Corrosion & Materials April 2011 by Australasian Corrosion Association

Official

Publication

the

Australasian

Corrosion

Association

â&#x20AC;˘

www.corrosion.com.au

Vol 36 No 2, April 2011 ISSN 1326-1932

Inside this Issue: ACA Corrosion Challenges Project List of ACA Certified Technologists and Technicians Microbially Influenced Corrosion Project Profile: Re-Lifing a CO2 Absorber Tower Using Welding Robots Project Profile: Refurbishment of the Vessel One and All University Profile: University of New South Wales Research Paper: Probing Corrosion Activities in Difficult-to-Test Media Using the Wire Beam Electrode: Case Studies Research Paper: Effectiveness of Cathodic Protection System on Constructed Tanks over Bituminous Sand Mix Layer

At last… a Pocket Rebar Locator Used by tradesmen for simple location of rebar and conduits … and by engineers for accurate cover measurement. n

Wireless handheld pocket covermeter for site engineers/ inspectors.

Cost effective as personal ‘i-cover’ device.

Bar, cable and copper pipe locator for tradesmen and building managers.

Easy to locate the centre of bars for diamond saw cutting or drilling.

Proceq reliability and after sale care.

Features n

Same accuracy as more expensive logging covermeters (i.e. generally ±2mm). Instinctive LED and target graphics for easy bar location.

Neighbouring bar cover correction.

Bar diameter estimate.

PCTEC1102PGX

A AT W

Sydney n Melbourne n Perth Phone 0408 034 668 www.pcte.com.au

Rebar location needs to be fast and accurate. Profoscope has a unique real-time rebar visualization that allows contractors to actually ‘see’ the location of the rebar beneath the concrete surface. That may be all that is needed for concrete drilling and sawing contractors but inspectors and engineers need accurate cover measurement and bar diameter assessment. The Profoscope provides this as well and is a wireless hand held device that slips easily into your pocket.

ISSN 1326-1932 Published by the Australasian Corrosion Association Inc. ABN: 66 214 557 257 Publications Director Mohammad Ali – GHD, MAli@ghd.com.au Editor Brian Cherry – Monash University, Brian.Cherry@monash.edu Associate Editors Research: Bruce Hinton – Monash University, bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants, Willie.Mandeno@opus.co.nz News: Ian Booth – Australasian Corrosion Association, ibooth@corrosion.com.au Reviewers Andy Atrens – University of Queensland Nick Birbilis – Monash University Lex Edmond – Monash University Harvey Flitt – Queensland University of Technology Maria Forsyth – Monash University Rob Francis – Aurecon Australia Warren Green – Vinsi Partners Doug John – Curtin University of Technology Graeme Kelly – Corrotec Services Nick Laycock – STOS Grant McAdam – Defence Science and Technology Organisation David Nicholas – Nicholas Corrosion John Robinson – Mount Townsend Solutions Paul Schweinsburg – Queensland University of Technology Raman Singh – Monash University Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science and Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South Wales Advertising Sales Wesley Fawaz - wesley.fawaz@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscription Print Version: ISSN 1326-1932 Subscription rates to non members: Within Australia: A$72.60, incl GST, single copies A$16.50, incl GST Outside Australia: A$77, excl GST posted airmail, single copies A$22 incl GST On-Line Version: ISSN 1446-6848 Subscription rates to non members: A$22 incl GST 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. Australasian Corrosion Association Inc PO Box 112, Kerrimuir Vic 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: aca@corrosion.com.au Internet: www.corrosion.com.au President: Ian MacLeod Chief Executive Officer: Ian Booth Operations Chairman: John Grapiglia Finance Director: Paul Vince Senior Vice President: Peter Dove Junior Vice President: Allan Sterling Immediate Past President: Roman Dankiw Technical Director: Graham Sussex Education Director: Geoffrey Will Membership Director: Fred Salome Communications Director: Bryan Pike Publications Director: Mohammad Ali Newcastle Representative: Matthew Dafter New Zealand Representative: John Duncan Branches & Divisions Auckland Division: Sean Ryder 64 9 261 1400 61 2 4954 2329 Newcastle: Bill Livingstone 61 2 9736 3911 New South Wales: Fred Salome 61 7 3821 0202 Queensland: Cathy Sterling 61 8 8267 4744 South Australia: Alex Shepherd 61 3 6335 4786 Tasmania: Bryan Pike 64 27 671 2278 Taranaki Division: Ron Berry 64 4 473 3124 Wellington Division: Alistair MacKenzie 61 0 433 251 728 Western Australia: Ben Coleman 61 3 9885 5305 Victoria: John Tanti Technical Groups Cathodic Protection: Bruce Ackland 61 3 9890 3096 Coatings: David Hopkins 61 400 522 944 Concrete Structures & Buildings: Frédéric Blin 61 3 9653 8406 61 8 9456 0344 Mining Industry: Peter Farinha 61 402 684 165 Refining & Processing Industry: Fikry Barouky 61 3 9905 4919 Research: Nick Birbilis 61 2 9385 4322 Research: David Young 61 419 816 783 Water & Water Teatment: David Mavros 61 3 9495 6566 Welding, Joining & Corrosion: Graham Sussex Young Corrosion Professionals: Erwin Gamboa 61 8 8303 5473 www.corrosion.com.au

4 » President’s Message 6 » Chief Executive Officer’s Message 8 » News 15 » ACA Branch News 16 » ACA Standards Update 20 » ACA Corrosion Challenges Project 25 » Coatings Group Member Profile 26 » ACA Technical Groups Update 28 » ACA Certified Corrosion Technologists and Technicians 30 » Microbially Influenced Corrosion 33 » P roject Profile: Re-Lifing a CO2 Absorber Tower Using Welding Robots 36 » Project Profile: Refurbishment of the Vessel One and All 38 » University Profile: University of New South Wales esearch paper: Probing Corrosion Activities in Difficult-to 41 » R Test Media Using the Wire Beam Electrode: Case Studies 50 » R esearch paper: Effectiveness of Cathodic Protection System on Constructed Tanks over Bituminous Sand Mix Layer 57 » Suppliers and Consultants

Front Cover Photo Weld Procedure Qualification in progress, using a mechanised GMAW system for the Bayu Darwin subsea pipeline project. Photo Supplied by IWES Pty Ltd

The ACA is a founder member of the World Corrosion Organization

Vol 36 No 2 April 2011

At last… a Pocket Rebar Locator Used by tradesmen for simple location of rebar and conduits … and by engineers for accurate cover measurement. n

Wireless handheld pocket covermeter for site engineers/ inspectors.

Cost effective as personal ‘i-cover’ device.

Bar, cable and copper pipe locator for tradesmen and building managers.

Easy to locate the centre of bars for diamond saw cutting or drilling.

Proceq reliability and after sale care.

Features n

Same accuracy as more expensive logging covermeters (i.e. generally ±2mm). Instinctive LED and target graphics for easy bar location.

Neighbouring bar cover correction.

Bar diameter estimate.

PCTEC1102PGX

A AT W

Sydney n Melbourne n Perth Phone 0408 034 668 www.pcte.com.au

Front Cover Photo Weld Procedure Qualification in progress, using a mechanised GMAW system for the Bayu Darwin subsea pipeline project. Photo Supplied by IWES Pty Ltd

The ACA is a founder member of the World Corrosion Organization

Vol 36 No 2 April 2011

Dear Members A walk along Los Angeles’ Malibu Beach on a recent chilly mid-spring February day showed a series of snapshots for the world of corrosion that was full of lessons for the unwary. Despite having spent millions of dollars in purchasing their chosen slabs of real estate, perched high above the relentless Pacific Ocean, the response of the owners was quite telling. Some massive wooden beams supporting the rafters and upper floors of the houses were clearly subject to localised attack from wood boring molluscs while the wise owners had the intertidal and splash zone areas protected by wrapped treatments that made me think “D***o”! Other posts had epoxy grouting in them for repairing and consolidating the structural beams. While some owners were content to have significant rusting on the face plates and bolts holding the timber structures in place others seemed almost oblivious of the pervasive yellow brown tide line of iron (III) hydroxy chlorides weeping from H sections and other fixtures. Imagine my delight when I came across the sparkling presence of a house where the owners had received and implemented the correct advice from a corrosion consultant. The white paint was not chalked and was clearly a high build coating with a UV resistant outer skin. The

window frames and guttering were a muted blue-green of copper hydroxy chlorides and there was only the merest hint of water run-off staining. These lessons are there for all to see as one walks along the beach and are a timely reminder that as the Australian government commits billions of dollars for the rebuilding of communities and infrastructure in the wake of the devastating floods and fires, the ACA has a vital advocacy role. All of us with contacts in the political arena need to make sure that the Federal, State and Local Governments are apprised of our vast wealth of experience that is available to ensure that the solutions to the present day problems do not become additional burdens for our children to bear in the coming years. I urge every member to give their full support to the ACA’s ongoing advocacy programme in this area. Indeed one of the vital components of the forthcoming 18th International Corrosion Congress in Perth will focus on the sustainability of our present day methods of fighting the battle against corrosion and premature collapse of infrastructure. It is time to make a firm decision and book ahead to achieve the best discounted air fares that you can find. The technical program promises to be brilliant with more than 460 abstracts received and reviewed and the organising committee is striving to ensure that all visitors to Western Australia will have a very positive and

enjoyable experience. The ACA as a team is totally committed to ensuring that you will get excellent value for your money and that the 18th ICC will be the best corrosion congress you have ever attended. One of the lasting benefits of attending an ACA conference is the re-exposure to products and services that have moved on while our minds and experiences might have been moving at a slightly slower pace. Physical isolation can also induce mental stagnation like waters trapped in a drying billabong. One of the benefits of being an observer in Adelaide was that I was able to discern a real change in the energy and commitment to excellence of the speakers and of all those who looked after the booths in the Trade Show areas. Taking in a balance of good food, stimulating conversation and amazing products developed to make our work of preventing and mitigating corrosion on the seas, in the skies and on the land are all part of the conference experience. A quick browse of the ACA website shows up a vast array of courses across the country so now there is no excuse left – enrol, participate and exchange ideas and we will then all have a much more sustainable future.

LOCATIONS: DARWIN WEDNESDAY 11Th MAY Engineers Australia, 14 Shepherd St, Darwin

MELBOURNE TUESDAY 17Th MAY Engineering House, 121 Bedford Street, North Melbourne

TASMANIA ThURSDAY 19Th MAY Zeps Café, 92–94 High Street, Campbell Town AUCKLAND TUESDAY 24Th MAY Hotel Grand Chancellor Auckland Airport, Ascot Roads, Airport Oaks, Auckland

WELLINGTON ThURSDAY 26Th MAY Abel Tasman Hotel 169 Willis Street, Wellington

ADELAIDE FRIDAY 3RD JUNE Mercure Grosvenor Hotel, 125 North Terrace, Adelaide

GLADSTONE TUESDAY 7Th JUNE CQUniversity, Bryan Jordan Drive, Gladstone

Yours in Corrosion

BRISBANE ThURSDAY 9Th JUNE

Ian MacLeod President

Brisbane Cricket Ground (GABBA), 411 Vulture Street, East Brisbane

PERTh ThURSDAY 16Th JUNE The Old Brewery, 173 Mounts Bay Road, Perth

WOLLONGONG TUESDAY 21ST JUNE Medina Executive, 19 Market Street, Wollongong

SYDNEY WEDNESDAY 22ND JUNE North Ryde RSL, Cnr Magdala & Pittwater Roads, North Ryde

SEMINAR SERIES: CORROSION MITIGATION AND MONITORING

The traditional and not so common techniques used to mitigate the onset and progress of corrosion are all based on the classic methods: change materials, change the environment, apply a coating or use electrochemical controls. The effectiveness of each method can be observed using a corrosion management plan and measured using a programme such as an inspection survey or more sophisticated corrosion monitoring. Corrosion monitoring can be defined as any method used to observe, measure and analyse the progress of corrosion. It involves myriad variables – materials, measurement techniques, instrumentation, budgets, standards, logistical support, data analysis, communication and, critically, information management. Real value is gained from corrosion monitoring initiatives when the information gathered over a period is translated into effective corrosion mitigation/control programmes. Each local seminar programme is available by visiting www.corrosion.com.au or by emailing aca@corrosion.com.au Register now at www.corrosion.com.au

Supported by:

Sponsored by:

NEWCASTLE ThURSDAY 23RD JUNE Engineers Australia, 122 Parry Street, Newcastle West

ACA has recently concluded an agreement with SSPC for the introduction to Australasia of a range of educational programs aimed specifically at the contracting sector. Depending upon the success of the introduction of these programs ACA will work with SSPC to expand on the initial offerings. Another recent development in the education arena is the possibility of a joint ACA and university accredited post graduate corrosion engineering program. Initially, the program will be aimed at the post graduate certificate level. Further integration into graduate diploma and masters levels is also under consideration. Important for the success of both operator level and post graduate programs will be the method of delivery. In the case of SSPC courses, ACA will be offering public and in-house courses, depending on the needs of the industry. The opportunity

for contractors to train their own staff in the delivery of the SSPC programs will also be available. With this option, ACA will moderate the assessment processes. The university level programs which are being proposed will be offered on a distance education platform with a block face-to-face component. This mode of delivery will allow all ACA members the maximum opportunity to participate as it isn’t location dependant. It may be possible to offer the face-to-face component in conjunction with ACA conferences thereby reducing travel costs. We are also examining how the existing conference model can be adapted to integrate the graduate program into the conference program. Substantial progress has also been made on the review of ACA’s advanced cathodic protection course. Once the review of this course is complete, the CP introduction and monitoring courses will be formally re-assessed.

The demand for in-house training programs is on the rise and ACA lecturers will shortly be travelling to New Guinea to offer programs. ACA is able to offer standard or modified packages in-house and Barry Hodder is available to assist members seeking these products. Finally, to better assist members to plan their ACA related educational requirements, the ACA education calendar for the first six months of 2012 will be released by early May 2011. In future, 6 month blocks will be added to the calendar at least 6 months in advance in order to allow members the maximum flexibility in planning. Ian Booth Chief Executive Officer ibooth@corrosion.com.au

Corrosion Engineering, Science and Technology Journal scope Corrosion Engineering, Science and Technology, an official journal of the European Federation of Corrosion, provides broad international coverage of research and practice in corrosion processes and corrosion control. Peer-reviewed contributions address all aspects of corrosion engineering and corrosion science; there is strong emphasis on effective design and materials selection to combat corrosion. CEST’s scope encompasses all metallic and non-metallic materials and composites.

Features n

INDEPENDENT CORROSION ENGINEERS NATA Accredited Inspections • Cathodic Protection Specialists • Investigation & Failure Analysis • Material Selection • Welding Inspections • Training • Protective Coating Specifications • Metallurgy & Materials Consulting • QA/QC Auditing • Asset Condition Surveys & Maintenance Management

Research papers — peer-reviewed contributions from research and practice Critical reviews — in-depth examination of topics of current interest Standard news and conference reviews Regular topical theme issues

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Vol 46 (2011), 7 issues per year Print ISSN: 1478-422X Online ISSN: 1743-2782

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UK Editor: Professor S B Lyon, Corrosion and Protection Centre, Manchester, UK US Editor: Dr S Lillard, Los Alamos National Laboratory, USA For further information, visit the journal homepage: www.maney.co.uk/journals/cst www.iom3.org

AUSTRALASIA • ASIA • UK • USA • AFRICA • MIDDLE EAST www.corrosion.com.au

Vol 36 No 2 April 2011

Features n

National Toll Free 1300 721 029

International + 61 8 8267 4744

Vol 46 (2011), 7 issues per year Print ISSN: 1478-422X Online ISSN: 1743-2782

MORE Materials Science & Engineering Collection This collection provides instant online access to twenty-eight highly-regarded, peer-reviewed, international materials science publications.

‘Global Corrosion Solutions’

Corrosion Engineering, Science and Technology

For a 30-day free trial to the MORE Materials Science & Engineering Collecion, visit: www.maney.co.uk/freetrial

Web www.incospec.com.au

www.maney.co.uk/journals/cst

AUSTRALASIA • ASIA • UK • USA • AFRICA • MIDDLE EAST www.corrosion.com.au

Vol 36 No 2 April 2011

18th International Corrosion Congress update Submission of abstracts for the 18th International Corrosion Congress closed 14th February 2011 with 468 abstracts submitted. Technical Chair Liam Holloway and a technical sub-committee then reviewed each abstract to accept as oral, poster or reject. Following the review and withdrawal of some abstracts, a list of 425 accepted abstracts are published in the preliminary programme and registration brochure. 307 abstracts accepted as oral presentations have been initially allocated within 19 streams. 118 abstracts were accepted for a poster session.

Plenary Lecturers: Tim Burstein, University of Cambridge, United Kingdom Alison Davenport, University of Birmingham, United Kingdom: Shedding Light on Corrosion David Scantlebury, The University of Manchester, United Kingdom: Underprotection of Mild Steel in Marine Conditions Hector Videla, University of La Plata, Argentina: The Role of Microorganisms on the Corrosion and Protection of Metals. A Critical Overview.

Abstracts were submitted from 55 countries with the five countries most represented being Australia, China, Japan, Korea and India.

Keynote Speakers: Maria Forsyth, Deakin University, Australia: Multifunctional Rare Earth Corrosion Inhibitors for Steel and Aluminium Alloys Mads Juhl, Hempel, Denmark: Advances in Corrosion Protection by Use of Coatings Ian MacLeod, Western Australian Museum, Australia: Consuming Corrosion â&#x20AC;&#x201C; A Journey into the World of Materials Conservation V.S. Raja, Indian Institute of Technology Bombay, India: High Temperature Corrosion Problems in Designing Graded Thermal Barrier Coatings

Each stream of abstracts can be downloaded from the congress website www.18iccperth2011.com

ACA to introduce SSPC application programs exam and a practical hands-on skill assessment.

a marine/industrial environment on steel or concrete.

Abrasive Blasting Program This program is designed for contractor personnel who wish to obtain certification or others who wish to learn about dry abrasive blast cleaning of steel. It covers principles of surface preparation, surface cleanliness, surface profile, dust and debris control, and abrasives.

Airless Spray Basics This program assesses the skills of sprayers who have a minimum of 800 hours applying protective coatings with airless spray in an industrial or marine environment. Candidates are certified through a brief certification written exam and a practical hands-on skill assessment. This course is designed to train and certify marine/industrial applicators to operate airless spray equipment.

Applicator Train-the-Trainer The course is designed to train owners, supervisors and other representatives of industrial painting contracting companies on the delivery of two levels of the SSPC Applicator Training Program for surface preparation and coating application. It will also provide you and your craft workers with a standardized curriculum for applicator training that you can present at your shop or job site at your own convenience.

Water Jetting Program This program assesses the skills of water-jetters who have a minimum of 120 hours water-jetting work experience and prior documented employer-provided training on the water-jetting equipment they use on the job. Candidates are certified through a brief written

Plural Component Basics This course is designed to train marine/industrial applicators in the application of protective coatings by airless spray using plural component spray equipment. The program focus is on the application of two component epoxy and polyurethane protective coatings in

ACA have commenced consultations with the contracting sector to ensure the programs are modified for local conditions. It is anticipated that the programs will be trialed on an in-house basis and then offered to the contracting sector either through public offerings or on an in-house basis.

ACA has been working with SSPC recently to introduce a range of applicator training and certification programs. Initially, ACA and SSPC will work together to establish the following 5 programs:

The congress organising committee can also confirm the following plenary lecturers and keynote speakers and paper titles:

INDUSTRIAL

COATINGS

Renewing NACE CIP certification

Coating Inspectors are assigned work experience points according to the tasks they perform and they

must have sufficient points or a combination of points and course attendance. Points are awarded per month of work experience in the following ways: Coating Inspection x 2 points per month

High performance coating systems qualified Inspectors can logon to their profile on the NACE website and complete their renewal application and make payment. If you have any further queries please contact Renata at the ACA on +61 (0)3 9890 4833.

Other Field Experience (other than inspections) x 1.5 points per month Non field experience x 1 point per month NACE have also introduced a new online renewal process where CIP

Corrosion & Materials

ADE IN

The ACA has received a number of enquiries recently related to how NACE qualified Coating Inspectors renew their CIP certification. The ACA has confirmed that to recertify an inspector must have sufficient work experience points or other professional development activity (including but not limited to the completion of a NACE CIP2) to recertify. However the Home Study Document mentioned on the NACE website is currently not required.

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Abstracts were submitted from 55 countries with the five countries most represented being Australia, China, Japan, Korea and India.

Each stream of abstracts can be downloaded from the congress website www.18iccperth2011.com

ACA to introduce SSPC application programs exam and a practical hands-on skill assessment.

a marine/industrial environment on steel or concrete.

ACA has been working with SSPC recently to introduce a range of applicator training and certification programs. Initially, ACA and SSPC will work together to establish the following 5 programs:

The congress organising committee can also confirm the following plenary lecturers and keynote speakers and paper titles:

INDUSTRIAL

COATINGS

Renewing NACE CIP certification

Coating Inspectors are assigned work experience points according to the tasks they perform and they

must have sufficient points or a combination of points and course attendance. Points are awarded per month of work experience in the following ways: Coating Inspection x 2 points per month

Other Field Experience (other than inspections) x 1.5 points per month Non field experience x 1 point per month NACE have also introduced a new online renewal process where CIP

Corrosion & Materials

ADE IN

Simple Solutions to Complex Problems

TRA

NEWS

Australian press slam Navy over rust buckets A review of press reports over recent months demonstrates that the Australian press is not averse to attacking slow moving targets which are not able to defend themselves.

recurring themes which appear to beset Australia’s navy. In early March this year the ABC News headlined “Calls for heads to roll over rustbucket Navy”.

In October 2010 the Herald Sun was trumpeting “the rust never sleeps on pride of navy fleet”. In November The Australian chimed in with “Rusting warships ….. will sail again after refit: navy”. February saw The West Australian outline a tale of woe faced by the responsible Minister charged with government oversight of the Defence Department. In that article, the words “rust” and “corrosion” are

ACA’s Corrosion Challenges studies (reported on elsewhere in this edition) clearly demonstrate that management practices play a significant role in adding to unnecessary costs of corrosion. It is unfortunate that the effects of corrosion on the preparedness of Australia’s naval fleet came to light due to the Navy’s inability to respond

to severe natural disasters such as Cyclone Yasi. ACA has been endeavouring to commence discussions with the Department of Defence on the recommendations which arise from the Corrosion Challenges studies. Hopefully, as the political heat drains away, cooler heads may prevail and senior Departmental representatives will accept the invitation from ACA to work with Navy and Defence to assist them to resolve their corrosion management problems.

Accreditation course for inspectors to undertake detailed bridge inspections for Main Roads WA In a first for Main Roads WA, their Structures Engineering branch held a two day course to provide training to appropriately qualified and experienced bridge engineers and engineering associates in order to become accredited to undertake Detailed Bridge Inspections, known as Level 2 inspections, on steel and concrete bridges throughout the State. Accreditation for Bridge Inspectors is recognised both internationally and nationally as an important part of bridge asset management. It helps provide consistency between different inspectors in how defects are assessed, and how condition states and priorities for the maintenance works are determined. In addition these courses will build a pool of accredited inspectors who will be able to assist Structures Engineering deliver this important part of the asset management process into the future. The numbers were restricted to a core fourteen people from engineering consultancies, Main Roads WA and other key stakeholders. The course combined the theory of concrete

10 Corrosion & Materials

and steel material properties and deterioration mechanisms with details of the on-site approach needed to successfully complete a detailed inspection in accordance with the in-house developed ‘Detailed Visual Bridge Inspection Guidelines for Concrete and Steel Bridges (Level 2 Inspections)’. A site visit was also arranged as part of the course, providing a great opportunity for the attendees to put that theory straight into practice. The course was established, organised and run by Structures Engineering staff. Specific lectures on the course including details of the characteristics of materials, deterioration mechanisms and repair methods were provided by Warren Green, an accredited Australasian Corrosion Association lecturer.

Erica Smith of Main Roads WA said “full accreditation by external participants, through attendance on this course and successful completion of a case study assignment, is now a requirement when leading on-site inspections and when responsible for the overall detailed inspection report for Main Roads WA”. “It was a fantastic opportunity for various bridge engineers and technicians throughout WA to share experiences and improve understanding in the diagnosis of existing structures and impacts of current condition on future asset management needs” said Erica. The course was well received and there is already much interest for a second course to be run later in the year.

Curtin University launch Graduate Certificate in Corrosion Engineering The first of its kind in the Southern Hemisphere, Curtin University launched its Graduate Certificate in Corrosion Engineering in the first semester of 2011. The Graduate Certificate in Corrosion Engineering is the first in a series of post-graduate courses Curtin University will offer to meet growing industry demand for qualified corrosion engineers and quality research in this field. The course is part of oil and gas companies Woodside and Chevron’s sponsorship of the Chevron-Woodside Chair in Corrosion Engineering.

Who will benefit from the program The course is designed to deliver specific corrosion engineering skills relevant to the energy and resources industries, and is suitable for qualified: Chemists Materials Engineers Process/Chemical Engineers Mechanical Engineers It can be applied in the following industries: Oil & Gas

The Graduate Certificate is offered online and is the equivalent of sixmonth’s full-time study. If you have an undergraduate degree in engineering or an applied science discipline, this course offers you a chance to fast track your career to practice the profession of Corrosion Engineering in a broad spectrum of industries. A unique opportunity for career development in the Energy and Resources Industry The online Graduate Certificate in Corrosion Engineering program is tailored to industry needs – specifically the energy and resource industries – and can be undertaken while working as there are no requirements to attend classes at the university.

Refining & Chemical Processing Mining & Mineral Processing Power Generation Defence How you will benefit from the program Through participation in this program you will gain expertise in the following: Understanding fundamental corrosion and prevention principles Diagnosing corrosion problems Developing corrosion management solutions

Concrete Repairs and Reconstruction

Upgrading your engineering skills by working on real-life corrosion cases and projects Entry Requirements Students must hold a recognised degree in engineering or science with equivalent of first year Chemistry. If you do not have an appropriate bachelor degree, you may be required to complete additional units which would extend the duration of the course. Duration and Availability This fee-paying course is one year part-time study. Each student will be advised of their individual study plan, which will be subject to the availability and sequencing of units within the program. Two intakes are offered each year in March and July. However, the July intake requires a minimum of three semesters to complete the course. For further information, please contact: Professor Rolf Gubner Chevron-Woodside Chair in Corrosion Engineering Science and Engineering Tel: +61 8 9266 7272 Fax: +61 8 9266 2300 Email: Corrosion@curtin.edu.au web: www.corrosion.curtin.edu.au

• hydro-demolition • shotcreting • formwork • crack injection • coatings and linings • carbon fibre wraps

• Cathodic protection • confined spaces • industrial rope access

NEWS

recurring themes which appear to beset Australia’s navy. In early March this year the ABC News headlined “Calls for heads to roll over rustbucket Navy”.

10 Corrosion & Materials

Concrete Repairs and Reconstruction

• hydro-demolition • shotcreting • formwork • crack injection • coatings and linings • carbon fibre wraps

• Cathodic protection • confined spaces • industrial rope access

NEWS

Coatings market to reach US$98.69 billion by 2015 A new market report â&#x20AC;&#x2DC;Coatings: A Global Strategic Business Reportâ&#x20AC;&#x2122; by research firm Global Industry Analysts (GIA) forecasts the worldwide coatings market to be valued at US$98.69 billion in 2015. The report outlines a number of reasons attributed to the expected growth, including an increase in industrialisation and a rise in the demand for construction and automotive sectors in developing countries. The mature markets of the US and Europe are also expected to increase in growth due to technological and product developments, unique formulations and a favourable regulatory environment. According to GIA, the coatings industry can be termed as mature in most regions of the world and its growth is dependant on a number of factors such as level of economic activity and state of the construction

industry (a major consumer of paints and coatings). Industrial growth in developing economies is also a major growth driver for the coatings industry. The availability of cheap labour and an abundance of resources have companies making a beeline for Asia-Pacific and Latin America and setting up production establishments in these regions. GIA report that the future developments in coatings are likely to focus on development of new coating systems as manufacturers are increasingly developing coating products that would differentiate them from their competitors, creating niche products to gain customer confidence. The global economic downturn affected the paint and coatings industry, particularly during the turbulent period of 2008 and 2009, according to the report. The developed and mature western markets of North America and Europe were the

worst hit recording high double-digit declines during the period. In the Asian markets, India, Vietnam and Indonesia among other countries weathered the recession and suffered only marginal losses. China recovered from the adverse affect of the downturn in 2009 when domestic demand for coatings rose, and coatings exports declined drastically, to post healthy growth rates. The report predicts the revival of the global economy post 20112012 to bring the sector gradually back on track. Asia-Pacific, led by advances from high growth markets including China, India, Indonesia and others stands tall as the largest regional market in growth. Europe and the US trail closely behind as other significant coatings markets worldwide. The Asian market is also forecast to surge ahead of other world regions at the overall fastest compounded annual growth rate of 4.2% through 2015.

Project performance of alternative stainless steels grades For many years, high quality, long service and durability have been associated with austenitic stainless steels such as 304 and 316 grades that account for more than 60% of the Australasian market. Popularity of these steels is due to combination of good fabrication properties, reasonable level of corrosion resistance and large experience with different applications. In addition to about 18% chromium, these steels also contain about 8% nickel that makes structure austenitic.

steel grades in the severe coastal environment in welded conditions. HERA in cooperation with New Zealand Stainless Steel Development Association (NZSSDA), local industries and international research partners has been conducting a corrosion study involving a number of corrosion tests on steel grades 304, 316, 430, J4, 404GP, 445M2 and LDX 2101 in welded conditions and different finishes.

First test results that include 24-month atmospheric exposure test were presented during the Metals Industry Conference in Wellington on 14 April 2011. Further results will be available at the 18th International Corrosion Congress - Perth 2011. For further details, please contact Dr Michail Karpenko, Manager NZWC at HERA, New Zealand. Email: welding@hera.org.nz Web: www.hera.org.nz

In recent years, as it has also been the case in the past, price of nickel has increased dramatically directly affecting cost of 304 and 316 grades. Historically, each peak in nickel prices has triggered research into low-nickel alternatives that ideally would be cheaper and not compromise with the qualities of the established austenitic grades. Typically, these alternatives are new ferritic, manganese bearing austenitic and duplex stainless steel grades. Until now, there has not been sufficient experience with using these

Test rack with stainless steel samples exposed at Muriwai Beach, Auckland

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Carboline has been global leader in the High Performance Coatings industry for over 63 yrs. Specify Carboline - Coatings that deliver: SPEED, COMPLIANCE, PERFORMANCE

1800-RentDH

(736 834)

www.rentdh.com

www.corrosion.com.au

Melbourne

ddawson@rentdh.com

Sydney

Adelaide

Perth

Brisbane

24 hours a day / 7 days a week on-call service Vol 36 No 2 April 2011

NEWS

Test rack with stainless steel samples exposed at Muriwai Beach, Auckland

Carboline has been global leader in the High Performance Coatings industry for over 63 yrs. Specify Carboline - Coatings that deliver: SPEED, COMPLIANCE, PERFORMANCE

1800-RentDH

(736 834)

www.rentdh.com

www.corrosion.com.au

Melbourne

ddawson@rentdh.com

Sydney

Adelaide

Perth

Brisbane

24 hours a day / 7 days a week on-call service Vol 36 No 2 April 2011

NEWS

ACA welcomes new members Corporate Members

Neil Brodie of Contract Resources

Transpower NZ (www.transpower.co.nz) Transpower is the State Owned Enterprise that plans, builds, maintains and operates New Zealand’s high voltage electricity transmission network – the National Grid – which links generators to distribution companies and major industrial users.

Emily Wai Lyn Chan of Woodside Energy

International Corrosion Services (www.internationalcs.com.au) International Corrosion Services (ICS) in based in Henderson WA and provides services in three core areas of post weld treatment of stainless steel , on-site operational stainless steel corrosion maintenance as well as stainless related pigging and flushing solutions. ICS mobilises staff and equipment for onsite work as well as offering a large industrial pickling and passivation bath conforming to ASTM A380-06 & ASTM A967-05e2. City West Water (www.citywestwater.com.au) As one of three Victorian Government-owned retail water businesses in metropolitan Melbourne, City West Water provides drinking water, sewerage, trade waste and recycled water services to residential and business customers in Melbourne’s central business district, inner and western suburbs. The company manages 3,909 kilometres of sewer pipes and over 4,000 kilometres of water mains – some of which date back to the 1850s.

Individual Members

Wellington Division February Meeting Aroonchai Rungvichaniwad of JBP International Paint Patrick Stevens of Mondelphous

Martin Donelan of ACOR Building Consultants

Peerapong Sueasuk of JBP International Paint

Colin Edgerton

Alastair Tawns of Wood Group

Matthew Edmonds of Edmonds Industrial

Donald Thomas of WA Corrosion Control

Stephen Holt of Shell Refining

John Tomlinson of Tomlinson Holdings

Corey Hope of Parchem Construction Supplies

Nicholas Van Styn

David Ireland of Bureau Veritas

Brian Walsh of FIB

Garry Luskan of Woodside Energy

Brenton Watts of Lloyd's Register Asia

Bobby Mathan of James Cook University David Morgan of Goodline Dale O'Toole of Savills Australia Keith Perry of Tenix

Student Members Amalia Yunita Halim of Curtin University

Michael Reynolds of Jeneilfen

V edapriya Pandarinathan of Curtin University

Quality range of blasting grades for your blast cleaning requirements.

Dinesh Bankar of Coating Inspection Services (India) Garry Bonadio of G & S Painting Services

14 Corrosion & Materials

Roz Julian of Quest Reliability spoke about aluminium conductors steelreinforced (ACSR) which carry the high voltage electricity around the country. These can be subject to almost all possible types of corrosion – most severe is internal attack on the aluminium by the environment, which in many areas of NZ is marine, and leads to pitting corrosion and enhanced crevice corrosion. There can be moss and deposits which lead to loss of surface passivity, which in turn leads to external surface attack. But bigger problems seem to come from galvanic corrosion between the aluminium and the steel core and occasionally from fretting as the aluminium strands rub against each other. Historically the core steel fibres are coated with zinc, which corrodes preferentially to both the steel and the aluminium, until it is gone, at which stage the aluminium corrodes preferentially to the steel. The steel core can have grease applied to it – but this grease application can be intermittent, so that there

are pockets of no-grease (with the consequent differential environment cell able to be established). The grease can also degrade with rising temperature and can react with the aluminium corrosion products to lose its flexibility and also create differential environment problems. The issues are understood well enough that the failure points can be predicted for example when bulges are observed since the corrosion products have three times the volume of the initial aluminium. Such bulges can be visible from the ground in inspections, and remanent life predictions can be made from such inspections or from on-line measurements of zinc integrity (loss of zinc signalling rapid corrosion of aluminium), bulging or aluminium area loss. Jonathan Morris of OPUS spoke about corrosion in an aluminium culvert lining under a major road. Pitting was observed during an inspection in 2006 of the culvert (built in 1987), and at further inspections in 2008 and 2010 it was seen to have become more noticeable. There needed to be an extensive investigation in situ to solve why the problems of perforating

corrosion seemed to be only in the upper half of the lining. Eventually the cause was tracked to the claylike fill that had been used to backfill the construction (even though the standard specification at the time of construction in 1987 had been to use a graded free-draining backfill – but the local authority specification for this job had not reproduced this requirement). This had resulted in significant attack starting on the soil side of the aluminium. A rehabilitation methodology has been devised, which will allow the work to be done without closing the road.

Roz Julian of Quest Reliability

Jonathan Morris of OPUS

Auckland Division February Meeting

GMA NewSteelTM New steel, surface with light rust & thin coatings

GMA SpeedBlastTM General purpose abrasive

GMA PremiumBlastTM Maintenance grade for tough jobs

Jayne Arthur of APA Group Peter Beckford of Apache Energy

The Wellington Division February Meeting involved two presentations on aspects of aluminium corrosion – one in the air and one in contact with the ground.

For more information, contact us at 08 9287 3250 or email sales@garnetsales.com GMA Garnet Group Level 18, Exchange Plaza, The Esplanade, Perth, WA 6000

www.garnetsales.com

The first meeting of 2011 for ACA Auckland Division was held at The Landing hotel on 23rd February. The speaker was Aaron Davey, Director of Marine & Civil Solutions Ltd who addressed the topic “Corrosion in Marine Environments – A Perspective from Above and Below the Waterline”. The talk commenced with an overview of the issues involved in assessing a marine asset for corrosion damage in the marine environment. The main factors to consider were seawater variations, risk assessment, accessibility for diving inspections, tides and the weather. Aaron then www.corrosion.com.au

described the types of corrosion that are often encountered on marine structures (usually steel) requiring repairs including galvanic, pitting corrosion and microbial corrosion (MIC) such as accelerated low water corrosion (ALWC). Aaron then described and illustrated the remediation of corroding marine assets such as ship hulls, a pontoon, an oil transfer platform, ship sea chests, ALWC on sheet piling, and steel piles under wharves. The remediation method often involved application of petrolatum tape

wrappings after the marine structure has been appropriately cleaned. Paint coatings and application of anodes (CP) were another remedial option. The remediation procedure employed depended upon the expected longevity and the maintenance requirements of the asset owner. Aaron’s presentation was followed by an extensive Q&A session in which many interesting aspects of marine corrosion were discussed with the audience present.

Vol 36 No 2 April 2011

NEWS

ACA welcomes new members Corporate Members

Neil Brodie of Contract Resources

Emily Wai Lyn Chan of Woodside Energy

Individual Members

Wellington Division February Meeting Aroonchai Rungvichaniwad of JBP International Paint Patrick Stevens of Mondelphous

Martin Donelan of ACOR Building Consultants

Peerapong Sueasuk of JBP International Paint

Colin Edgerton

Alastair Tawns of Wood Group

Matthew Edmonds of Edmonds Industrial

Donald Thomas of WA Corrosion Control

Stephen Holt of Shell Refining

John Tomlinson of Tomlinson Holdings

Corey Hope of Parchem Construction Supplies

Nicholas Van Styn

David Ireland of Bureau Veritas

Brian Walsh of FIB

Garry Luskan of Woodside Energy

Brenton Watts of Lloyd's Register Asia

Bobby Mathan of James Cook University David Morgan of Goodline Dale O'Toole of Savills Australia Keith Perry of Tenix

Student Members Amalia Yunita Halim of Curtin University

Michael Reynolds of Jeneilfen

V edapriya Pandarinathan of Curtin University

Quality range of blasting grades for your blast cleaning requirements.

Dinesh Bankar of Coating Inspection Services (India) Garry Bonadio of G & S Painting Services

14 Corrosion & Materials

Roz Julian of Quest Reliability

Jonathan Morris of OPUS

Auckland Division February Meeting

GMA NewSteelTM New steel, surface with light rust & thin coatings

GMA SpeedBlastTM General purpose abrasive

GMA PremiumBlastTM Maintenance grade for tough jobs

Jayne Arthur of APA Group Peter Beckford of Apache Energy

The Wellington Division February Meeting involved two presentations on aspects of aluminium corrosion – one in the air and one in contact with the ground.

For more information, contact us at 08 9287 3250 or email sales@garnetsales.com GMA Garnet Group Level 18, Exchange Plaza, The Esplanade, Perth, WA 6000

www.garnetsales.com

Vol 36 No 2 April 2011

ACA TGs, with this edition's group focus being the “Coatings” TG.

ACA Standards Officer Arthur Austin has prepared a schedule of the latest standards developments. The standards reporting for 2011 is scheduled against Technical Groups (TG) as indicated below: Issue 2011

Standards search for TG interests

Feb

Concrete Structures & Buildings

April

Coatings

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 2 January to 23 March 2011, using the key words and key word groups:

June

Refining & Processing

‘durability’.

August

Cathodic Protection

October

Mining Industry

‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’.

December Water & Waste Water and Welding, Joining & Corrosion

'paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’.

Issue one was the Concrete Structures and Buildings TG; this issue is for the Coatings TG.

'galvanize' or ‘galvanized’ or galvanizing’.

As in the past, this report is in two stages, namely:

'electrochemical' or ‘electrolysis’ or ‘electroplated’.

1. A global standards and publication focus, searching through SAIGLOBAL Publications at https:// infostore.saiglobal.com/store, for all current publications and standards relating to one of the

‘cathode’ or 'cathodic'. ‘anode’ or ‘anodic’. 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’.

Summary 1. Through SAIGLOBAL Publications at https://infostore.saiglobal.com/ store there were 620 Publications found from 35 Publishers as listed in Table 1 below against a search for “coatings and corrosion” with 18 AS AS/NZS publications listed. The publications listed by Subject are in Table 2 below. 2. Across SAIGLOBAL online Standards Publications there was a total of 47 listings of new standards, Drafts and Amendments, found issued from to 2 January to 23 March 2011. There was one AS draft (DR AS/NZS 3566.2 Selfdrilling screws for the building and construction industries - Part 2: Corrosion resistance requirements and requirements for non-conductive seals) and one AS Amendment (AS 2841-2005/Amdt 1-2011 Galvanized steel wire strand. 3. There was one standard relating to the re-alkalization of concrete (DD CEN/TS 14038-2:2011 electrochemical re-alkalization and chloride extraction treatments for reinforced concrete. Chloride extraction) that may be of interest. See the attached tables for details.

Report on SAIGLOBAL Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “coatings and corrosion” for the “Coatings” Technical Group A total of 620 Publications found from 35 Publishers as listed in Table 1 below. Table 1 List of Publishers and number of publications for each American Architectural Manufacturers Association (1)

American Society for Testing and Materials (8)

American Welding Society (1)

Asociacion Espanola de Normalizacion (25)

Association Francaise de Normalisation (32)

Belgian Standards (22)

Brazilian Standards (7)

British Standards Institution (37)

Bureau of Indian Standard (4)

Comité Européen de Normalisation (27)

Det Norsk Veritas (1)

Ford Motor Company (73)

German Institute for Standardisation (Deutsches Institut für Normung) (40)

Germanischer Lloyd (1)

International Organization for Standardization (16)

Interstandard (Russia) (38)

Italian Standards (29)

Japanese Standards Association (7)

16 Corrosion & Materials

NACE International (5)

National Standards Authority of Ireland (27)

Nederlands Normalisatie Instituut (26)

Norwegian Standards (Norges Standardiseringsforbund) (29)

Osterreichisches Normungsinstitut (31)

Polish Committee for Standardization (34)

Society of Automotive Engineers (3)

South African Bureau of Standards (4)

Standardiserings-Kommissionen I Sverige (31)

Standardization Administration of China (5)

Standards Australia (18)

Swiss Standards (29)

SSPC – The Society for Protective Coatings (1)

Union Internationale des Chemins de Fer (1)

US Military Specs/Standards/Handbooks (4)

Verlag Stahleisen GmbH (1)

Wirtschafts und Verlagsgesellschaft Gas und Wasser (2) Publications by Subject are listed in Table 2 below: Table 2 List of publications by subject Manufacturing engineering (339) - Surface treatment and coating (339) - Industrial automation systems (1)

Paint and colour industries (86) - Paints and varnishes (50) - Paint coating processes (37)

Construction materials and building (73) - Structures of buildings (58) - Construction materials (12) - Installations in buildings (2) - Elements of buildings (1) - Protection of and in buildings (1)

Metallurgy (29) - Corrosion of metals (28) - Iron and steel products (1)

Fluid systems and components for general use (19) - Pipeline components and pipelines (19)

Generalities. Terminology. Standardization. Documentation (18) - Vocabularies (18)

Aircraft and space vehicle engineering (14) - Fasteners for aerospace construction (12) - Coatings and related processes used in aerospace industry (2)

Precision mechanics. Jewellery (8) - Jewellery (8)

Testing (4) - Environmental testing (3) - Mechanical testing (1)

Chemical technology (2) - Analytical chemistry (2)

Mechanical systems and components for general use (2) - Fasteners (2)

Electronics (1) - Electronic components in general (1)

Environment. Health protection. Safety (1) - Environmental protection (1)

Road vehicles engineering (1) - Road vehicle systems (1)

To access these publications, go to https://infostore.saiglobal.com/store and type ‘coatings and corrosion’ into the search box and examine the search results. STANDARDS FOR AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI AND STANDARDS AND AMENDMENTS FOR ISO & IEC PUBLISHED from 2 January to 23 March 2011 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 2 January to 23 March 2011 Key word search on ‘durability’.- 1 BS EN citations found relating to solid biofuel durability BS EN 15210-2:2010

Solid biofuels. Determination of mechanical durability of pellets and briquettes. Briquettes

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 18 citations in all – 1 AS/NZS Draft citations; DR AS/NZS 3566.2

Self-drilling screws for the building and construction industries - Part 2: Corrosion resistance requirements and requirements for non-conductive seals

ISO 5952:2011

Continuously hot-rolled steel sheet of structural quality with improved atmospheric corrosion resistance

www.corrosion.com.au

Vol 36 No 2 April 2011

ACA TGs, with this edition's group focus being the “Coatings” TG.

Standards search for TG interests

Feb

Concrete Structures & Buildings

April

Coatings

June

Refining & Processing

‘durability’.

August

Cathodic Protection

October

Mining Industry

‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’.

December Water & Waste Water and Welding, Joining & Corrosion

'paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’.

Issue one was the Concrete Structures and Buildings TG; this issue is for the Coatings TG.

'galvanize' or ‘galvanized’ or galvanizing’.

As in the past, this report is in two stages, namely:

'electrochemical' or ‘electrolysis’ or ‘electroplated’.

1. A global standards and publication focus, searching through SAIGLOBAL Publications at https:// infostore.saiglobal.com/store, for all current publications and standards relating to one of the

‘cathode’ or 'cathodic'. ‘anode’ or ‘anodic’. 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’.

American Society for Testing and Materials (8)

American Welding Society (1)

Asociacion Espanola de Normalizacion (25)

Association Francaise de Normalisation (32)

Belgian Standards (22)

Brazilian Standards (7)

British Standards Institution (37)

Bureau of Indian Standard (4)

Comité Européen de Normalisation (27)

Det Norsk Veritas (1)

Ford Motor Company (73)

German Institute for Standardisation (Deutsches Institut für Normung) (40)

Germanischer Lloyd (1)

International Organization for Standardization (16)

Interstandard (Russia) (38)

Italian Standards (29)

Japanese Standards Association (7)

16 Corrosion & Materials

NACE International (5)

National Standards Authority of Ireland (27)

Nederlands Normalisatie Instituut (26)

Norwegian Standards (Norges Standardiseringsforbund) (29)

Osterreichisches Normungsinstitut (31)

Polish Committee for Standardization (34)

Society of Automotive Engineers (3)

South African Bureau of Standards (4)

Standardiserings-Kommissionen I Sverige (31)

Standardization Administration of China (5)

Standards Australia (18)

Swiss Standards (29)

SSPC – The Society for Protective Coatings (1)

Union Internationale des Chemins de Fer (1)

US Military Specs/Standards/Handbooks (4)

Verlag Stahleisen GmbH (1)

Paint and colour industries (86) - Paints and varnishes (50) - Paint coating processes (37)

Construction materials and building (73) - Structures of buildings (58) - Construction materials (12) - Installations in buildings (2) - Elements of buildings (1) - Protection of and in buildings (1)

Metallurgy (29) - Corrosion of metals (28) - Iron and steel products (1)

Fluid systems and components for general use (19) - Pipeline components and pipelines (19)

Generalities. Terminology. Standardization. Documentation (18) - Vocabularies (18)

Aircraft and space vehicle engineering (14) - Fasteners for aerospace construction (12) - Coatings and related processes used in aerospace industry (2)

Precision mechanics. Jewellery (8) - Jewellery (8)

Testing (4) - Environmental testing (3) - Mechanical testing (1)

Chemical technology (2) - Analytical chemistry (2)

Mechanical systems and components for general use (2) - Fasteners (2)

Electronics (1) - Electronic components in general (1)

Environment. Health protection. Safety (1) - Environmental protection (1)

Road vehicles engineering (1) - Road vehicle systems (1)

Solid biofuels. Determination of mechanical durability of pellets and briquettes. Briquettes

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 18 citations in all – 1 AS/NZS Draft citations; DR AS/NZS 3566.2

Self-drilling screws for the building and construction industries - Part 2: Corrosion resistance requirements and requirements for non-conductive seals

ISO 5952:2011

Continuously hot-rolled steel sheet of structural quality with improved atmospheric corrosion resistance

www.corrosion.com.au

Vol 36 No 2 April 2011

Standards Update

ISO 8994:2011

Anodizing of aluminium and its alloys - Rating system for the evaluation of pitting corrosion - Grid method

I.S. EN ISO 2811-2:2011 Paints and Varnishes - Determination of Density - Part 2: Immersed Body (plummet) Method

ISO/DIS 11997-2

Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 2: Wet (salt fog)/dry/humidity/UV light

I.S. EN ISO 2811-4:2011 Paints and Varnishes - Determination of Density - Part 4: Pressure cup Method

ISO/DIS 14802

Corrosion of metals and alloys - Guidelines for applying statistics to analysis of corrosion data

11/30217717 DC BS EN ISO 15091

Paints and varnishes. Determination of the electrical conductivity and the specific electrical resistivity

ISO/DIS 17752

Corrosion of metals and alloys - Procedures to determine and estimate runoff rates of metals from materials as a result of atmospheric corrosion

11/30233262 DC

BS EN 1871. Road marking materials. Paint, thermoplastic and cold plastic materials. Specifications

I.S. EN ISO 4404-2:2010 Petroleum and Related Products - Determination of the Corrosion Resistance of Fire-resistant Hydraulic Fluids - Part 2: Non-aqueous Fluids

BS EN ISO 1519:2011

Paints and varnishes. Bend test (cylindrical mandrel)

11/30204373 DC BS ISO 17752

Corrosion of metals and alloys. Procedures to determine and estimate runoff rates of metals from materials as a result of atmospheric corrosion

ISO 26945:2011

Metallic and other inorganic coatings - Electrodeposited coatings of tin-cobalt alloy

I.S. EN ISO 12690:2010

Metallic and Other Inorganic Coatings - Thermal Spray Coordination - Tasks and Responsibilities

11/30215346 DC BS ISO 14802

Corrosion of metals and alloys. Guidelines for applying statistics to analysis of corrosion data

I.S. EN ISO 14921:2010

Thermal Spraying - Procedures for the Application of Thermally Sprayed Coatings for Engineering Components

11/30241787 DC BS EN 62321-7-1

Determination of certain substances in electrotechnical products. Part 7-1. Determination of the presence of hexavalent chromium (Cr(VI)) in colourless and coloured corrosion-protected coatings on metals by the colourimetric method

I.S. EN ISO 26945:2011

Metallic and Other Inorganic Coatings - Electrodeposited Coatings of Tin-cobalt Alloy

I.S. EN ISO 3613:2010

Metallic and Other Inorganic Coatings - Chromate Conversion Coatings on Zinc, Cadmium, Aluminium-zinc Alloys and Zinc-aluminium Alloys - Test Methods

BS EN 2596:2006

Aerospace series. Washers, lock, with radial serrations in corrosion resisting steel, cadmium plated for flight control rods. Dimensions

11/30237910 DC BS EN 927-3

Paints and varnishes. Coating materials and coating systems for exterior wood. Part 3. Natural weathering test

BS EN ISO 4404-2:2010

Petroleum and related products. Determination of the corrosion resistance of fire-resistant hydraulic fluids. Non-aqueous fluids

11/30241787 DC BS EN 62321-7-1

BS ISO 5952:2011

Continuously hot-rolled steel sheet of structural quality with improved atmospheric corrosion resistance

BS EN ISO 12690:2010

Metallic and other inorganic coatings. Thermal spray coordination. Tasks and responsibilities

JIS G 0596:2010

Method of corrosion test for stainless steel tube fittings

BS EN ISO 14921:2010

DIN EN 4538-003 (2011-02)

Aerospace series - Bearings, spherical plain, in corrosion resisting steel with self-lubricating liner elevated load under low oscillations - Narrow series - Dimensions and loads - Part 003: Inch series with low friction coefficient; German and English version EN 4538-003:2010

Thermal spraying. Procedures for the application of thermally sprayed coatings for engineering components

BS EN ISO 26945:2011

Metallic and other inorganic coatings. Electrodeposited coatings of tin-cobalt alloy

BS EN ISO 3613:2010

DIN 65307 (2011-03)

Aerospace series - Inserts for composite materials, with MJ thread, closed type, light weight, screw-locking, corrosion-resisting steel; Text in German and English

Metallic and other inorganic coatings. Chromate conversion coatings on zinc, cadmium, aluminium-zinc alloys and zinc-aluminium alloys. Test methods

BS ISO 9717:2010

Metallic and other inorganic coatings. Phosphate conversion coating of metals

DIN 65308 (2011-03)

Aerospace - Inserts for composite materials, with MJ thread, open type, screw-locking, corrosionresisting steel; Text in German and English

DIN EN 4539-003 (2011-02)

Aerospace series - Bearings, spherical plain, in corrosion resisting steel with self-lubricating liner elevated load under low oscillations - Wide series - Dimensions and loads - Part 003: Inch series with low friction coefficient; German and English version EN 4539-003:2010

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 27 Publications found; 3 Drafts; no publications from AS/NZS; ISO 1519:2011

Paints and varnishes - Bend test (cylindrical mandrel)

ISO 2811-1:2011

Paints and varnishes - Determination of density - Part 1: Pyknometer method

ISO 2811-2:2011

Paints and varnishes - Determination of density - Part 2: Immersed body (plummet) method

ISO 2811-3:2011

Paints and varnishes - Determination of density - Part 3: Oscillation method

ISO 2811-4:2011

Paints and varnishes - Determination of density - Part 4: Pressure cup method

ISO/DIS 11997-2

Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 2: Wet (salt fog)/dry/humidity/UV light

ISO/DIS 15091

Paints and varnishes - Determination of the electrical conductivity and the specific electrical resistivity

I.S. EN ISO 1519:2011

Paints and Varnishes - Bend Test (cylindrical Mandrel)

I.S. EN ISO 2811-3:2011 Paints and Varnishes - Determination of Density - Part 3: Oscillation Method

Key word search on 'galvanize' or ‘galvanized’ or 'galvanizing’ –1 AS Amendment Standard Publications found; AS 2841-2005/Amdt 1-2011

Galvanized steel wire strand

Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ - 0 Standard Publications found. Key word search on ‘cathode’ or 'cathodic' - 0 corrosion related Standard Publications found Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 3 Standard Publications found – None from AS/ANZS ISO 2106:2011

Anodizing of aluminium and its alloys - Determination of mass per unit area (surface density) of anodic oxidation coatings - Gravimetric method

ISO 8251:2011

Anodizing of aluminium and its alloys - Measurement of abrasion resistance of anodic oxidation coatings

ISO 8994:2011

Anodizing of aluminium and its alloys - Rating system for the evaluation of pitting corrosion - Grid method

Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ DD CEN/TS 140382:2011

Electrochemical re-alkalization and chloride extraction treatments for reinforced concrete. Chloride extraction

Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found

I.S. EN ISO 2811-1:2011 Paints and Varnishes - Determination of Density - Part 1: Pyknometer Method

18 Corrosion & Materials

www.corrosion.com.au

Vol 36 No 2 April 2011

Standards Update

ISO 8994:2011

Anodizing of aluminium and its alloys - Rating system for the evaluation of pitting corrosion - Grid method

I.S. EN ISO 2811-2:2011 Paints and Varnishes - Determination of Density - Part 2: Immersed Body (plummet) Method

ISO/DIS 11997-2

Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 2: Wet (salt fog)/dry/humidity/UV light

I.S. EN ISO 2811-4:2011 Paints and Varnishes - Determination of Density - Part 4: Pressure cup Method

ISO/DIS 14802

Corrosion of metals and alloys - Guidelines for applying statistics to analysis of corrosion data

11/30217717 DC BS EN ISO 15091

Paints and varnishes. Determination of the electrical conductivity and the specific electrical resistivity

ISO/DIS 17752

Corrosion of metals and alloys - Procedures to determine and estimate runoff rates of metals from materials as a result of atmospheric corrosion

11/30233262 DC

BS EN 1871. Road marking materials. Paint, thermoplastic and cold plastic materials. Specifications

I.S. EN ISO 4404-2:2010 Petroleum and Related Products - Determination of the Corrosion Resistance of Fire-resistant Hydraulic Fluids - Part 2: Non-aqueous Fluids

BS EN ISO 1519:2011

Paints and varnishes. Bend test (cylindrical mandrel)

11/30204373 DC BS ISO 17752

Corrosion of metals and alloys. Procedures to determine and estimate runoff rates of metals from materials as a result of atmospheric corrosion

ISO 26945:2011

Metallic and other inorganic coatings - Electrodeposited coatings of tin-cobalt alloy

I.S. EN ISO 12690:2010

Metallic and Other Inorganic Coatings - Thermal Spray Coordination - Tasks and Responsibilities

11/30215346 DC BS ISO 14802

Corrosion of metals and alloys. Guidelines for applying statistics to analysis of corrosion data

I.S. EN ISO 14921:2010

Thermal Spraying - Procedures for the Application of Thermally Sprayed Coatings for Engineering Components

11/30241787 DC BS EN 62321-7-1

I.S. EN ISO 26945:2011

Metallic and Other Inorganic Coatings - Electrodeposited Coatings of Tin-cobalt Alloy

I.S. EN ISO 3613:2010

Metallic and Other Inorganic Coatings - Chromate Conversion Coatings on Zinc, Cadmium, Aluminium-zinc Alloys and Zinc-aluminium Alloys - Test Methods

BS EN 2596:2006

Aerospace series. Washers, lock, with radial serrations in corrosion resisting steel, cadmium plated for flight control rods. Dimensions

11/30237910 DC BS EN 927-3

Paints and varnishes. Coating materials and coating systems for exterior wood. Part 3. Natural weathering test

BS EN ISO 4404-2:2010

Petroleum and related products. Determination of the corrosion resistance of fire-resistant hydraulic fluids. Non-aqueous fluids

11/30241787 DC BS EN 62321-7-1

BS ISO 5952:2011

Continuously hot-rolled steel sheet of structural quality with improved atmospheric corrosion resistance

BS EN ISO 12690:2010

Metallic and other inorganic coatings. Thermal spray coordination. Tasks and responsibilities

JIS G 0596:2010

Method of corrosion test for stainless steel tube fittings

BS EN ISO 14921:2010

DIN EN 4538-003 (2011-02)

Thermal spraying. Procedures for the application of thermally sprayed coatings for engineering components

BS EN ISO 26945:2011

Metallic and other inorganic coatings. Electrodeposited coatings of tin-cobalt alloy

BS EN ISO 3613:2010

DIN 65307 (2011-03)

Aerospace series - Inserts for composite materials, with MJ thread, closed type, light weight, screw-locking, corrosion-resisting steel; Text in German and English

Metallic and other inorganic coatings. Chromate conversion coatings on zinc, cadmium, aluminium-zinc alloys and zinc-aluminium alloys. Test methods

BS ISO 9717:2010

Metallic and other inorganic coatings. Phosphate conversion coating of metals

DIN 65308 (2011-03)

Aerospace - Inserts for composite materials, with MJ thread, open type, screw-locking, corrosionresisting steel; Text in German and English

DIN EN 4539-003 (2011-02)

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 27 Publications found; 3 Drafts; no publications from AS/NZS; ISO 1519:2011

Paints and varnishes - Bend test (cylindrical mandrel)

ISO 2811-1:2011

Paints and varnishes - Determination of density - Part 1: Pyknometer method

ISO 2811-2:2011

Paints and varnishes - Determination of density - Part 2: Immersed body (plummet) method

ISO 2811-3:2011

Paints and varnishes - Determination of density - Part 3: Oscillation method

ISO 2811-4:2011

Paints and varnishes - Determination of density - Part 4: Pressure cup method

ISO/DIS 11997-2

Paints and varnishes - Determination of resistance to cyclic corrosion conditions - Part 2: Wet (salt fog)/dry/humidity/UV light

ISO/DIS 15091

Paints and varnishes - Determination of the electrical conductivity and the specific electrical resistivity

I.S. EN ISO 1519:2011

Paints and Varnishes - Bend Test (cylindrical Mandrel)

I.S. EN ISO 2811-3:2011 Paints and Varnishes - Determination of Density - Part 3: Oscillation Method

Key word search on 'galvanize' or ‘galvanized’ or 'galvanizing’ –1 AS Amendment Standard Publications found; AS 2841-2005/Amdt 1-2011

Galvanized steel wire strand

Anodizing of aluminium and its alloys - Determination of mass per unit area (surface density) of anodic oxidation coatings - Gravimetric method

ISO 8251:2011

Anodizing of aluminium and its alloys - Measurement of abrasion resistance of anodic oxidation coatings

ISO 8994:2011

Anodizing of aluminium and its alloys - Rating system for the evaluation of pitting corrosion - Grid method

Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ DD CEN/TS 140382:2011

Electrochemical re-alkalization and chloride extraction treatments for reinforced concrete. Chloride extraction

Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found

I.S. EN ISO 2811-1:2011 Paints and Varnishes - Determination of Density - Part 1: Pyknometer Method

18 Corrosion & Materials

www.corrosion.com.au

Vol 36 No 2 April 2011

ACA Report ACA corrosion challenges project A report on the impact of failure of infrastructure assets through corrosion as a result of current practices and skilling in the Australian mainland urban water and Naval defence sectors. Introduction Numerous studies have been undertaken across the globe to determine the economic impact of corrosion and it’s degradation of infrastructure and assets. Through these studies, an evaluation of the cost of corrosion to a first world economy has been estimated as 3% to 5% of GDP. In Australasian terms, this represents an annual cost to the Australian economy of between $36B and $60B per year. For the New Zealand economy, the estimate lies between $5.5B and $9.2B annually. What is not clear is the size and impact of the role management and inappropriate technology applications contribute to corrosion costs, and what opportunities are available to reduce such costs. Objective The objective of this Project was to examine, identify and estimate corrosion failure costs attributable to industry practices, industry skilling and regulatory frameworks, and estimate potential corrosion failure cost reductions by implementing avoidable/preventable strategies. The Naval defence and mainland Australia domestic water industries were chosen as test cases, based on the availability of industry professionals and access to data. It is expected that a key outcome will be to expand and improve the ACA’s training programme and general education activities. By achieving these objectives, the ACA is fulfilling its mandate and serving the interests of its Membership though this leadership initiative on corrosion in Australasia. Briefing Paper The following briefing paper was drawn from the combined report on the Australian mainland urban water and Naval defence sectors. The full report may be accessed at www.corrosion.com.au There is a pressing need to address the present and growing cost of corrosion and improve the economic sustainability of Australia’s infrastructure Corrosion prevention is a fundamental component of economic sustainability for Australia’s infrastructure assets and economy. Corrosion creates a significant economic drag that limits growth and profitability. The cost of corrosion increases as Australia develops and the population grows.

20 Corrosion & Materials

Internationally it is well recognised that corrosion costs, on average, between three and five per cent of GDP annually. The ABS 4613.0 reported that during 2008-09 Australia’s total chain volume GDP was AUS$1.194 trillion. A rough extrapolation of the three to five percent rule would put the cost of corrosion for Australia’s economy at between AUS$35 billion and AUS$60 billion during 2008-09. Improved corrosion prevention can deliver substantial gains in productivity and cost savings to industry, government and the community.

Where extensive internal corrosion of water mains occurs, taste and aesthetic qualities are compromised (known as red water) which invariably leads to water quality complaints.

USNiii case studies of three vessel groups showed that deferring corrosion maintenance and repairs for only four years resulted in an exponential increase in costs – from US$4.8 million to US$36.5 million. In the Royal Australian Navy (RAN) RAN case studies examined both aged amphibious vessels and relatively new, Military Off The Shelf (MOTS), Surface Force vessels.

As examples, the following summarises the findings of investigations into the causes, cost and opportunities to address corrosion in Australia’s wateri and defenceii sectors.

The findings of the RAN case studies suggest that a cost benefit ratio of between 7:1 and 10:1 is achievable through corrosion preventative maintenance for aged vessels constructed to Merchant rules with a high damage tolerance.

The financial burden of corrosion is significant In the urban Water Utility sector

For MOTS, vessels built to naval rules with less damage tolerance the cost benefit ration would reasonably exceed 10:1.

The annual cost of corrosion to the 52 urban Water Utilities servicing approximately 75% of Australia’s population is estimated at $982M ± 30%:

The current focus on maintenance in place of corrosion prevention in the RAN results in:

Aggregated corrosion costs to the Australian urban Water Industry

Annual cost $m

significantly higher repair and replacement costs,

Water loss from pipeline leakage (at $1.53 per kL)

120.0

unnecessarily higher maintenance expenditure, and

Water loss from pipeline failures (at $1.53 per kL)

4.3

delays to identifying corrosion prevention works.

91.2

Water pipeline corrosion repairs

118.7

Sewer pipeline corrosion repairs

39.0

Sewage treatment costs due to infiltration

38.0

Capital cost for water and sewer pipeline replacements

298.7

Maintenance & repair water treatment plants

52.0

Maintenance and repair of other assets (tanks, pump stations etc)

42.4

Maintenance & repair sewage treatment plants

176.8

Total cost

981.1

The average repair cost for reticulation water mains of up to 300mm nominal diameter (DN) is around $4550.

In the United States Navy (USN)

The benefits of early intervention are significant and can be achieved through improved design and maintenance, education and training.

Intangible costs associated with water and sewer pipe failures and replacements

The percentage of breaks attributed to corrosion is approximately 79%.

The RAN case studies showed that effective and timely corrosion prevention would significantly reduce avoidable labour costs, comprising up to 89% of repair costs.

The most significant repairs to larger mains greater than DN300 can cost up to $1.0 million. The consequences of failure in Australia’s 260 water treatment plants are generally not as serious as pipeline failure but can be significant and require ongoing repair and maintenance. Hydrogen sulphide by-products, often in conjunction with marine atmospheric environments, cause a high number of corrosion issues in the 442 wastewater treatment plants that treat raw sewage. Concrete sewer pipes are also susceptible to internal corrosion from hydrogen sulphide. A significant percentage of maintenance and repair in the large number of water storage tanks, reservoirs and associated pump stations can be attributed to corrosion. In the RAN The case studies found that the cost of routine on board maintenance (ship’s husbandry) to remove accumulated debris, or setup and conduct preservation and repair is significantly cheaper than steelwork renewal. Case studies found that by implementing expenditure of $0.19M to $0.27M in corrosion prevention maintenance, around $1.9 million in additional expenditure could have been avoided. In one case study, in addition to lost expenditure of installing and removing earlier repairs, avoidable final repair costs were $377,000 or 650% higher than the original repair budget of $58,000.

The incidence and cost of repairs, and maintenance attributable to corrosion is unacceptably high

Current asset management practices leave significant opportunity for improvement

In the urban Water Utility sector

In the urban Water Utility sector, maintenance and management of water supply and sewerage pipeline networks involves:

During 2008-09, one minor or major pressure pipe break or failure occurred every 20 minutes. For the 139,000km of existing mains pipeline, approximately 26,700 minor and major breaks or failures occurred during 2008/2009. For every 100km of pressured water and sewer pipes, an average of 19 failures occurs each year. www.corrosion.com.au

Retrofitting of Cathodic Protection (CP) systems to pipelines where economical – usually involving continuously welded steel, cement mortar lined pipes. Condition assessments of critical mains (within the limitations of existing technology).

Vol 36 No 2 April 2011

20 Corrosion & Materials

Where extensive internal corrosion of water mains occurs, taste and aesthetic qualities are compromised (known as red water) which invariably leads to water quality complaints.

As examples, the following summarises the findings of investigations into the causes, cost and opportunities to address corrosion in Australia’s wateri and defenceii sectors.

The financial burden of corrosion is significant In the urban Water Utility sector

For MOTS, vessels built to naval rules with less damage tolerance the cost benefit ration would reasonably exceed 10:1.

The annual cost of corrosion to the 52 urban Water Utilities servicing approximately 75% of Australia’s population is estimated at $982M ± 30%:

The current focus on maintenance in place of corrosion prevention in the RAN results in:

Aggregated corrosion costs to the Australian urban Water Industry

Annual cost $m

significantly higher repair and replacement costs,

Water loss from pipeline leakage (at $1.53 per kL)

120.0

unnecessarily higher maintenance expenditure, and

Water loss from pipeline failures (at $1.53 per kL)

4.3

delays to identifying corrosion prevention works.

91.2

Water pipeline corrosion repairs

118.7

Sewer pipeline corrosion repairs

39.0

Sewage treatment costs due to infiltration

38.0

Capital cost for water and sewer pipeline replacements

298.7

Maintenance & repair water treatment plants

52.0

Maintenance and repair of other assets (tanks, pump stations etc)

42.4

Maintenance & repair sewage treatment plants

176.8

Total cost

981.1

The average repair cost for reticulation water mains of up to 300mm nominal diameter (DN) is around $4550.

In the United States Navy (USN)

The benefits of early intervention are significant and can be achieved through improved design and maintenance, education and training.

Intangible costs associated with water and sewer pipe failures and replacements

The percentage of breaks attributed to corrosion is approximately 79%.

The RAN case studies showed that effective and timely corrosion prevention would significantly reduce avoidable labour costs, comprising up to 89% of repair costs.

The incidence and cost of repairs, and maintenance attributable to corrosion is unacceptably high

Current asset management practices leave significant opportunity for improvement

In the urban Water Utility sector

In the urban Water Utility sector, maintenance and management of water supply and sewerage pipeline networks involves:

Vol 36 No 2 April 2011

ACA Corrosion Challenges Project

Application of structural or semi-structural linings to extend the life of critical pressure water mains. Where stray current corrosion from traction systems is likely, Utilities carry out active electrolysis testing and corrosion mitigation.

The case studies showed that additional costs and the necessity for corrective maintenance caused by corrosion could be avoided by:

In the urban Water Utility sector

conducting corrosion prevention maintenance at an appropriate time,

CCTV inspection programs of non-pressure sewer pipes are actively undertaken to determine the pipe condition and to enable internal repairs to be carried out before corrosion can cause a major collapse.

replacing and repairing areas of corrosion when identified,

building to design specifications, and

Leak detection programmes.

employing appropriate ship’s husbandry regimes.

However While there is considerable application of CP, it is likely that a greater use of this technology could be made to mitigate external corrosion of steel mains. The use of CP on other metallic pipe such as cast iron or ductile iron (sleeved or un-sleeved), is not a viable application of this technology.

Data collection fails to adequately recognise and account for the cost of corrosion, nor does it inform optimum return-oninvestment decisions. In the urban Water Utility sector Data collection is an important and recognised aspect of all water utility Asset Management practices. However

Grey cast iron and asbestos cement pipes make up the largest proportion of reticulation pipes. Many of these are reaching a time where replacement will be required. There are also no specific requirements to treat domestic drinking water pipes with corrosion inhibitors. In the RAN, considerable effort and expenditure is undertaken on ship’s maintenance: Maintenance for RAN vessels is subject to two regimes: conducted on board by RAN personnel; and maintenance by RAN personnel and contractors during scheduled maintenance periods. Maintaining Naval certification (Classification Society certification or ‘Class’) requires a structured survey regime, incorporating a system of imposed “Conditions of Class”, when surveyed items are found to be below the minimum ‘Condition’ requirement, and identified for corrective action within an agreed timeframe. The Condition itself results in additional expense to the Vessel Owner for the Class Society’s costs associated with Independent Validation and Verification to ensure the Owner’s repair actions comply with applicable standards. However Class Conditions are always corrective rather than preventative, and lead to missed opportunities in preventative maintenance that could significantly reduce costs and repairs.

22 Corrosion & Materials

Codes and regulations do not adequately recognise or address the principle of corrosion prevention

Most corrosion expertise rests with specialist groups in some water utilities. Programs to disseminate this knowledge across the Utilities would be of benefit. Collection of reliable data as aimed for in the National Water Mains Failure Data Base (7.1.3)1 is reliant on the interpretation of pipeline failures by operations staff that do not have specific training in corrosion management. In the RAN The cost of operating a vessel on a daily basis is known, and data is collected through the Class Society survey regime and RAN inspection processes. However There is no detailed breakdown of repair costs. Limitations of data records make it difficult to isolate and analyse corrosion costs amongst other repair activities. Data collection occurs in the absence of a methodology to predict time, effort and resources required for corrective maintenance, impacting upon the ability to ascertain value for money. The cost of operating a vessel is not articulated in such a way that lost days of operation is measured in dollar terms against the cost of corrosion prevention or corrective maintenance.

The Water Supply Code of Australia and Sewerage Code of Australia cover the design and construction of water and sewerage network infrastructure, and cover limited aspects of materials and corrosion prevention. The Water Services Association of Australia has recently implemented a Design Assurance Scheme, focused on ensuring competency using the Sewerage Code of Australia and the Water Supply Code of Australia. There are no specific regulations or legislation that could be directly linked to factors that may exacerbate corrosion or hinder any measures, which may be implemented to mitigate corrosion. However While the Australian Codes cover aspects of materials and corrosion, the focus is on civil design and construction; although specifications and standards for individual items often address material durability issues including corrosion. Some regulation can exacerbate corrosion. For example, in response to odour complaints, local authorities may close off sewer vent pipes or enclose treatment facilities to prevent the escape of hydrogen sulphide gases; gases which accelerate concrete corrosion and cause significant damage to infrastructure.

Class condition and repair certification always details corrective action rather than preventative measures so the cause of the corrosion is not being identified or addressed early. Processes to engage contracted labour result in a ‘report and forget’ approach with limited or no follow through or review once a work request has been sent from the ship. A lack of consideration for contingent requirements invariably results in cost and schedule blowouts and safety impacts such as low risk safety issues elevating to a higher risk. Education and training programs do not place sufficient focus on corrosion prevention In the urban Water Utility sector Extensive training is available for water and wastewater operations (Government Skills Australia, NWP07 Water Training Package) which include a large number of competency requirements but only a limited focus on corrosion theory. Requirements for designers and design auditors to show competency in using the Water Supply and Sewerage Codes of Australia are being introduced. However More detailed information/training and specific accreditation on corrosion prevention is required as part of, or as a separate requirement to, the Water Services Association of Australia’s Design Assurance Scheme.

In the RAN Australian Defence Naval Assets are subject to an extensive regulatory regime, as articulated in the Naval Technical Regulations Manual (NTRM)iv. Compliance with NTRM is addressed by an extensive certification regime with a combination of Independent Third Party or Naval certification. However

Specific corrosion courses aimed at the water industry and competency training involving a unit specifically relating to corrosion are required. Corrosion training courses that are supportive and complementary to the initiatives of the National Water Mains Failure Data Base would aid in more effective data collection. In the RAN

Existing engineering policy could be adapted to provide greater assurance of technical integrity in conjunction with sound economic judgement.

Considerable resources are applied to the education of Naval Engineering personnel, Marine Engineering Officers (ME) and Marine Technician (MT) Sailors.

Application of Naval Technical Regulatory requirements appears inconsistent with its intent.

Within the Marine Technician branch there are course modules on welding, fabrication, ship’s stability and construction.

Staff within Naval sustainment organisations do not understand the cost benefit of preventative maintenance as this is not required to maintain Classification Society certification but is at the Vessel Owner’s discretion. www.corrosion.com.au

Bosun’s Mate (BM) Corrosion Control includes a course on corrosion control, and will shortly be the only one of its kind. Vol 36 No 2 April 2011

ACA Corrosion Challenges Project

The case studies showed that additional costs and the necessity for corrective maintenance caused by corrosion could be avoided by:

In the urban Water Utility sector

conducting corrosion prevention maintenance at an appropriate time,

replacing and repairing areas of corrosion when identified,

building to design specifications, and

Leak detection programmes.

employing appropriate ship’s husbandry regimes.

22 Corrosion & Materials

Codes and regulations do not adequately recognise or address the principle of corrosion prevention

Existing engineering policy could be adapted to provide greater assurance of technical integrity in conjunction with sound economic judgement.

Considerable resources are applied to the education of Naval Engineering personnel, Marine Engineering Officers (ME) and Marine Technician (MT) Sailors.

Application of Naval Technical Regulatory requirements appears inconsistent with its intent.

Within the Marine Technician branch there are course modules on welding, fabrication, ship’s stability and construction.

Bosun’s Mate (BM) Corrosion Control includes a course on corrosion control, and will shortly be the only one of its kind. Vol 36 No 2 April 2011

ACA Corrosion Challenges Project

However

Employ data collection methodology that recognises and accounts for the incidence and cost of corrosion and encourages anticipatory rather than reactionary decisions,

There remains difficulty in understanding and implementing Class requirements; in particular for Vessel Owners defining and integrating their vessel maintenance obligations with Class requirements.

Develop strategy around data collection that considers aspects of return on investment and the analysis required to enable proper evaluation,

The focus on Operator Technician training rather than maintenance and prevention has created a generation of Senior Sailors who lack the knowledge and experience which underpins the maintenance of Naval Assets.

Collect data using structures that enable reporting on the impact of corrosion upon financial, social and the service of infrastructure and assets, and

As mentors and leaders, Senior Sailors do not have the experience and information to pass on to Junior Sailors so their skills can be practiced and improved.

Analyse and improve codes and regulations to recognise and incorporate the principles of corrosion mitigation and relevant decision-making processes.

There is an unnecessary reliance on resources external to vessels to perform tasks that could be conducted by naval personnel with resultant long-term savings. This report was subject to expert peer review by: In practical terms, the MT branch is responsible for managing the condition of the vessel whilst those in the BM branch are charged with ship’s husbandry. The methods of training within each branch ensure that neither branch relates the importance of these complementary roles. Research indicates that existing training modules for ship’s husbandry have fallen into disuse and require resurrection and review. Within the MT branch there are no modules on protective coatings or corrosion. Training courses for junior sailors involving Spray Painting and Ships Preservation are inactive, whilst Basic Corrosion Control is about to become inactive.

Dr Nick Birbilis Monash University David Cox WSAA Dr Bruce Hinton Monash University Dr Peter Mart DSTO Paul Vince SA Water Greg Moore - Principal, Moore Materials Technology Pty Ltd, Corrosion Challenges – Urban Water Industry, 2010, is based on data collected by the Water Services Association of Australia (WSAA) National Performance Report 2008/09. The NPR records and measures up to 117 indicators from 73 water utilities across Australia, serving approximately 75% of Australia’s population. This was supplemented by specific information obtained from four major water utilities.

To capitalise on the critical principles of preventative maintenance teamed with early intervention both the Urban Water and Naval Defence sectors should: Undertake a strategic shift in policy to recognise the significant corrosion cost avoidance through early prevention and preservation, Educate senior staff about corrosion prevention in asset management, emphasising the cost benefit and encouraging more strategic in-depth data analysis,

Graeme Emerton - Defence Materiel Organisation, Sydney, Corrosion Challenges – Naval Defence, 2010, is based on a number of case studies. The report aimed to assess the various systems and structures that exist within the Australian Defence Naval sector and evaluate how they influence the management of corrosion and used selected case studies to assess the potential for more effective expenditure by prevention of deterioration.

24 Corrosion & Materials

AlphaBlast was established in 2002, however from 1st December 2010 we have taken on our parent company’s name of ORONTIDE. What differences is there in the company since your name change in December 2010? The key people and focus of the business remain the same. The only change is that we can now offer additional complementary services with the addition of our Engineering Services division. How many do you currently employ? Across the two divisions –Industrial Services and Engineering Services – ORONTIDE employs approximately 250 people Australia wide. Do you operate from a number of locations in your home state or in other states of Australia? Our head office is in Henderson, Western Australia where we also have a state of the art blasting facility and engineering workshop. We also have facilities in Port Hedland, Bunbury, Kalgoorlie and Sydney.

The Cost of Corrosion for US Navy Ships – From Metrics to Action, Megarust Conference June 2010

What is your core business? (eg blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring, etc). Our core business is Asset Integrity Management. We undertake surface preparation using both UHPWJ and abrasive blasting (wet and dry), together with the application of High Performance Protective Coatings such as Phenolic, Novalac and Intumescent epoxies (incl. conventional coating systems). Our Engineering Division in turn adds to that with Design, Machining, Fabrication and Fitting.

Do you offer any specialty services outside your core business? (eg primary yard based but will do site touch up, etc). We are able to provide NACE Inspection Services and corrosion/coating condition assessments. We have always specialised in Cold Cutting and Hydro-demolition by means of UHP Water Jetting. Our coating capability extends to the application TSA/TSZ and thermoplastic coatings like EnviroPeel. What is the most satisfying project that you have completed in the past two years and why? Cold cutting project. Offshore on the Ngujima Yin M60 which proved to be very technical as well as rewarding. What positive advice can you pass on to the Coatings Group from that satisfying project or job? Use your knowledge and network innovatively to create enduring and economical solutions for your clients needs. Do you have an internal training scheme or do you outsource training for your employees? Selected staff are undertaking Certificate III in Surface Preparation and Coatings Application. All of our Supervisors, Coordinators and Inspectors are NACE Certified (Level 1 to 3). Ongoing training for all operations staff to keep abreast of industry requirements and ensure continuous professional development. ORONTIDE Invests heavily in people.

What markets do you cover with you products or services? eg: oil & gas, marine, chemical process, general fabrication, tank lining, offshore, etc. We service the oil & gas sector, mining, defence and commercial marine markets.

iii

ABR 6492 Naval Technical Regulations Manual.

The National Water Mains database is based on that used in the United Kingdom but tailored to address the Australian context. This data base allows the upload, collation and anonymous comparison of water pipe data between water utilities. 1

Develop training modules to include prevention and early intervention principles, thereby strengthening core competencies of junior staff,

In what year way your company established?

Recommendations:

ORONTIDE Ltd.

Is the business yard based, site based or both? We undertake work both in our yard as well as on-site, both on and offshore. What is your monthly capacity or tonnage that you can blast and prime? Approx 500 tonne (yard based).

www.corrosion.com.au

Contact Details: 54 Sparks Road Henderson Western Australia, 6166

E: orontide@orontide.com.au T: 61 8 9236 2555 F: 61 8 9410 2056 www.orontide.com.au

Vol 36 No 2 April 2011

ACA Corrosion Challenges Project

However

Employ data collection methodology that recognises and accounts for the incidence and cost of corrosion and encourages anticipatory rather than reactionary decisions,

There remains difficulty in understanding and implementing Class requirements; in particular for Vessel Owners defining and integrating their vessel maintenance obligations with Class requirements.

Develop strategy around data collection that considers aspects of return on investment and the analysis required to enable proper evaluation,

Collect data using structures that enable reporting on the impact of corrosion upon financial, social and the service of infrastructure and assets, and

As mentors and leaders, Senior Sailors do not have the experience and information to pass on to Junior Sailors so their skills can be practiced and improved.

Analyse and improve codes and regulations to recognise and incorporate the principles of corrosion mitigation and relevant decision-making processes.

24 Corrosion & Materials

The Cost of Corrosion for US Navy Ships – From Metrics to Action, Megarust Conference June 2010

iii

ABR 6492 Naval Technical Regulations Manual.

Develop training modules to include prevention and early intervention principles, thereby strengthening core competencies of junior staff,

In what year way your company established?

Recommendations:

ORONTIDE Ltd.

www.corrosion.com.au

Contact Details: 54 Sparks Road Henderson Western Australia, 6166

E: orontide@orontide.com.au T: 61 8 9236 2555 F: 61 8 9410 2056 www.orontide.com.au

Vol 36 No 2 April 2011

ACA Technical Groups Update Over the past twelve months ACA has been working to reinvigorate its eight Technical Groups (TG). For each TG, a call has been put to membership, seeking nominations to form a steering committee. The first task of each newly formed steering committee was to write and ratify their Charter, six of which can be found on the ACA website at www.corrosion.com.au/contents/10633

This process resulted in some changes to names of TG which made the TG more inclusive and reflective of their membership. Currently four groups have scheduled mid-year meetings in the form of day long seminars. For further information, please refer to the ACA website at www.corrosion.com.au

A full list of steering committee members for each TG can be seen tabulated below. The contact point for each TG is the Group Chair and Secretary (* denotes these roles). If members are interested in attending or contributing to future technical events, please contact Caitlin Granowski at cgranowski@corrosion.com.au

Cathodic Protection Member Bruce Ackland* Alireza Kouklan* Richard Brodribb Graham Carlisle Francis Carroll Peter Clark Andrew Hargrave Doug Herd Ulf Kreheru Nick Riley Dave Robertson Mark Sigley Colin Symonds Rajko Vukcevic

Company Bruce Ackland & Associates SP AusNet M. Brodribb Pty Ltd Orontide GHD Peter Clark & Associates Hargrave Pipeline Group Savcor Aurecon Clough AMEC United Water Watercare Shell SMPS

State/Branch Victoria Victoria Victoria Western Australia Queensland New South Wales Tasmania Queensland Victoria South Australia South Australia New Zealand Victoria Victoria

Lyndon Zimmerman

Solaris

South Australia

Coatings Member David Hopkins* Steve Wickham* Graham Carlisle Mark Davidson Peter Dove Peter Hart Willie Mandeno Peter Mayes Dean Wall

Company Leighs Paints Eptec Orontide WorleyParsons Ltd Australian Corrosion Technologies Incospec & Associates Australia Opus International Consultants Bredero Shaw Robayne Distributors

State/Branch Queensland New South Wales Western Australia Western Australia Victoria South Australia New Zealand New South Wales Tasmania

Concrete Structures & Buildings Member FrĂŠdĂŠric Blin* Warren Green* Mohammad Ali Arthur Austin Hal Burkett Ian Donoghue Adrian Dundas Philip Karajayli Ike Solomon Don Wimpenny

26 Corrosion & Materials

Company AECOM Vinsi Partners GHD ALS Global Painting Inspection Services Structural Systems BRS Savcor ART Aurecon Halcrow Group

State/Branch Victoria New South Wales New South Wales Queensland Western Australia New South Wales Queensland New South Wales Victoria Victoria

Mining Industry Member Peter Farinha* Ted Riding* Rob Dawson Liam Holloway Willie Mandeno Mick Morris Chris Partington Allan Sterling

Company Extrin Consultants Jotun Ovation Investments Savcor Finn Opus International Consultants Harrison Group Promat Australia Anode Engineering

State/Branch Western Australia Victoria New South Wales Western Australia New Zealand Northern Territory South Australia Queensland

Company Anti Corrosion Technology A.S. Harrison & Co ALS Global CQUniversity Australia Curtin University Savcor Shell Refining Australia Mobil Refining Caltex

State/Branch Western Australia New South Wales Queensland Queensland Western Australia Western Australia New South Wales Victoria New South Wales Victoria

Research Member Nick Birbilis* David Young* Reza Javaherdashti Robert Jeffrey Rolf Gubner Rajko Vukcevic

Company Monash University University of NSW Qatar University Pacific Testing Curtin University Infoware Consulting

State/Branch Victoria New South Wales Qatar New South Wales Western Australia Victoria

Water & Water Treatment Member David Mavros* Matthew Dafter* Nick Critchley Warren Green Mark Jones Des McInnes Greg Moore Jonathan Morris David Nicholas Kerryn Wilson

Company SA Water Hunter Water Savcor Vinsi Partners MRJ Industrial Services Tarong Energy Moore Materials Technologies Opus International Consultants Nicholas Corrosion AECOM

State/Branch South Australia New South Wales Queensland New South Wales Tasmania Queensland South Australia New Zealand New South Wales Victoria

Company Sussex Material Solutions Department of Defence TechnoWeld Inspection International Welding & Engineering Solutions Shell Refining

State/Branch Victoria South Australia South Australia Western Australia

Refining & Processing Member Fikry Barouky* Phil Fleming* Arthur Austin Richard Clegg Rolf Gubner Liam Holloway Ripan Kapoor David Monk Greg Reece Frank Thompson

Welding, Joining & Corrosion Member Graham Sussex* Roman Dankiw Graham Fry Paul Hilton Ripan Kapoor www.corrosion.com.au

New South Wales Vol 36 No 2 April 2011