting Valicote Pty Ltd Vappro Corrosion Control Australia Pty Ltd VDM Metals Australia Pty Ltd Vector Gas Limited Vincent Painting VT Industrial Coatings WAG Pipeline Proprietary Ltd Wairau Paint Centre Ltd Wannon Region Water Corporation Wolfchester Australia Pty Ltd Wood Group Integrity Management Woodside Energy Ltd Yarra Valley Water Zinfra Network Services
Corrosion Control Directory If you are seeking a Cathodic Protection Consultant, a Coatings Inspector or Applicator – search an extensive list of service providers in the corrosion prevention industry at www.corrosion.com.au under Directories. The Australasian Corrosion Association is a not-for-profit, membership Association which disseminates information on corrosion and its prevention or control by providing training, seminars, conferences, publications and other activities.
December 2014 www.corrosion.com.au p.25
C&P2014 CONFERENCE REVIEW
OVERVIEW
PLENARY SPEAKERS
The ACA and its Tasmanian Branch welcomed 445 delegates, exhibitors, partners and staff to the subtropical city of Darwin for Corrosion & Prevention 2014 (C&P2014). The annual conference is established as the Australasian corrosion industry’s premier technical event and 2014 was no exception. Held over three days at the Darwin Convention Centre, C&P2014 embodied its theme “Get On Top Of Corrosion” with a cutting-edge blend of the latest research and industry practice including eight plenary lectures, five technical forums and over 90 individual paper presentations.
The conference was officially opened on Monday morning by ACA President Andrew Hargrave, Conference Convenor Dean Wall, Vin Brereton, General Manager of major sponsor Dulux Protective Coatings and conference technical committee member Raman Singh. The traditional ACA Corrosion Clock, powered by a galvanic corrosion cell, was officially started by Bruce Hinton. The clock is used to keep time at every ACA conference.
As always, the social element of the conference was well enjoyed by delegates. The Sunday evening Welcome Function sponsored by Incospec & Associates was held at Il Lido, in a relaxed outside setting overlooking the Darwin Waterfront lagoon, Convention Centre and the Darwin Stokes Hill Wharf. Monday’s Exhibition Opening and Young Corrosion Group (sponsored by the Galvanizers Association of Australia) events were also thoroughly enjoyed. On Tuesday evening the ACA Annual Dinner and Awards sponsored by Denso Australia was held with a live band entertaining delegates and partners. Finally the Farewell Function on Wednesday closed the conference.
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After the official opening, proceedings commenced with plenary lecturer Professor Prabhakar Singh from the University of Connecticut, speaking on corrosion of materials and coatings in advanced energy systems. This was followed by Jason Farrugia of Dulux Protective Coatings presenting on techniques for protecting assets in marine and coastal environments. After lunch delegates were treated to plenary lecturer George Keller who spoke on the new technologies and future challenges for the prevention of corrosion in the US Department of Defense Assets. Following George was the fourth plenary lecture by Scott Collins from Santos and Andrew Mills from Wood Group Integrity Management discussing the implementation of a comprehensive quantitative risk based inspections program across Santos’ facilities. On Tuesday morning delegates were presented the annual PF Thompson Lecture by Warren Green
of Vinsi Partners. Warren venerably upheld the tradition of the PFT lecture, started by Dr Edmund Potter in 1970, providing a very animated presentation style in conjunction with practical demonstrations to illustrate electrochemistry and its relevance in reinforced concrete durability, repair and protection. The PFT is recognised as the highlight of the technical program each year. After completion of the PFT, Ben Fultz from Bectel Corporation (USA) spoke about the challenges of LNG materials selection. Pat Teevens from Broadsword Corrosion Engineering opened the Wednesday plenary session with a review of petroleum pipeline integrity under the public microscope, the essential role of internal corrosion direct assessment. This was followed by Harvey Hack from Northrop Grumman Corp speaking on the design of small structures to control marine corrosion. The conference committee thanks all of the plenary lecturers, both local and international, for their outstanding presentations.
FORUMS AND TECHNICAL PROGRAM The technical paper program was substantial as always and sessions were arranged to bring theory and practice together. Corrosion & Prevention 2014 saw the delivery of 90 papers in Darwin, more papers than were delivered at the previous year in Brisbane. Major areas such as corrosion mechanisms, materials, coatings, cathodic protection, pipelines and, concrete structures were spread over the three days of the conference. In response to feedback, in 2014 there was a big focus on introducing more case studies and practical industry updates into the conference program. A feature of Corrosion & Prevention 2014 was the technical forums organised by the ACA Technical Groups. Forums held included Coatings, Cathodic Protection, Concrete Structure & Buildings, Petroleum & Chemical Process Industries and Marine. The discussion was robust as usual in these sessions and very worthwhile for the attendees. These forums are an ideal setting for both formal and informal exchange of experiences, case studies, problems, ideas and solutions with experts in each field.
TRADE EXHIBITION Corrosion & Prevention 2014 featured a large trade show with 58 exhibitors. These included materials suppliers, equipment vendors, specialist contractors and consultants. Delegates were able to browse the stands throughout the conference and take the opportunity to discuss products and services with the exhibitors. Exhibitors benefited from broad exposure to corrosion industry practitioners from around Australia, New Zealand and the world.
CONCLUSION On behalf of the ACA and the conference committee, thanks are extended to major sponsor Dulux Protective Coatings, supporting sponsors International Paint, Jotun Australia, PPG Protective & Marine Coatings and Russell Fraser Sales, event sponsors Denso Australia, Incospec and Associates, Galvanizers Association of Australia, Blast One, Master Builders Solutions and Zinga and all the exhibitors for their support of the conference. Thanks also go to the plenary lecturers, speakers, session chairs and all delegates without whom the conference would not exist. A special mention must be made of the ACA conference committee and ACA staff for their outstanding work in organising the conference. In 2015 the conference will be held in Adelaide. Corrosion & Prevention 2015 will be held from 15-18 November at the Adelaide Convention Centre. For more information refer to the ACA conference website www.acaconference.com.au
MAJOR SPONSOR:
SUPPORTING SPONSORS: Standard
Jotun blue
SPONSORS:
Black and white
December 2014  www.corrosion.com.au  p.27
C&P2014 PHOTOS
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C&P2014 PHOTOS
December 2014 www.corrosion.com.au p.29
C&P2014 PHOTOS
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C&P2014 EXHIBITORS
BEST BOOTH AWARD
Denso (Australia) Pty Ltd are leaders in Corrosion Prevention and Sealing Technology. The Denso range of products have been used successfully for over 80 years and have a proven track record with verifiable case histories.
The Denso range comprises a variety of specialised pipe & structural coatings, marine protection systems, concrete and tank coatings, tapes, brush and spray applied liquid coatings, mastics, primers and sealants based on materials such as petrolatum, butyl rubber, bitumen, plastics and epoxy resins. Systems are tailor made for individual anti-corrosion and sealing problems developed with the realities of an on-site application in mind. Our extensive product range is suitable for use in a wide range of highly corrosive environments with operating temperatures ranging from sub-zero to 250ºC.
December 2014 www.corrosion.com.au p.31
C&P2014 EXHIBITORS
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C&P2014 EXHIBITORS
December 2014 www.corrosion.com.au p.33
C&P2014 EARLY BIRD COMPETITION
EARLY BIRD REGISTRATION
COMPETITION
The ACA orgnanised an Early Bird Competition to encourage early registrations to Corrosion & Prevention 2014.
Those who registered before 20 June 2014 for the discounted conference registration fee, were eligible to go into the draw to win one major prize of: 2 return domestic economy flights, 4 nights’ accommodation at the Vibe Hotel Waterside Darwin and 1 ‘Cage of Death’ Experience at Crocosaurus Cove Darwin, Northern Territory, Australia, valued at $3000 (AUS) . Andy Caddy from Absafe was the lucky winner! Andy had a great time and wrote to us to share his experience !
I have to thank the ACA team for the amazing prize I received as the winner of the Early Bird registration competition for this year’s C&P 2014 conference in Darwin. The prize was all flights and accommodation for 2 at the Vibe hotel next to the conference centre. The added bonus was a swim with a large crocodile in the ‘Cage of Death’. I must admit I was a bit ambivalent about this one. Even going for an early morning swim in the lagoon pool had me feeling a bit antsy, I mean I know that they have done a wonderful job building a safe swimming area but crocs are ‘smart’ and big crocs are the ‘smartest’. I’ve no doubt that one day a big saltie is going to figure out where the best place to dine in Darwin really is! Same with the Croc Cage. They basically put you in a plexiglass bait cage and then drop you in with a 5 meter croc that has nothing to do but spend its days working out how to access the tasty prize inside. Actually as I was getting lowered into the croc pool I figured out 2 ways that a croc could manage it but thought best to keep that to myself. Needless to say the cage dive went without a hitch. The croc and I eyed each other off, but I feel we came to a mutual understanding. He wouldn’t eat me and I wouldn’t wee in his pool. Photos were taken for posterity and I was out of there smelling faintly of crocodile wee. They really are magnificent creatures and I am truly thankful to have had the experience. Regards, Andy Caddy Director Absafe Pty Ltd
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C&P2014 AWARDS
Each year a series of ACA Awards are announced and presented to successful recipients during the gala dinner at the annual ACA conference. The ACA awards papers of outstanding quality presented at a conference, seminar or symposium held under the auspices of the ACA, or published in the ACA’s publication Corrosion & Materials. These papers are judged by the ACA Awards Committee comprised of Les Boulton, Bruce Hinton and Erwin Gamboa.
during paint curing, service abrasion and weathering, but has often required the use of advanced statistical analysis methods such as chemometrics to discern these changes. Results from our studies using this and related techniques and the technical challenges that have arisen will be presented. Graeme George received the AC Kennett Award, accepted on his behalf by Antony Trueman.
The ACA also recognises members for outstanding services to the Association through Life Membership and services to the industry through other prestigious awards.
AC KENNETT AWARD The AC Kennett Award is awarded each year to the best paper presented under the auspices of the Association that deals with non-metallic corrosion. The recipient also receives a cheque for $1,500. Graeme George of Queensland University of Technology for the paper ‘Sensitive Methods for Studying the Environmental Performance of Protective Coatings’ co-authors J. Colwell, T. Trueman & G. Will Graeme was not able to attend C&P2014, so Tony Trueman accepted the award on his behalf SUMMARY: The safe working lifetime of a structure in a corrosive or other harsh environment is frequently not limited by the material itself but rather by the integrity of the coating material. Advanced surface coatings are usually cross linked organic polymers such as epoxies and polyurethanes which must not shrink, crack or degrade when exposed to environmental extremes. While standard test methods for environmental durability of coatings have been devised, the tests are structured more towards determining the end of life rather than in anticipation of degradation. We have been developing prognostic tools to anticipate coating failure by using a fundamental understanding of their degradation behaviour which, depending on the polymer structure, is mediated through hydrolytic or oxidation processes. Fourier transform infrared spectroscopy (FTIR) is a widely-used laboratory technique for the analysis of polymer degradation and with the development of portable FTIR spectrometers, new opportunities have arisen to measure polymer degradation non-destructively in the field. For IR reflectance sampling, both diffuse (scattered) and specular (direct) reflections can occur. The complexity in these spectra has provided interesting opportunities to study surface chemical and physical changes
BEST PAPERS In pursuit of attracting quality technical papers, the ACA annually awards two certificates of merit for papers either published in Corrosion & Materials or presented at the annual conference. The award will be made only where the standard of papers is of a level warranting recognition; one certificate is for the best review paper and the other is for the best research paper.
MARSHALL FORDHAM BEST RESEARCH AWARD Amy Spark of RMIT University and CSIRO for the paper ‘Studying the Synergistic Effects of Microbes and Environment on Carbon Steel Pipeline Corrosion’ co-authors L. Ward, I. Cole & D. Marney, presented at Corrosion & Prevention 2013, Brisbane, QLD.
December 2014 www.corrosion.com.au p.35
C&P2014 AWARDS
SUMMARY: Biological corrosion is a process whereby deterioration of a metal occurs directly or indirectly due to the activity of, and interaction with, living organisms such as bacteria or algae. Micro-organisms can influence corrosion to occur at much higher rates than normally anticipated, leading to premature and sometimes catastrophic failure. This phenomenon is known as microbial influenced corrosion (MIC). MIC can accelerate corrosion in buried carbon steel pipes in small, isolated areas causing reduced pipe performance and ultimately failure and thus disruption to potable water services. While there is a detailed knowledge base of the electrochemical processes associated with the corrosion of carbon steel in a wide variety of conditions and uses, limited research has previously been undertaken into understanding the specific processes when bacteria are involved. This project aims to study the fundamental processes relating to how bacteria influence the electrochemical processes of steel corrosion and how the behaviour of the bacteria is influenced in turn by the electrochemical processes. It is focussed principally on the conditions experienced at the micro-interface between steel and the surrounding soil, in the context of buried metallic pipes. The focus of this paper is to review the literature surrounding MIC of carbon steel pipelines, highlighting the areas where there is a lack of information, and, to design and conduct preliminary studies to optimize a system for assessing the corrosion behaviour of a carbon steel pipeline material in nutrient enriched agar media, a gel commonly used to isolate pure cultures of bacteria. The findings from the initial review and preliminary studies are presented, as well as an articulation of the research problem. Amy Spark received the Marshall Fordham Best Research Paper Award.
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DAVID WHITBY BEST REVIEW PAPER AWARD Warren Green of Vinsi Partners for the paper ‘Concrete Repair and Protection - Overlooked Issues’ co-authors B. Dockrill & B. Eliasson, presented at Corrosion & Prevention 2013 in Brisbane, QLD. SUMMARY: Concrete repair and protection of reinforced and prestressed concrete structures and buildings remains as necessary today as ever. Various technologies exist with new technologies continually being developed and offered. Mistruths, bold claims, misstatements and misconceptions about some aspects of concrete repair and protection are considered to have become quite prevalent in the industry. This paper presents a reminder of some overlooked issues of some concrete repair and protection aspects including:incipient anode management, concrete patch repair performance, migrating inhibitors, coatings, penetrants, galvanic anode systems and the hybrid treatment system. Some facts can be derived and have been referenced from the literature and in some instances literature of many decades past. Other facts lie in fundamental corrosion science and these are also presented.
Warren Green received the David Whitby Best Review Paper.
C&P2014 AWARDS
LIFE MEMBERSHIP Life Membership is awarded for outstanding service to the ACA over an extended period either to a Branch or the Council and is awarded only as agreed by Council.
Ian MacLeod Ian MacLeod.
unable to attend Corrosion & Prevention 2014. Ian had prepared and filmed a few words and this was replayed to the audience on the night.
VICTOR NIGHTINGALL AWARD The Victor Nightingall Award is in recognition of distinguished achievement in the development, manufacture or application of protective coatings or advancement of the protective coatings industry.
Rob Francis Rob Francis received the Victor Nightingall Award.
Ian MacLeod has been a member of the Australasian Corrosion Association for over 36 years. He has a Ph D in Chemistry and a D Sc in materials conservation from the University of Melbourne. Ian is the author and co-author of over 170 papers and technical documents and has presented at both national and international conferences. He has been awarded a Fellowship of the Royal Society of Chemistry, elected Fellow of the Australian Academy of Technological and Engineering Sciences. He has been Plenary Lecturer on numerous occasions for various professional associations, including delivering the PF Thompson Memorial Lecture in 1988, 2002 and 2011. He was awarded the Corrosion Medal in 2004 and the Centenary Medal by the Prime Minister for ‘service to Australian Society in metallurgical science and engineering’ in 2003. He has served the ACA as President, Branch President and Conference Convenor and currently serves as the editor of ‘Corrosion & Materials’ and is also the Chairman of the ACA Foundation Scholarship Fund. Unfortunately Ian was chairing the International Council of Museums' Committee for Conservation, Wet Organic Archaeological Materials Working Group Meeting and was
Rob Francis is a metallurgist and a corrosion and coatings specialist. He has over 40 years’ experience in metals, materials and corrosion, especially regarding protective coatings. He is a regular presenter of a number of Australasian Corrosion Association and NACE training courses. Dr. Francis obtained a B.Sc. in metallurgy from the University of Melbourne and has a Ph.D. in corrosion science from the Corrosion and Protection Centre at the University of Manchester, UK. He is an ACA Corrosion Technologist and Coating Inspector, a NACE Certified Coating Inspector and is Chairman of MT14/2, which has developed AS/NZS 2312 on the selection and application of protective coatings. He is also Chairman of Committee MT 14/5 which produced AS 4312 on atmospheric corrosivity zones in Australia. He edited the recently-released revision of the ACA publication ‘Inorganic Zinc Coatings – History, Chemistry, Properties, Applications and Alternatives’. He has been awarded the JPCL editor’s award twice and was made a JPCL Top Thinker in 2012.
December 2014 www.corrosion.com.au p.37
C&P2014 PARTNER PROGRAM
PARTNER PROGRAM The ACA developed a delightful program of locally inspired activities for the Corrosion & Prevention 2014 Partner Program. The 4 day program included a visit to Darwin’s eclectic and action-packed Mindil Beach Sunset Market. The group was introduced to local Aboriginal music and art, while having the opportunity to design and paint their own canvas and a set of chap sticks under the direction of artists from the Larrakia Nation. Partners were provided with the opportunity to participate in the Defence of Darwin Museum Experience, the surprising story of Darwin's role in World War II as well as the chance to engage with the Cyclone Tracy exhibit at the NT Museum. One of the highlights of the Corrosion & Prevention 2014 partner program was the privilege of securing an invitation to Government House for a house and garden tour.
PARTNER PROGRAM TESTIMONIAL I have to admit, I was pretty hesitant about joining the Partner Program this year. I have never been to an ACA conference and from the majority of meetings I had attended in Melbourne; I had noted the dominant male presence. So I told my husband to sign me up, but secretly my agenda was to only attend the first day and then spend the rest of the time on my own. So along came day one and we headed off the Mindil Sunset Markets. I am a market lover and really enjoyed looking through all the stalls and eating some amazing food whilst watching the amazing Darwin sunset. However I still wasn’t convinced that this Partner Program was for me. The next morning the ACA had scheduled a Collaborative Aboriginal Arts Workshop. I was hesitant to attend and participate because I didn’t know anyone yet and some of these women had been on the ACA conference circuit together for 20+ years and are great friends. However I mustered up the pluck and went along. And I was so glad that I did. This was an experience to remember and the beginning of some amazing friendships. After a short music performance we were seated at some tables to start our indigenous paintings. As we sat there painting music sticks and canvases, together
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we chatted and got to know one another. The creativity that all of the attendees showed was incredible and the artwork produced was Gallery worthy. Our next day included the defence of Darwin Museum and a High Tea at the Cornucopia Museum. At the defence of Darwin we were taught about the bombing of Darwin and shown some of the artillery that the military used at the time. The next museum was a lunch break and for those that wanted it, a viewing of the Cyclone Tracy exhibition, which was very moving. Later on that evening we partied the night away at the ACA annual ball. Even though it was boiling hot, the men made the effort to look very sharp and the women were all so glamourous. It was a great night of good food, drinks and dancing. On our final day in Darwin we had the privilege of being invited to Government House. The women were all so impressed with our Gold Embossed invitations and excited to experience this rare opportunity. For those that don’t know, Government House gardens are only open once a year to the public. We were welcomed by the chief of staff at the House and then taken on a beautiful tour of the Gardens. Once we had finished our short tour we were invited into the house and enjoyed some light refreshments. We were also lucky enough to meet the Territory administrator, Her Honour the Honourable Sally Thomas AC. It was a once in a lifetime opportunity and all the women were so appreciative to have had such a great morning organised by the ACA. On behalf of everyone that participated in the Partner Program we would like to thank the ACA organisers for all the time and effort they put in to make the program so enjoyable. And a huge thankyou to Karen our Tasmanian host for keeping us all in line and on the bus for the four days. I am genuinely looking forward to next year’s ACA conference and can’t wait to meet up with all the wonderful women I met this year. Rachelle Rigby Compliance Manager, Commercial Industrial Painting Services
COATINGS GROUP MEMBER PROFILE
Adflex Protective Coatings Q: In what year was your company established? A: We began operations in 1989. Q: How many employees did you employ when you first started the business?
A: Our market is quite broad as our product is the perfect solution for so many varied situations. Factory floors, machines, schools, wineries, private garages, public works and even show rooms. We are quite adaptable in what we can provide.
A: Sole Trader.
Q: Is the business yard based, site based or both?
Q: How many do you currently employ?
A: Our business is site based.
A: Five regular staff plus a bookeeper.
Q: What is your monthly capacity or tonnage that you can blast and prime?
Q: Do you operate from a number of locations in Australia? A: We are primarily based in South Australia with potential national capabilities. We have competed jobs in Queensland, Victoria, Western Australia and of course South Australia. Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.) A: We specialise in concrete, steel coatings, repair, safety non slip, chemical protection, potable water coatings, SL epoxy and cement applications. Q: What markets do you cover with your products or services? e.g. oil & gas, marine, chemical process, general fabrication, tank lining, offshore etc.
A: N/A Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.) A: Our core business is concrete. However our services also extend to the coating and protection of steel structures. We are innovative and are always looking into new products and new services we can provide to our broad range of clients. Q: What is the most satisfying project that you have completed in the past two years and why?
floor with the vision to improve working conditions, cleanliness and a brighter workplace. The result? PMB have almost completed covering their entire factory with Adflex’s coating and protection system. This job was especially enjoyable as the improvements were met with outstanding positive feedback from employees and management. Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job? A: Our client was willing to do things without cutting corners, which gave an excellent long lasting result. Q: Do you have an internal training scheme or do you outsource training for your employees? A: As we are a small team, we outsource training to ensure we are all kept up to the highest standards both in safety and knowledge. Contact Us Contact: Richard Aue Mobile: 0402 448 566 Email: info@adflexcoatings.com.au Website: www.adflexcoatings.com.au
A: Pacific Marine Batteries (PMB Defence). Going back 2 years PMB contacted Adflex to provide a floor coating to an area of their production
December 2014 www.corrosion.com.au p.39
UNIVERSITY PROFILE
RMIT University RMIT University has a well established corrosion group, with a track record of research into materials corrosion and durability, in both condition monitoring and service life assessment. The group offers a comprehensive range of NDT techniques to assess the corrosion of metals and of reinforced concrete structures. The corrosion group includes academics from a number of disciplines, providing a wide range of expertise and a multidisciplinary approach. The group is involved in research in a number of different key areas having strong industrial links and also offering consultancy and training to industry. A number of grant schemes are also available for collaborative research and development projects. Some of the key current research topics are: i. The impact of corrosion on bond in reinforced concrete; Research at RMIT has investigated the relationship between bond and surface crack width. The results have shown a potential relationship which can be used in the assessment of structures to predict the residual bond, enabling a management strategy to be developed for the structures.
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ii. Microbial influenced corrosion (MIC) of carbon steel pipes; MIC, a deterioration process involving the interaction with bacteria, is prevalent in a number of areas, particularly oil and gas fields, structures exposed to seawater, including ships and underground potable water pipelines. Fundamental studies into the interactions between the electrochemical corrosion processes and bacteria and the development of an agar based laboratory test system to replicate the soil environment are currently being undertaken, which can be extended to MIC studies in other areas. iii. Residual Effects of Cathodic Protection; It has recently been noted in a number of studies that steel which has been passivated via an Impressed Current Cathodic Protection (ICCP) system is able to remain passive for a period of up to 3 years. The corrosion group is undertaking a project to assess the long term operation of ICCP systems and the residual protection after they have stopped operating to develop an understanding of the electrochemical process controlling the passivation and protection of reinforcing steel when subjected to ICCP. This is involving both laboratory trials and site monitoring around Australia
iv. Corrosion of high performance steel welds; One area of importance in the oil and gas industry, particularly for subsea application, is the corrosion behaviour of high performance duplex stainless steel welds for critical applications such as valves, manifolds, etc. Here, assessment of the weld integrity, using electrochemical techniques such as DL-EPR and CPT measurements, is carried out in terms of the susceptibility to IGC, SCC, pitting corrosion and weld design for eliminating such forms of corrosion. v. Coatings for corrosion control; A number of projects are focussed on the corrosion assessment of surface coatings for structural engineering applications using accelerated corrosion monitoring techniques such as potentiodynamic scanning. In particular, the philosophy of coating design to reduce porosity and pin holes and overall improve structural integrity of the coating. vi. Improved Management of Australian Maritime Infrastructure by Development of a Predictive Management Tool; An ARC Linkage project in collaboration with Monash University, AECOM, Port of Sydney and Port of Portland is developing a 3-Dimensional
UNIVERSITY PROFILE
probabilistic model for the initiation and propagation of reinforcement corrosion in port infrastructure. The project is using Finite Element Analysis software to develop a three dimensional model to predict the ingress of chloride ions, the initiation of corrosion and the propagation of the corrosion to cracking, spalling and structural failure. vii. Laser scanning; A research project is being undertaken to use laser scanning to monitor the rate of deterioration due to corrosion. By taking scans at discreet points in time both the current condition and any changes can be identified. This is particularly useful for large structures where access or detailed investigation is problematic. Software is being developed to interrogate the data to determine crack width, length and rate of growth. The second stage of the project will look at corrosion monitoring in steel structures, such as piles, girders and beams. The University has a range of instrumentation available for materials investigation and characterisation including, SEM, XPS, EDX, XRF, Impedance Spectroscopy and LPR. The group is comprised of members of staff from Civil Engineering, Dr David Law and A/Prof Sujeeva Setunge, the Chemical Engineering discipline, Dr Liam Ward and Architecture and Design, Lucas Holden Further details may be obtained from researchers in the various areas: Corrosion monitoring, non-destructive testing and predictive modelling Dr David Law, david.law@rmit.edu.au 03 9925 0321 Metallic corrosion and coatings Dr Liam Ward, liam.ward@rmit.edu.au 03 9925 1713 Laser scanning Lucas Holden, lucas.holden@rmit.edu.au 03 9925 1956 General Enquiries School of Civil, Environmental and Chemical Engineering GPO Box 2476V Melbourne 3001, Victoria, Australia Tel +61399250321 Fax +6139639013
December 2014  www.corrosion.com.au  p.41
NEW PRODUCT SHOWCASE
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New Arc 150 Metal Spray System Metallisation and MSSA have launched their new Arc150/S500CL Arcspray Metalspray system, which has been specifically designed for higher throughput with up to 500 amp capacity. The Arcspray 150 system is a high throughput spray system ideal for corrosion protection applications spraying 2.3/2.5mm Zinc, Aluminium, and alloys such as ZNAL85/15.
Typical performance figures for the ARC150 pistol
There is also a growing Industry requirement for high temperature alloys to be Metalsprayed such as Inconel 625 or Hastelloy C276, which can be applied using the ARC 150 system.
With its unique design it delivers increased productivity for large areas, whilst retaining its flexibility when spraying smaller or more complex areas. The optimal design uses the Metallisation patented ‘Synchrodrive’ system which delivers a push /pull drive system, which allows wire feed up to a length of 20 metres. The design of the Energizer (power source) allows for multiple customer specific packaging options for the wire and drive dispensing. The system is easy to maintain and less expensive to run than gas flamespray systems.
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p.42 CORROSION & MATERIALS
NEW PRODUCT SHOWCASE
SHOWCASE Fight Rust and Save Time and Money Chemsearch Australia’s specially developed rust converter Chelade can save businesses time and money and extend the life of steel. The readyto-use solution does not require any pre-surface treatment and does not leave any rust behind that may lead to future corrosion. In addition to converting the rust and corrosion Chelade creates a black polymeric protective barrier resistant to renewed oxidation and deterioration. Chemsearch Australia went beyond conventional approaches when designing Chelade with the aim of cutting labour time while producing longer lasting protection. Its proven ready-to-use formulation does not require sandblasting, grinding or
scraping before application. This unique time saving feature could greatly reduce potential labour costs. Chemsearch’s Country Manager, Robert Epps, said; “Chelade is an ideal solution to this kind of problem and has the potential to save hundreds of dollars in maintenance and replacement costs while minimising business interruption. It provides a long-term solution that is versatile enough to work on nearly any surface where rust forms.” To learn more about the Chelade or to find more information about Chemsearch visit: www.chemsearch.net.au or contact: stuart.dunlop@nch.com
The ACA does not officially endorse any of the products advertised in Corrosion & Materials.
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PROJECT PROFILE
Australia’s Newest Tourism Attraction – The Melbourne Star Observation Wheel As the capital of the State of Victoria and second most populous city in Australia, the vibrant and colourful city of Melbourne is attracting locals and tourists alike to its newest tourism and entertainment attraction; the Melbourne Star Observation Wheel. Standing at a towering 120 metres tall— equivalent to a 40 storey building— the Melbourne Star is the only giant observation wheel in the Southern Hemisphere, with its seven jutting spokes representing the seven-pointed Federation star on the Australian flag. One complete rotation of the Star takes approximately 30 minutes, giving guests’ an uninterrupted 360-degree view of up to 40 km that includes such landmarks as the Docklands Precinct, Melbourne’s city business district, Port Phillip Bay, Mount Macedon and the Dandenong Ranges. Melbourne Star Observation Wheel against the Melbourne CBD in the background (Image courtesy of Melbourne Star Observation Wheel).
The Melbourne Star Observation wheel was commissioned by Sanoyas Rides Corporation and the project involved the engineering team from Arup, Alfasi Steel Construction in Melbourne and Haywards Steel Fabrication and Construction of Tasmania. AkzoNobel’s International® brand was selected as the sole supplier of protective coatings for the massive steel structure. The Melbourne Star Observation Wheel officially opened on December 23, 2013, and has already received a string of prestigious accolades. The Melbourne Star was awarded a Steel Excellence Award in Engineering
Projects at the 2014 Australian Steel Institute (VIC) Awards, and a High Commendation award at both the Buildings and Structures category at the 2014 Victorian Engineering Excellence Awards; and 2014 National Steel Institute Awards. The Melbourne Star is constructed from approximately 1,200 tons of steel that incorporates the whole of the superstructure, including the columns and hub, which was fabricated and transported to the site in giant sections by Alfasi and Haywards. The technology of its International® products, combined with the technical expertise and supply capabilities were the driving factors that helped AkzoNobel secure the contract for the Melbourne Star. This giant project was another accolade in the long term relationship between AkzoNobel’s with Alfasi. AkzoNobel’s Brendan Mutimer, Project Manager Victoria, recommended a two coat Interzinc® 52 primer and Interfine® 979 polysiloxane topcoat system, instead of a traditional three coat system. Together, the coatings’ excellent adhesion and fast curing properties helped fast track the construction schedule, without
Construction of the 7 outer spokes.
p.44 CORROSION & MATERIALS
Steel section featuring Interfine 979 high gloss finish. compromising the corrosion protection standards for the job. The polysiloxane topcoat color was appropriately named Melbourne Star Observation Wheel White, after the original color specification. AkzoNobel received praise for the accuracy of the color match and for the long term color and gloss retention its topcoat will provide. Painting Contractors, Action Alliance of Melbourne and McElligott Partners of Tasmania, were contracted to sprayapply the coatings to the complex steel sections after fabrication, and later provided touch ups at the job site—both on the ground and after the sections were erected, which was no easy feat. The high durability of the two coat system will ensure an extended lifecycle of the tourism attraction for decades to come.
Construction of the outer rim section of the wheel.
“Action Alliance was very pleased with the uninterrupted process of application due to the fast curing performance of Interfine® 979 polysiloxane. Not only did this assist with the off-site application, once the company proceeded with on-site touch up and rectification works it really enhanced its abilities of recoating with minimal effort. This will be a positive product for the future maintenance programs”, according to a spokesperson from Action Alliance.
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Mutimer commented, “The success of this project was a true team effort across the business. It was a combination of strategic collaboration on detailed specifications, warranties, maintenance plans, site visits and meetings, random inspections, problem solving and uninterrupted product supply that made it possible. The project owners
Project Team: Owners: Sanoyas Rides Australia Pty Ltd Engineers: Arup Contractor: Sanoyas Rides Corporation, Osaka Japan Steel Contractors for Wheel: Alfasi and Haywards Applicators: Action Alliance and McElligott Partners
Today the Melbourne Star Observation Wheel is one of only four giant observation wheels in the world, offering breathtaking flights in 21 spacious air conditioned cabins. AkzoNobel’s advanced International® two coat system will help keep the Melbourne Star looking its best for years to come.
Completed Melbourne Star at the new Docklands home (Image courtesy of Melbourne Star Observation Wheel).
December 2014 www.corrosion.com.au p.45
CORROSION HISTORY
Corrosion Engineering – an Historical View
As a new immigrant I became fascinated with how corrosion technology has impacted Australia. As a corrosion engineer it was a fantastic research topic for me. There is a treasure of materials from the National Library of Australia with newspapers from the 1800s reporting on items such as shipbuilding technologies including the advent of the steam engine and coating systems for the ‘new’ iron ships. The information regarding submarine telegraph cables was a hot news item in the 1860s. These two technologies helped usher Australia into a new age of more rapid communication and corrosion engineering (although not specifically called that) helped pave the way1.
Steam Ship Boilers The reports of the successful sea trials of the steam ship Hercules arrived via The Colonist, a New South Wales publication, in September 1836. “The leading object of Mr. Hall’s [steam engine], is the preservation of the boilers from the injurious action of sea-water, or water containing earthy or saline matters, which occasion incrustations and rapid corrosion” [1]. There is no mention of what the “preservation” measures were, whether coating or simply fresh water washing. Knowledge of corrosion in boilers was established in England early in steam ship development and by 1843, the Sydney Morning Herald reported on maintenance actions by the colonial whaling fleet: “The Rapid, steamer, was employed yesterday in plying to and from the North Shore, in order to afford an opportunity of having the boilers of the Steam Punt cleaned. This is to be done once a month to prevent corrosion from the collection of salt on the inside of the boilers” [2]. Fresh water washing to clean sea salt from ship’s equipment is still in practice today. Figure 1. A line drawing of a boiler during the manufacturing process. From [3].
Ship Preservation Clearly, preservation of iron was on the shipbuilder’s mind. The Iron Queen as reported by the London Emigration Press May 12, 1843 made a voyage to America and return with no corrosion and no fouling. “There is no appearance of corrosion, the red lead being fresh on the plates, and neither bells, barnacles or any foulness was on her bottom. This desirable result is caused by the single application of a compound of tallow, bright varnish, arsenic, and brimstone, which effectively destroys marine vegetable and animal substances” [4]. What a combination the chemists of the day invented – rendered fat, arsenic, and sulphur with bright varnish! We can appreciate how far we’ve come with HS&E for painting practices after learning this. However the efficacy of the treatment provides an insight into the creativity of the coatings manufacturers. An amazing find for me as a former US Navy researcher was the demonstration of two coating systems on an iron hulled steamship reported in July 1860.
“In the early part of last May the Royal Mail Company’s steamship Atrato was coated on the starboard side with McInnes’s green copper soap and on the port side with Peacock and Buchan’s pink composition for the purpose of practically testing the relative merits of the two articles in keeping the bottom of the ship clean” [5]. The coatings were examined after three months service in the Royal Mail route between England and Australia. Typically this route arrived from England via Cape Horn in approximately 80 days. The green copper soap, starboard side, provided virtually no protection, showing “coral pipe, shells, and barnacles, with a good deal of corrosion.” The pink composition, port side, showed only a biofilm. The author of the article concludes that the copper containing coating was “of little value” for antifouling and caused corrosion of the iron rivets. It is interesting to note that a common technology for coating steel ships today is three coats of an anticorrosive paint followed by three coats of a copper ablative antifouling paint. This is an especially interesting tradition of a demonstration and validation project, which many researchers still use today to prove the performance of coating systems (even with test patches on aircraft). Submarine Telegraph Cables In this section, I will take a slight detour from using only the newspaper references. I was lucky enough to be able to read the Engineer’s Final Report2 for the laying of the Port Darwin to Banjoewangie cable, which as an appendix had the original and modified contracts for the cable. The design and manufacture of submarine telegraph cables was hotly debated in the press due to great anticipation with which Australia waited to be connected to the rest of the world3 and the concern over the many failures of the early submarine cables. An insight into the
1 The dependence of Australia on the British Post Office for most communications prior to the late 1850s is described quite well in K.T. Livingston’s “The Wired Nation Continent,” Oxford University Press Australia, 1996
p.46 CORROSION & MATERIALS
Figure 2. The steamship Otago circa 1855. A similar ship to the Royal Mail Steamship Atrato. The RMSP Atrato was originally commissioned for the England to West Indies mail route. Later the route was extended around Cape Horn and across the Pacific to Sydney. Image from [6].
scepticism and politics of the time can be gleaned from the articles listed after the references at the end of this article. The focus here will be reporting of the actual materials, manufacturing methods and design of the submarine telegraph cables with respect to corrosion and degradation. In 1861, the Sydney Morning Herald ran an article which mentions inadequate/ non-existent testing and the contractor laying cables too taut as causes of failures of the Red Sea lines. It also cites differences in corrosion rates in different parts of the sea so that cables degrade unevenly. Protection schemes for the cables contained tar, gutta percha, India rubber and “jute saturated with common asphalte”. The Red Sea Line was considered essential to the eventual connection of the AngloAustralia telegraph. [8] In 1863, the same newspaper again published an article on ocean telegraph lines, “How To Make An Atlantic Telegraph Cable.” This article reviews the materials and manufacturing processes that were current at the time for the Atlantic cable [9]. The materials used did not change significantly to the cable laid to connect Australia. However, the Australian cable had additional protection added.
The Engineer’s Final Report (22April1872) was written by J.L. Clark and H.C. Forde, the engineers for the British-Australia Telegraph Company (BATC) [10]. The company was contracted to oversee the manufacture and laying of the line from Port Darwin to Banjoewangie (Java). The Telegraph Construction and Maintenance Company Ltd. manufactured and tested the cable according to the terms laid out in the contract with the BATC (available as part of the Appendix to [10]). The submarine telegraph cable consisted of a conductor and insulator (the core) and any protection schemes necessary forming the outer covering. The protection schemes were designed for mechanical properties and degradation protection. The core was 7 stranded copper wires covered by 3 coatings of gutta-percha according to Mr. Willoughby Smith’s system, alternating with 3 coatings of Chatterton’s Compound. The outer coverings were jute yarn steeped in tar covered by a number of galvanised iron wires covered by 2 layers of jute yarn laid in opposite directions with 2 coatings of Mr. Latimer Clark’s compound (also known as Bright & Clark’s Compound). The number and size of iron wires used depended on the type of cable needed: deep sea,
shallow sea, or shore end. [10] When assembled, the cable looked similar to that pictured below (however, the cable pictured below has a second iron wire layer over the Clark’s Compound layer). The core was designed for electrical properties, i.e., conductivity of the copper and resistivity of the insulator. Interestingly enough, initially, cables were laid with only the core in shallow seas. However, it was found that marine “worms” liked to eat the gutta-percha, so the outer coverings were developed. Additionally, it was found for deep sea cables, additional strength was needed to ensure proper laying and raising of the cable and for shallow sea cables for wear resistance against rocks. The final layers of jute yarn/Clark’s compound were added to prevent the iron from corroding so rapidly. [11] A section of the Red Sea cable had this “hard, bituminous covering” for corrosion protection [12]. Clark’s compound consisted of a mixture of “asphalte or mineral pitch, silica, and tar.” Pitch was the watertight casing with tar additions to make the compound more workable. Additions of silica gave an improvement to marine life attack (see the worms
2 A special note of thanks to the Northern Territory Library, especially the research and special collections librarians, who uncovered some amazing references, including the (hand written) notebook containing the Engineer’s Final Report. 3 Australia was connected internationally from Port Darwin to Banjoewangie, Java on 20 November 1871. The first words across that cable were “Advance Australia Fair.” The connection from Adelaide to Darwin was finished in August 1872, which connected the whole of Australia to the world. [7]
December 2014 www.corrosion.com.au p.47
CORROSION HISTORICAL SNIPPETS
mentioned previously). The methods of manufacturing cables with this casing were not designed and patented until 1862. [11]
Figure 3. Example of a submarine telegraph cable advertised in 1898. It is different from the BAT telegraph cable with two iron wire layers rather than the one used by the BAT for the Port Darwin to Banjoewangie cable. From [11, picture taken from advertisements at conclusion of text]. Closing Remarks Most solutions to corrosion issues presented here came from engineering solutions. Many of the articles mention insufficient testing when failure occurred. Those statements I believe to be hind-sight based. I will venture as far as to say that corrosion was of course not understood at the depth it is today, so that the durability testing needed was not fully understood. The amount and types of testing needed to understand the durability of materials in harsh environments may not have been available to those engineers designing the systems described here. However, they were able to innovate solutions that had amazing impacts on Australia. One final thought: we have seen the prediction of Dr. Kentworthy of Tasmania [13] come to fruition, “I cannot but anticipate, that, in the future disclosures of this branch of science, [galvanism], a fertile and widely extended field will be opened to us…”
1840), p. 6. Retrieved August 20, 2014, from http://nla.gov.au/nla.newsarticle31718451 [2] COLONIAL WHALERS AT SEA. (1843, June 23). The Sydney Morning Herald (NSW : 1842 - 1954), p. 2. Retrieved August 13, 2014, from http:// nla.gov.au/nla.news-article12423656 [3] Haldane, J.W.C., Steamships and Their Machinery: from First to Last, London: E. & F.N. Spon, 1893, pp. 57-76. [4] ENGLISH EXTRACTS. (1843, October 25). The Sydney Morning Herald (NSW : 1842 - 1954), p. 3. Retrieved August 13, 2014, from http://nla.gov. au/nla.news-article12410839 [5] COMPOSITION FOR COATING SHIPS’ BOTTOMS (1860, July 27). The Sydney Morning Herald (NSW : 1842 - 1954), p. 6. Retrieved August 18, 2014, from http://nla.gov.au/nla.newsarticle13043598 [6] Gregorgy, George Fredrick. No. 13 Otago. 1855, photograph : albumen silver, The State Library of Victoria, Melbourne, Victoria. [7] The Story of the Australia-England Telegraph Link: The Wonder Working Wire, Australia’s International Telecommunications Authority, The Overseas Telecommunications Commission Information Broadsheet No. 1. On file at the Northern Territory Library, Darwin, NT. Accessed on 23 September 2014. [8] The Sydney Morning Herald. (1861, August 5). The Sydney Morning Herald (NSW : 1842 - 1954), p. 4. Retrieved August 15, 2014, from http:// nla.gov.au/nla.news-article28624595
References
[9] HOW TO MAKE AN ATLANTIC TELEGRAPH CABLE. (1863, March 17). The Sydney Morning Herald (NSW : 1842 - 1954), p. 8. Retrieved August 18, 2014, from http://nla.gov.au/nla.newsarticle13075722
[1] IMPROVEMENTS IN STEAM NAVIGATION. (1836, September 1). The Colonist (Sydney, NSW : 1835 -
[10] BAT Engineer’s Final Report and Appendix, Section 2, Banjoewangie to Port Darwin, J.L. Clark and H.C. Forde,
Elissa Trueman Corrosion Engineer & Researcher
p.48 CORROSION & MATERIALS
British-Australia Telegraph Company, 22April 1872. (Held in the special collections of the Northern Territory Library, Darwin, NT, Australia.) [11] Bright, Charles, FRSE, Submarine Telegraphs: Their History, Construction, and Working. London: Crosby Lockwood and Son, 1898. [12] The Sydney Morning Herald. (1862, September 15). The Sydney Morning Herald (NSW : 1842 - 1954), p. 4. Retrieved August 15, 2014, from http:// nla.gov.au/nla.news-article28623305 [13] Dr. Kentworthy in lecture to the Mechanics Institute of Hobart on 10 September 1847. MECHANICS' INSTITUTE. (1847, September 15). The Courier (Hobart, Tas. : 1840 - 1859), p. 2. Retrieved October 21, 2014, from http://nla.gov.au/nla.newsarticle2970934. Articles on the politics and financing of the submarine telegraph cables: [1] Monday 20 May 1861 Ocean Telegraphs. OCEAN TELEGRAPHS. (1861, May 20). The Sydney Morning Herald (NSW : 1842 - 1954), p. 3. Retrieved August 14, 2014, from http:// nla.gov.au/nla.news-article13064166 [2] ELECTRIC TELEGRAPHS. (1863, September 21). The Sydney Morning Herald (NSW : 1842 - 1954), p. 11. Retrieved August 18, 2014, from http:// nla.gov.au/nla.news-article13093649 [3] OCEAN TELEGRAMS. (1864, December 27). The Sydney Morning Herald (NSW : 1842 - 1954), p. 3. Retrieved August 18, 2014, from http:// nla.gov.au/nla.news-article13101321 [4] TELEGRAPHIC CONNEXION WITH ENGLAND. (1870, January 1). The Australasian (Melbourne, Vic. : 1864 - 1946), p. 16. Retrieved November 7, 2014, from http://nla.gov. au/nla.news-article138062232 [5] The Courier. (1870, March 11). The Brisbane Courier (Qld. : 1864 1933), p. 2. Retrieved November 7, 2014, from http://nla.gov.au/nla.newsarticle1311867
ACA Foundation Centurion What is an ACA Foundation Centurion? An ACA Foundation Centurion is an individual or company that commits themselves to a contribution to the ACA Foundation Ltd Scholarship Fund of at least AUD$100 annually for as long as they are able.
Thank You The ACA Foundation would like to thank ACA Foundation Centurions for their generous support of the work and mission of the ACA Foundation - Advancing Corrosion Mitigation through Education.
A Word from a Centurion "It’s a pleasure to be an ACA Foundation Centurion as I have received so much assistance and encouragement from the ACA community throughout my career. It’s a privilege to be able to support the association that has supported me and to contribute to the education of future generations of corrosionists.” Dr. David Nicholas, Nicholas Corrosion & ACA Foundation Centurion.
Alex Shepherd
Graeme Kelly
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Alexander (Sandy) McPherson
Graham Robert Carlisle
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Becoming a Centurion If you would like to become an ACA Foundation Centurion, please download the commitment form from the Foundation page of the ACA website www.corrosion. com.au, or alternatively email Jacquie Martin at jmartin@corrosion.com.au *Donations over $2.00 made to the Scholarship Fund are tax deductible
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Leading Suppliers of NDT Equipment for the Corrosion Industry
Cathodic Anodes Australasia
Head Office T +61 7 5476 9788 sales@cathodicanodes.com.au www.cathodicanodes.com.au
Unit 23, 58 Box Rd Taren Point NSW 2229 Tel: 02 9524-0558 • Fax: 02 9524-0560 Email: ndt@ndt.com.au • Web: www.ndt.com.au
ANODE MANUFACTURER siNCE 1984 abn 93 821 370 828 CAA advert 60x40 nov 2012.indd 1
tawfik
tawfik
- Forensic engineering (material failure, safety/accidents, fire)
- Forensic engineering (material failure, safety/accidents, fire)
- Compliance (metal fabrication, quality, fitness for purpose)
- Compliance (metal fabrication, quality, fitness for purpose)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
Dr David Tawfik — Principal Materials Engineer
Dr David Tawfik — Principal Materials Engineer
Impartial investigation and independent expert witness in:
BEng(Hons) BDes PhD MIEAust CPEng RPEQ
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
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Impartial investigation and independent expert witness in:
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tawfik
- Forensic engineering (material failure, safety/accidents, fire)
- Forensic engineering (material failure, safety/accidents, fire)
- Compliance (metal fabrication, quality, fitness for purpose)
- Compliance (metal fabrication, quality, fitness for purpose)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
Victoria New South Wales Brisbane Western Australia Distributors all States and Auckland N.Z.
Impartial investigation and independent expert witness in:
1300 782 501 1300 782 503
General Manager
Dr David Tawfik — Principal Materials Engineer
Dr David Tawfik — Principal Materials Engineer
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
w w w .taw fikg rou p. co m. a u
w w w .taw fikg rou p. co m. a u
BEng(Hons) BDes PhD MIEAust CPEng RPEQ
Australasian Principal Elcometer Service Centre
Phone: BEng(Hons) BDes PhD MIEAust CPEng RPEQ1300 503 610 Email: sales@phillro.com.au m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au www.phillro.com.au
tawfik
Impartial investigation and independent expert witness in:
31/10/12 12:09 P
BEng(Hons) BDes PhD MIEAust CPEng RPEQ
INTERPROVINCIAL CORROSION CONTROL CO. LTD. Leaders in the Cathodic Protection Industry…Since 1957
SOLID-STATE CATHODIC ISOLATOR® Mitigation Of AC Induced Voltages • Lightning • AC Fault Current
tawfik
Impartial investigation and independent expert witness in:
TEL: 905-634-7751 FAX: 905-333-4313 - Forensic engineering (material failure, safety/accidents, fire)
tawfik
www.cceng.com.au
Cathodic Protection | Integrity Management | Design & Testing | CP Products
Impartial investigation and independent expert witness in:
Sydney | Melbourne | Brisbane | Perth | Townsville | Auckland | New Plymouth
- Forensic engineering (material failure, safety/accidents, fire)
- Compliance (metal fabrication, quality, fitness for purpose) www.Rustrol.com
- Compliance (metal fabrication, quality, fitness for purpose)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
Dr David Tawfik — Principal Materials Engineer
Dr David Tawfik — Principal Materials Engineer
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
w w w .taw fikg rou p. co m. a u
w w w .taw fikg rou p. co m. a u
BEng(Hons) BDes PhD MIEAust CPEng RPEQ
BEng(Hons) BDes PhD MIEAust CPEng RPEQ
D R MAY Inspections
David May
tawfik
tawfik
- Forensic engineering (material failure, safety/accidents, fire)
- Forensic engineering (material failure, safety/accidents, fire)
- Compliance (metal fabrication, quality, fitness for purpose)
- Compliance (metal fabrication, quality, fitness for purpose)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
- Material characterisation(metallurgy/corrosion/welding/fatigue)
Impartial investigation and independent expert witness in:
Dr David Tawfik — Principal Materials Engineer BEng(Hons) BDes PhD MIEAust CPEng RPEQ
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
Welding Supervision Welding Inspection NDT Specialist Coating Inspection Inservice Inspection
Impartial investigation and independent expert witness in:
Geelong Office: 193 Station Street, Corio, Victoria 3214 Australia Postal Address: P.O. Box 1080, Corio, Victoria 3214 Australia Tel: +61 3 5275 3339 Fax: +61 3 5275 0585 Mob: 0412 520 699 Email: dmay@drmay.com.au
Dr David Tawfik — Principal Materials Engineer December 2014 www.corrosion.com.au BEng(Hons) BDes PhD MIEAust CPEng RPEQ
m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au
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