Corrosion & Materials August 2013

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Vol 38 No 4, August 2013 ISSN 1326-1932

Inside this Issue: Meet the…ACA Secretaries Technical Note: Pipelines and Polyurethane Coatings: A Winning Combination Industry Insight: Overcoming Corrosion Challenges Faced in Alumina Processing Project Profile: Sydney Desalination Pipeline Cathodic Protection System Performance Review after 3 Years Project Profile: Don’t Gamble on Your Coating Selection Research Profile: CSIRO’s Environmental Surface Design Team Professional Practice Paper: Stainless Steel in Bridges: A New Zealand Perspective

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Proudly presented by:

Major Sponsor:

Darwin Convention Centre

21–24 September 2014

www.acaconference.com.au

FIRST ANNOUNCEMENT & CALL FOR PAPERS CALL FOR PAPERS

DARWIN

Submissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2014.

Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are:

Darwin is a fascinating, tropical modern city, with a fusion of people and cultures which engender a unique and friendly laid back lifestyle. Soak up Darwin’s balmy weather while enjoying the diversity of food and culture in the city’s many markets, restaurants and bars. Explore the region’s dramatic history in the many museums and galleries, sail beautiful Darwin harbour at sunset, cruise next to crocodiles or swim in the crystal clear waterholes of Litchfield National Park.

Close of Abstracts: 31st January 2014 Acceptance of Abstracts: 14th February 2014 Receipt of Papers: 2nd May 2014

SUBMIT AN ABSTRACT Please refer to www.acaconference.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (31st January 2014). Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process for Corrosion & Prevention 2014.

GUIDE TO SUBMISSION Papers submitted to the Corrosion & Prevention 2014 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/ permission from their organisation. Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary.

All authors whose papers are accepted are required to attend the conference to present.

Darwin Conference Centre

p.2 CORROSION & MATERIALS

Darwin has a population of over 100,000 people and boasts a lively mix of more than 50 nationalities. This vibrant capital has a youthful energy you will find hard to resist and is noted for its consistently warm to hot climate throughout the year. Darwin is the gateway to the Australian outback and some of the country’s best tourism experiences. Progressive, vibrant and energising, Darwin is a breath of fresh air that will always prove irresistible to all who visit.

The Northern Territory is a place with landscapes as diverse as they come, from Uluru, the spiritual heart of the Australian continent in the dry Red Centre, to the teeming-with-wildlife tropical wetlands of the Kakadu and Nitmiluk National Parks in the Top End. In many ways the Northern Territory is the most quintessentially Australian of all the Australian States, and there is a little bit of everything for everyone. www.travelnt.com

TECHNICAL TOPICS

CONFERENCE COMMITTEE

Corrosion and Prevention 2014 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion on a daily basis. Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application. Submissions may include research papers, posters, review papers and case studies related to the technical streams listed below.

George Curran

Advances in Sensing and Monitoring Cathodic/Anodic Protection Coatings Concrete & Architecture Integrity Management Manufacturing & Production

Erwin Gamboa Andrew Hargrave Brian Hickinbottom Raman Singh Dean Wall

SPONSORSHIP AND EXHIBITION Sponsorship will enable your company to make a significant contribution towards the success of Corrosion & Prevention 2014. In return, the conference offers strong branding and exposure in a focussed and professional environment. As with every Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services.

Marine Corrosion Oil & Gas Sustainability, Environment & Energy Water & Wastewater

INDUSTRY SECTORS This conference will have material of value to those working within the following industries, or related areas: Aviation Concrete Structures and Buildings Defence Education and Research

YOUR HOSTS The Australasian Corrosion Association Inc (ACA) is a membership based, not-for-profit, industry association, promoting the co-operation of academic, industrial, commercial and governmental organisations in relation to corrosion and its mitigation. The ACA disseminates information on all aspects of corrosion and its prevention by promoting lectures, symposia, publications and other activities. www.corrosion.com.au The mission of the ACA is to disseminate knowledge to enable best practice in corrosion control thereby ensuring all impacts of corrosion are responsibly managed, the environment is protected, public safety is enhanced and the performance of economies improved.

Manufacturing Marine Mining Oil & Gas Power Transport Water and Wastewater

CONTACT The Australasian Corrosion Association Inc PO Box 112 Kerrimuir, Victoria, Australia, 3129 Ph: +61 3 9890 4833 Fax: +61 3 9890 7866 Email: conference@corrosion.com.au www.acaconference.com.au

August 2013 www.corrosion.com.au p.3

CONTENTS

The Australasian Corrosion Association Inc The Australasian Corrosion Association Inc (ACA) is a non-profit membership based organisation akin to a “learned society”. The ACA was established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion. It is dedicated to ensuring all aspects of corrosion are responsibly managed, protecting the environment and ensuring public safety.

ACA members are drawn from a wide cross section of industries united by their common interest – to reduce the impact of corrosion in Australasia.

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President’s Message

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News

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ACA Branch and YCG Events

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ACA Standards Update

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New Product Showcase

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C&P2013 Plenary Speaker Abstracts

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Meet the…ACA Secretaries

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Coatings Group Member Profile

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Technical Event Review: Reinforced Concrete Performance for Water and Wastewater Assets - Sharing Experience through Case Studies

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Technical Group Meeting Review: Improving the Longevity of Protective Coatings – Industry Updates and Lessons Learnt!

The ACA is a founder member of the World Corrosion Organization Front Cover Photo: Thermal Metal Spray is a coating process used to change the surface properties of a part by adding a layer(s) of material to increase corrosion protection, hardness, increase or reduce friction, increase durability, change electrical properties or even to replace worn or damaged material.

Photo supplied by Metal Spray Supplies Australia

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ISSN 1326-1932 Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257 Editor Ian MacLeod – Western Australian Museum ian.macleod@museum.wa.gov.au Associate Editors Research: Bruce Hinton – Monash University bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants, willie.mandeno@opus.co.nz News: Wesley Fawaz – The Australasian Corrosion Association Inc, wesley.fawaz@corrosion.com.au

Reviewers Andy Atrens – University of Queensland Nick Birbilis – Monash University Frederic Blin – AECOM Lex Edmond Harvey Flitt – Queensland University of Technology Maria Forsyth – Deakin University Rob Francis Warren Green – Vinsi Partners Graeme Kelly – Corrotec Services Grant McAdam – Defence Science & Technology Organisation David Nicholas – Nicholas Corrosion Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science & Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South Wales

Advertising Sales Wesley Fawaz – The Australasian Corrosion Association Inc, wesley.fawaz@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscriptions Print Version: ISSN 1326-1932 Subscription rates: Within Australia: AU$72.60, incl GST Outside Australia: AU$77, excl GST posted airmail The views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.

The Australasian Corrosion Association Inc PO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: aca@corrosion.com.au Internet: www.corrosion.com.au

CONTENTS

42

Technical Note: Pipelines and Polyurethane Coatings: A Winning Combination

46

Industry Insight: Overcoming Corrosion Challenges Faced in Alumina Processing

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Project Profile: Sydney Desalination Pipeline Cathodic Protection System Performance Review after 3 Years

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Project Profile: Don’t Gamble on Your Coating Selection

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Research Profile: CSIRO’s Environmental Surface Design Team

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Professional Practice Paper: Stainless Steel in Bridges: A New Zealand Perspective

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Suppliers and Consultants

Corrosion & Materials Corrosion & Materials is the official publication of The Australasian Corrosion Association Inc (ACA).

Published bi-monthly, Corrosion & Materials has a distribution of 2,500 to ACA members and other interested parties. Each issue features a range of news, information, articles, profiles and peer reviewed technical papers. Corrosion & Materials publishes original, previously unpublished papers under the categories “Research” and “Professional Practice”. All papers are peer reviewed by at least two anonymous referees prior to publication and qualify for inclusion in the list which an author and his or her institution can submit for the ARC “Excellence in Research Australia” list of recognised research publications. Please refer to the Author Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au with a copy to bruce.hinton@monash.edu ACA also welcomes short articles (technical notes, practical pieces, project profiles, etc) between 500 – 1,500 words with high resolution photos for editorial review. Please refer to the Article Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au

ACA Operations Board President: Allan Sterling

ACA Branches & Divisions Auckland Division: Grant Chamberlain

64 21 245 9038

Chief Executive Officer: Ian Booth

Newcastle: Karen Swain

Operations Chairman: Paul Vince

New South Wales: Jim Galanos

61 2 9763 5611

Senior Vice President: Andrew Hargrave

Queensland: Cathy Sterling

61 7 3821 0202

61 0 418 854 902

ACA Technical Groups Cathodic Protection: Bruce Ackland

61 3 9890 3096

Coatings: Matthew O'Keeffe

61 437 935 969

Concrete Structures & Buildings: Frédéric Blin

61 3 9653 8406

Mining Industry: Ted Riding

61 3 9314 0722

Junior Vice President: Mohammad Ali

South Australia: Dennis Richards

61 0 419 860 514

Immediate Past President: Peter Dove

Tasmania: Grant Weatherburn

61 0 418 120 550

Directors: Graham Carlisle Matthew Dafter Roman Dankiw John Duncan Fred Salome Graham Sussex Dean Wall Geoffrey Will

Taranaki Division: Ron Berry

64 27 671 2278

Research: TBA

Victoria: John Tanti

61 3 9885 5305

Water & Water Teatment: Matthew Dafter 61 419 816 783

Wellington Division: Monika Ko Western Australia: Gary Bennett

64 4 978 6630 61 0 408 413 811

Petroleum & Chemical Processing Industry: Fikry Barouky 61 402 684 165

Young Corrosion Group: Erwin Gamboa

61 403 523 771

* all the above information is accurate at the time of this issue going to press.

PRESIDENT’S MESSAGE

ahead. Can we do better? Of course we can, but growth needs to be managed and controlled for it to be sustainable.

I would also like to have travelled to each Branch, preferably in conjunction with a technical event. Unfortunately work commitments have prevented me from getting out and about as much as I would have liked. There is still a bit of time left in the year, so we will see what happens.

As I mentioned in one of my earlier columns, the role of the President is not so much to achieve something momentous (although that would be good), but rather to participate in the process that ensures the Association has planned where it wants to be and is geared towards achieving those goals in a realistic timeframe.

Allan Sterling President Hi All, I am now very close to the end of my term as President and I find myself asking the question: What have I achieved? The first answer that comes to my mind is, probably very little.

That may seem a bit harsh, but it is very difficult to achieve any significant change in such a short period of time.

But what did I want to achieve? Well first and foremost I hoped that the Association continued to prosper.

The last thing I wanted was for the Association to go backwards on my “watch”. Through the hard work of those in Head Office and all the volunteers, the Association is moving

We are progressing well along the path outlined in our strategic plan. One of the more important steps is the constitution review. That has lost a bit of momentum in recent times, however it is such an important document that we need to keep moving ahead with the review. Our constitution needs to more accurately reflect how the Association now operates and take into account new technologies, which allow the speeding up of the change process.

Hopefully by the end of the process we will have a document that the entire membership is happy with.

Education & Training is a very important part of the operation of the Association. Firstly; it is the major

income stream. Consequently we need to spend money on the courses to ensure they remain up to date and relevant to the industry. I am happy to report that the Association is focused on the review and upgrade of many of our training courses. In particular the Cathodic Protection courses are currently undergoing a major upgrade after a number of years of neglect.

Planning for the November conference C&P2013 “Where Theory Meets Practice” is very well advanced. The call for papers has well and truly closed and hopefully those authors of the successful abstracts are now beavering away on the final touches of their papers. From last reports we have around 80 papers for the conference.

The conference will be held in the Brisbane Convention & Exhibition Centre and we look forward to seeing you all there at what is shaping up to be a very successful conference.

On the subject of conference, our success is now causing us a number of venue selection headaches. Wherein the past each branch was able to host the conference locally, we are now restricted to selected venues due to the size and layout required. This is unfortunate for the smaller branches, however it is one of the changes that needs to be addressed in our strategic plan and our constitution review.

Allan Sterling ACA President 2013

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Major Sponsor:

CORROSION & PREVENTION 2013 C O N F E R E N C E

&

Proudly Presented by:

E X H I B I T I O N

Where Theory Meets Practice Brisbane Convention & Exhibition Centre

Early Bird Registration: Register before 23rd August for the discounted conference registration fee.

10–13 November 2013 www.acaconference.com.au

Technical streams include: • Corrosion mechanisms, modelling and prediction • Protective coatings • Cathodic protection • Concrete corrosion and repair • Materials selection and design • Asset and integrity management • Corrosion prevention implementation

The conference will be integrated with an exhibition which will showcase the products and services within the corrosion mitigation industry.

• Failure analysis • Corrosion in biomedical applications • Contractor perspectives • Education and training

For further information contact The Australasian Corrosion Association Inc on +61 (0)3 9890 4833, Email: conference@corrosion.com.au or refer to www.acaconference.com.au

CORROSION & PREVENTION 2013 August 2013 www.corrosion.com.au p.7

NEWS

ACA conducts training for Fleet Support Unit – South East At the publication of this article, the ACA will have completed the first of three planned courses for the Fleet Support Units of the Royal Australian Navy.

To facilitate this practice, the training undertaken by the personnel is to be the Protective Coatings Quality Control Course. The course was led by ACA Lecturer Fred Salome.

In 2012 staff from the ACA office travelled to Sydney and met with key personnel of the Fleet Support Unit at Garden Island Naval Dockyard. The aim of the visit was to initially present options in support of a report (Rizzo, 2011) that outlined suggested changes and reforms to Ships Husbandry Procedures currently employed in the Fleet as a whole.

Fred has extensive experience with coatings and the quality assurance properties and procedures which may extend and promote the life of an asset.

On 19th June 2013, 17 Navy personnel, led by CPOB Scott Barker, commenced the first of 3 courses to be undertaken by members of FSU Nationally.

Each course involves FSU members undertaking a 3 day training program.

With each course, the intent of the training is to assist naval personnel in identifying and resolving issues that may lead to coatings failure on board naval vessels whilst at sea and at dock.

Naval personnel were exposed to case studies and demonstrations in the field of QA for coatings using both familiar and unfamiliar equipment and test procedures.

Course participants were familiarised with common QA practices with a ‘back to basics’ outlook in the area of preparation of a steel substrate.

The course attendees were shown examples of, and given the opportunity to identify initial rust grades and the different classes of finish after cleaning had taken place by various methods.

Visual Reference Guides (SSPC and ISO 8501) were demonstrated with practice given in their correct use along with profile testing and the various accepted methods and equipment that may be employed to conduct the test.

It appears that certain ‘Contaminant Test’ equipment and methods were afforded praise by personnel of the course. The Naval personnel had the opportunity of conducting contaminant testing on prepared and unprepared steel substrates during the course through practical applications with Bresle, 134S, 134CSN, Conductivity and the use of Potassium Ferricyanide Test Paper applications.

The ACA has been approached to conduct a total of three of the Protective Coatings Quality Control Courses for the Royal Australian Navy Fleet Support Units. Additionally selected Naval personnel will be attending the NACE Coating Inspector Program (CIP) range of courses.

FSU - SE Course Participants.

Recording profile types by use of visual comparators.

p.8 CORROSION & MATERIALS

Conducting tests for contamination and recording findings.

In this picture Fred is discussing the finer points of Ferricyanide Paper with members of the course.

THE AUSTRALASIAN CORROSION ASSOCIATION INC SEMINAR

Water & Wastewater Seminar Series 2013

PROUDLY PRESENTED BY:

Investigation of Corrosion in the Water and Wastewater Industries International Guest Speaker – Carol Powell Overview

Biography

International guest speaker Carol Powell, Consultant Metallurgist to the Nickel Institute and Copper Development Association in the UK is coming to Australia and New Zealand to share her knowledge and expertise in corrosion issues in the Water and Wastewater Industries.

Carol Powell, Consultant Metallurgist – Nickel Institute and Copper Development Association

Carol will speak on the following two issues: The Nature and Corrosion Resistance of Stainless Steel in the Water Industry.

This presentation will cover the following topics: • What is stainless steel, and which stainless steels are used in the water industry • How do stainless steels behave in the atmosphere, in various water chemistries, under flow and in stagnant conditions • The presentation will also look into galvanic behaviour, leaching characteristics and good fabrication practices Guidelines and Applications in Water and Wastewater Treatment Environments.

This presentation will cover the following topics: • Resistance of materials to plant environments in the water treatment industry • Chlorides, Oxidants, Hydrogen Sulphide • Hydrotesting • MIC • Behaviour of stainless steels in waste water treatment environments • Guidelines for use & applications Complementing Carol’s presentations will be a look at actual case studies. These will be presented by local practitioners in water and wastewater treatment projects/plant. Case Studies will vary depending on location and will include consultants and asset owners.

Career Summary Carol Powell has been a consultant metallurgist to the Nickel Institute and Copper Development Association in the UK for over 20 years with particular specialisation in copper-nickels and their application in marine and related industries. She has been a member of the UK Marine Corrosion Forum and International Copper Association Copper-Nickel Task Force since their inception and is currently deputy chair of the European Federation of Corrosion Marine Working Party.

In addition, her Nickel Institute activities have developed an in depth knowledge of stainless steels and their application in the water industry.

During this time, she has been involved in many workshops and conferences internationally including the USA, Europe and South East Asia and the Far East. In the UK, she has actively worked on guidelines and standards for the industry and provided material advice for companies associated with water and waste water treatment plants.

She began her career as a technical investigator in the corrosion laboratories of INCO Alloys Ltd, Hereford, England, later becoming marketing engineer with responsibilities for nickel alloys used in marine and chemical industries. In 1983, she joined YARD Ltd; a firm of marine consulting engineers as their specialist in nickel alloys and stainless steels primarily working with the British Navy. Since 1989, she has been an independent consultant.

Mrs Powell is a graduate of Birmingham University, a member of the Institute of Marine Engineering, Science and Technology and a Fellow of the Institute of Materials, Minerals and Mining. She has written over 40 papers and publications.

Time

Session

1.30 – 2.00

Speaker

Registration

2.00 – 2.05

Welcome and Seminar Opening

Chairperson

2.05 – 3.05

The Nature and Corrosion Resistance of Stainless Steel in the Water Industry

Carol Powell

3:05 – 3.30

Case Study 1 – will vary depending on location

3.30 – 4.00

Afternoon Tea

4.00 – 5.00

Guidelines and Application in Water and Wastewater Treatment Environments Carol Powell

5.00 – 5.25

Case Study 2 – will vary depending on location

5.25 – 5.30

Seminar Close

5.30 – 7.00

Networking & Cocktail Function

Chairperson

SUPPORTED BY:

AUSTRALIAN STAINLESS STEEL DEVELOPMENT ASSOCIATION

Register now at www.corrosion.com.au August 2013 www.corrosion.com.au p.9

NEWS

Micro-capsules and bacteria to be used in self-healing concrete A new research project involving researchers from the University of Bath in England aims to develop novel self-healing concrete that uses an inbuilt immune system to close its own wounds and prevent deterioration.

The life of concrete structures is reduced when the material cracks and water is able to get at the steel reinforcement, causing corrosion and degradation.

The project is funded by a £2 million research grant, matched by an additional industrial contribution of just over £1 million.

The aim is to develop a concrete mix that contains bacteria within microcapsules, which will germinate when water enters a crack in the concrete to produce limestone (calcite), plugging the crack before water and oxygen has a chance to corrode the steel reinforcement.

Self-healing concrete could vastly increase the life of concrete structures, and would remove the need for repairs, reducing the lifetime cost of structures.

Over seven per cent of the world’s CO2 emissions are caused by cement production, so reducing the amount required by extending the lifetime

of structures and removing the need for repairs will have a significant environmental impact.

Dr Richard Cooper, from the Department of Biology & Biochemistry, said: “Cement is highly alkaline, making it a hostile environment for bacteria. We’ll be assessing different species of bacteria to find one that is able to form abundant spores and which will survive and germinate in this environment. The work will involve finding alkaline-tolerant isolates and testing their biology and physiology.”

Dr Cooper added: “Including bacteria in concrete offers a double layer of protection in preventing steel corrosion.

Not only do the bacteria work to plug cracks in the concrete, the process of doing so uses oxygen present which would otherwise be involved in the corrosion process of the steel bars.”

The research team will assess the survival of different species of bacteria in the concrete over time. They’ll allow the concrete to mature over certain time periods and then grind it down to create a suspension which can be assessed by biologists for surviving bacteria.

Dr Kevin Paine, from the Department of Architecture & Civil Engineering, said: “Concrete densifies as it hardens, so the pore size decreases to a level where bacteria may be crushed. We’re looking at enclosing the bacteria in microcapsules, along with nutrients and calcium lactate which the bacteria will convert when water becomes present and use to fill cracks in the concrete.”

Dr Andrew Heath, also from the Department of Architecture & Civil Engineering, said: “Self-healing materials are particularly suited to situations where safe access for maintenance is costly, so the outputs of this extended research programme could reduce the life-cycle costs of infrastructure.”

The research team at Bath will work to develop methods to keep bacteria alive in concrete.

NZ Branch Young Corrosion Professionals Award ACA NZ Branch has made a NZ$2000 award to Afsaneh Sharifi to attend the ACA Annual Conference, to be held this year in Brisbane in November, as the 2013 winner of the NZ Young Corrosion Professionals Award. The Branch committee chose Afsaneh from a very competitive field of applicants.

Afsaneh has been pursuing a PhD in Materials Engineering at the University of Auckland since 2010.

She came to Auckland with a Master of Science in Corrosion and Protection of

p.10 CORROSION & MATERIALS

Materials from the Shiraz University, Iran, where she scored an ‘A’ Grade Point Average, and then gained some experience in the Iranian oil and gas industry. Her PhD project is on development and characterization of electroplated black Ni coatings, which are finding wide applications in the solar thermal energy industry and as decorating fashions. Afsaneh says she looks forward to the opportunity at the conference to expand her knowledge of the wide spectrum of corrosion issues facing Australasia.

Afsaneh Sharifi receiving her award from Wayne Thomson.

NEWS

Safety down under The strength, durability and versatility of nickel-containing stainless steel ensure that this powerful metal has a myriad of applications, none of which are more important than those that save lives.

In 2009, in Auckland, New Zealand, a toddler went missing from her home.

A week later, the two-year-old was found drowned in an underground water drain accessed via a manhole cover that had become dislodged during a recent storm.

This fatality so troubled local builder and father-of-two Kevin Maskell, that he felt compelled to do whatever he could to prevent infants from slipping through manholes ever again.Maskell gave the matter a great deal of thought, he says, “then woke up one morning with the solution in my head.”

The solution was in fact surprisingly simple: design a safety grille that can be easily and speedily bolted into place underneath the manhole cover.

Maskell’s design does not interfere with the integrity of the closed manhole and poses no danger to drivers or pedestrians. What’s more, removal and reinstallation of the grille take less than a minute and no odours are permitted to escape.

Maskell engaged an engineer to fabricate the prototype, then took out a patent, calling his invention the “Caliber Safety Grille.”

The round device is created from 8mm steel bar mesh welded at 150mm centers. It is constructed either of mild steel, hot-dipped galvanized steel for a rugged underground life, or Type 316 (UNS S31600) nickel-containing stainless steel for particularly aggressive environments such as coastal areas or places where acidic water or corrosive waste might be present. Grilles in Type 304 (S30400) are also available.

all three versions can be retrofittted into new and existing manhole covers, regardless of their size.

Thousands of drains are in need of being fitted with the safety grille, so the hassle-free installation and low maintenance requirements are huge drawing cards for city councils.

The device is already part of a major safety program carried out by the city council of Auckland, New Zealand’s largest city, which is having the stainless steel version installed.

The Caliber Safety Grille won’t bring back the child whose death prompted it, but it will at least help prevent such fatal accidents from happening again.

Advantages of the stainless steel version include high strength, durability, low maintenance, and ease of use. Also,

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SUPPORTING SPONSORS OF CORROSION & PREVENTION 2013

August 2013 www.corrosion.com.au p.11

NEWS

Boat owners can fight barnacles with new eco-friendly method A new eco-friendly method to fight the accumulation of barnacles on the hulls of boats and ships has been developed by Emiliano Pinori in cooperation with colleagues at the University of Gothenburg (Sweden) and the SP Technical Research Institute of Sweden.

Barnacles can be found in all marine environments and are a major problem for both small boats and large ships.

Barnacles accumulate on the hulls and can reduce the fuel economy of a vessel by up to 40 per cent, increasing CO2 emissions accordingly.

While most marine organisms that attach themselves to hulls – for example mussels and algae – can easily be scraped off, barnacles literally grow into the surface and form dense calcium deposits underneath the paint.

The most common method used to prevent fouling is to mix the paint with a poisonous substance. The poison is then released slowly from the painted hull to discourage invaders, and eventually ends up in the water to the detriment of other marine organisms. This is how for example tributyltin oxide (TBTO), a biocide used in the 1980s and 1990s, led to a global environmental disaster. TBTO was banned worldwide after it was discovered that the use was making oysters and similar animals infertile.

About 90 per cent of the anti-fouling hull paints used today are based on copper oxide, causing large amounts of copper to be released into the seas and oceans.

to continuing the development of this method” says Pinori.

Emiliano Pinori.

Now, Pinori has found a new method where the paint and the poison are modified so that the poison is kept inside the paint, minimising the release of it into the water. Instead, the barnacle’s own ability to penetrate the paint is used. When the organisms attach to the surface, the poisoning begins.

“You can say that they dig their own grave in the paint,” says Pinori.

The toxin used in the new type of paint is ivermectin – a molecule produced by the bacterium Streptomyces avermitilis.

A good effect has been achieved with only one gram of ivermectin per litre of paint, or a concentration of only 0.1 per cent. The effect lasts for many years and can replace the copper currently used in hull paints. The research indicates that only very small amounts of the substance leach into the water.

“My research shows that the small amounts that are released are unrelated to the effectiveness of the method.

This means that if we can eliminate the leaching completely, the effect will not be sacrificed. Zero emissions will be our next goal. We’re looking forward

All photos by Mats Hulander, Department of Chemistry and Molecular Biology, University of Gothenburg.

Vinsi Partners expansion Vinsi Partners are delighted to announce the opening of a new Brisbane office and the appointment of two new Materials Scientists.

The Brisbane office is located in Stones Corner, Brisbane and is a result of increased need for independent consulting services in Engineering, Corrosion and Asset Control and Durability Assurance from Vinsi Brisbane and Queensland clients.

Dr David Harrison is joining the Newcastle office as a Senior Materials Scientist and has over 20 years experience in various technical

p.12 CORROSION & MATERIALS

roles within the steel, water and manufacturing sectors. He has been responsible for a range of different projects throughout his career, including the development of a remedial water treatment strategy for copper pitting corrosion and has specialist knowledge on metallic coatings performance and coating processes.

Dr Matthew Hales is joining the newly opened Brisbane office as a Materials Scientist following his work on corrosion sensors as a postdoctoral research fellow at Queensland University of Technology (QUT). He has previously worked on a number

of projects involving the development of engineering test systems for novel chemical processes through to chemical / forensic analysis and identification of various materials.

Vinsi’s Brisbane Office.

NEWS

EPTEC and MUEHLHAN unite for oil and gas sector MEPL was established to provide a professional alternative to the traditional methods of delivering integrated maintenance services to the Oil and Gas sector.

Muehlhan has vast experience working with the oil and gas majors in the North Sea, Middle East, Asia and the Americas. Muehlhan operates a multi-award winning Research and Development department that is continuously developing new processes and technologies, identifying improvements by challenging traditional methodologies. At the same time, Muehlhan is working to reduce its carbon footprint and impact on our environment.

Throughout the world, the name Muehlhan stands for ultimate technical expertise, state-of-theart equipment and innovative solutions. In the oil and gas industry, Muehlhan offers a wide range of new construction and maintenance services including surface preparation and specialist coating, passive fire protection, thermal insulation, scaffolding and rope access technology.

Eptec’s expertise is engineered solutions using resin technology to provide corrosion protection, concrete rehabilitation, glass reinforced plastics, water proofings and linings and thermal insulation.

Eptec has a proven operational capability in Australia, particularly through its skilled permanent labour resource and decades of experience working throughout Australia in the

Long standing ACA members EPTEC and MUEHLHAN AG have joined forces in Australia, forming MUEHLHAN EPTEC PTY LTD (MEPL) to provide an unparalleled range of integrated project support services to the oil and gas industry.

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In an industry sector characterised by high demands of safety, quality and environmental awareness, both Muehlhan and Eptec are proud of their records and understand that skills and training must be regularly refreshed and updated. To that end MEPL will continue to utilise the resources of ACA training wherever possible.

With a combined workforce approaching 2,500 and their own state of the art equipment, MEPL represents a resource largely untapped

by Australia’s oil and gas industry.

MEPL will utilise Eptec’s existing offices and facilities across Australia and are ideally positioned to service and deliver projects in all of Australia’s oil and gas precincts.

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August 2013 www.corrosion.com.au p.13

NEWS

Start-up seals robot funding deal One of Australia’s leading technology universities has signed a deal to commercialise its “intelligent” robot design in a bid to crack the international market for cleaning major steel structures such as the Sydney Harbour Bridge.

Sydney robotics start-up, Sabre Autonomous Solutions, has received a major investment from Australian company, Burwell Technologies, to commercialise the world’s first autonomous grit-blasting robot.

Sabre is a new Australian robotics company formed by the University of Technology, Sydney (UTS).

UTS research commercialisation partner, UniQuest, negotiated the agreement for Sydney-based abrasive blasting equipment company, Burwell, to invest in the start-up.

Steel structures dominate the landscape of the world’s major cities but to remain functional they need regular maintenance, says UniQuest CEO Dean Moss.

“That maintenance involves heavy duty grit-blasting, which is a

fatiguing and potentially hazardous task for the blasters, and costly,” says Dr Moss. “Australia spends over $200 million each year on bridge maintenance alone.”

the Centre for Autonomous Systems within the Faculty of Engineering and Information Technology at UTS, in collaboration with Roads and Maritime Services NSW over the past six years.

In the US, the annual estimated direct cost of corrosion of infrastructure is $US276 billion, or about 3.1 per cent of US gross domestic product.

Grit-blasting is used in many industries for cleaning and preparing steel for corrosion protection and for cleaning stone and concrete.

Smart robots are helping clean major steel structures.

Photo: Courtesy Sabre Autonomous Solutions.

The investment will help Sabre refine the robot’s unique capabilities to autonomously sense and map a steel structure, and then plan a suitable collision-free grit-blasting pathway, so that human workers can operate outside the blasting zone.

The robot can also perform work on areas that are difficult for humans to reach, such as corners, upper beams, ceilings and roofs, without additional scaffolding.

The intellectual property underpinning Sabre’s technology originated from a team led by Professor Dikai Liu of

Zinc: The perfect material for bioabsorbable stents?

Stents which are inserted into coronary arteries are tiny mesh tubes used to prop open blood vessels healing from procedures. They widen arteries blocked by clots or plaque deposits. After about six months, most damaged arteries are healed and stay open on their own. The stent, however, is there for a lifetime.

Many studies have investigated iron- and magnesium-based stents.

However, iron is not promising: it rusts in the artery. Magnesium, on the other hand, dissolves too quickly.

“We wondered, ‘Isn’t there something else?’” Bowen said. “And we thought, ‘Why not zinc?’”

Most of the time, that’s not a problem, says Patrick Bowen, a doctoral student studying materials science and engineering at Michigan Technological University in the USA. The arterial wall heals in around the old stent with no ill effect. But the longer a stent is in the body, the greater the risk of late-stage side effects.

So they placed tiny zinc wires in the arteries of rats. The results were amazing. “The corrosion rate was exactly where it needed to be,” Bowen said. The wires degraded at a rate just below 0.2 millimeters per year—the “magic” value for bioabsorbable stents—for the first three months.

After that, the corrosion accelerated, so the implant would not remain in the artery for too long. On top of that, the rats’ arteries appeared healthy when the wires were removed, with tissue firmly grasping the implant.

That’s why researchers are trying to develop a bioabsorbable stent, one that would gradually—and harmlessly— dissolve after the blood vessel is healed.

p.14 CORROSION & MATERIALS

There is one drawback. “A stent made of conventional zinc would not be strong enough to hold open a human artery,” he said. “We need to beef it up, double the strength.”

“The good news is that there are commercial zinc alloys that are up to three times stronger,” Bowen said. “We know we can get there. We just don’t want to ruin our corrosion behavior.”

The researchers have filed a provisional patent on their discoveries and are now testing new zinc-based stent materials.

Bowen’s research is supported by a twoyear, $52,000 predoctoral fellowship from the American Heart Association.

THE AUSTRALASIAN CORROSION ASSOCIATION INC SEMINAR

Control and Manage Corrosion in the Oil & Gas Industries

PROUDLY PRESENTED BY:

A Vital Role in Preventing Future Disasters SPONSORED BY:

The Petroleum & Chemical Processing Industry Technical Group (PCPI TG) of ACA provides a technical platform for the Oil & Gas Industries. It is a forum to discuss the latest developments and best practices in materials engineering and corrosion control in onshore and offshore environments. This one day technical event will look into these areas:

- The design phase of a project - Decommissioning of plant assets - Oil & Gas upstream and downstream operations - Refining - Distribution - Petrochemical and other chemical processing assets Speakers and participants will have the opportunity to share their work and experiences from the Oil & Gas Industries to develop best practices,

share solutions and look at new technologies.

Highlights of the event will include: • Corrosion under insulation in refineries and gas plants • Risk based inspection practicality versus reality • Life cycle costing in the Oil & Gas industries • Emerging technologies in the Oil & Gas Industries

Date: 29th August 2013 Location: The Old Brewery, 173 Mounts Bay Road, Perth

Register now at www.corrosion.com.au Time

Schedule

Speaker

8.30 – 9.00

Registration

9:00 – 9:10

Welcome and Seminar Opening

Fikry Barouky & Philip Fleming

9.10 – 9.50

Keynote Address – “Prescient Transparency” within a Diversified Oil and Gas Producer

Colin Beasley, Woodside Energy

9.50 – 10.30

Corrosion Under Insulation – Find It, Fix It & Design It Out

Frank Egan, FeAIMS

10.30 – 11.00

Morning Tea

11.00 – 11.40

A Guide to Coating Specification for the Oil & Gas Industry

Mario Blasco, Dulux Protective Coatings

11.40 – 12.20

Inspection Planning of Corrosion Under Thermal Insulation Systems

Vahid Afshari, GHD

12.20 – 13.00

Towards the Qualification of Petroleum Surfactant Corrosion Inhibitors Using Atomic Force Spectroscopy

Brian Kinsella, Strategic Chemistry

13.00 – 14.00

Lunch

14.00 – 14.40

Detecting Corrosion in Long Pipes Using Guided Wave Ultrasonics

Richard Nowak, Olympus

14.40 – 15.20

Innovations from Nanotechnology Provide New Solutions to Prevent Corrosion and CUI (Corrosion Under Insulation)

Graham Carlisle, Inovas Asset Integrity

15.20 – 15.50

Afternoon Tea

15.50 – 16.30

Design, Application and Efficacy of Vapor Phase Corrosion Inhibitors for Preservation of Above Ground Storage Tanks (ASTs): Field Report from Kingdom of Saudi Arabia

Tim Whited, Cortec Engineering & Field Service & Philip Fleming, A S Harrison & Co

16.30 – 17.00

Open Floor Speakers Forum and Discussion

Fikry Barouky & Philip Fleming

17.00 – 17.10

Seminar Close

Fikry Barouky & Philip Fleming

17.10 – 18.30

Cocktail Function

August 2013 www.corrosion.com.au p.15

NEWS

Fitness test for corrosion protection coatings Internal coatings in the different sections of oil treatment plants are subjected to a variety of stresses.

By conducting comparative tests, researchers are analysing which materials are best suited to each individual section.

The internal coatings of oil treatment plants have quite a lot to handle: aggressive chemical substances, high temperatures and pressures, as well as sand and stone particles that stick to the tank walls. Over time, this causes the steel linings to corrode, which is why the coatings of tanks, separators, and pipelines must be renewed on a regular basis. However, how long the material “holds” depends on the individual levels of stress it is exposed to. A single coating is not necessarily equally wellsuited to every application. But until now, there has been no systematic analysis of the materials available on the market. Such a comparative analysis would allow plant operators to assess a material’s suitability for different types of stress.

Researchers at the Fraunhofer Institute for Mechanics of Materials IWM in Germany are now working to close this gap. In a project sponsored by the DGMK German Society for Petroleum and Coal Science and Technology, researchers at the Institute have come up with a test program that assesses corrosion resistance in different stress scenarios. The program closely replicates real treatment conditions.

“In the different sections of the plant,

p.16 CORROSION & MATERIALS

the coating material is exposed to completely different conditions,” says Dr. Matthias Gurr of the IWM. For instance, sand or stone particles are generally present in the extracted mix in the immediate vicinity of the drilling hole. In this part of the plant, it is especially important that the coating is able to withstand the mechanical stress caused by abrasion.

However, chemical factors also put the material under stress, among them saline solutions such as the reservoir water that is pumped out of the ground with the crude oil during extraction. To effectively protect the underlying steel surface, coatings that are exposed to this solution require high chemical resistance and a good level of impermeability. “The saline solution is separated from the oil in the separator later on,” says Gurr. “For plant sections that are located downstream of the separator, resistance to the saline solution is, in most instances, not as important.”

Taking the effects of condensation into account To assess the corrosion resistance of coatings in a laboratory environment, the researchers apply a number of different tests. In the autoclave test, for instance, researchers put a material sample together with a medium – such as an oil-saline mix – in a gas-tight container and expose it to temperatures up to 150 degrees Celsius. For most materials, the critical temperature limit for heightened susceptibility to corrosion is far lower. While the test is

state of the art, not all conditions that actually occur in a treatment plant can be simulated. For instance, in containers that do not have additional insulation, thermally induced stress and the effects of condensation also have an influence on materials, as there can be stark differences in temperature between the container’s exterior and interior walls. To create such a difference in temperature in laboratory conditions, the researchers use special Atlas cells. To seal these steel pipes, material samples are pressed into their open ends. “As a result, the coating becomes part of the container wall,” says Gurr. While the medium is heated up on the inside of the cell, the researchers can use a cooling circuit to regulate the ambient temperature downward.

The experts are compiling their results in a comprehensive table.

With its help, plant operators will one day be able to find out at a single glance which materials are best suited for specific stress parameters.

The researchers aim to test coating materials under real conditions at a treatment plant, and talks are currently underway with several industry partners from the project consortium.

Gurr and his team are hoping to have the initial results in about two years.

“Correlating our lab tests with the field experiments in this way would form an important basis for concrete forecasts about the life cycle of coating systems in the future,” says Gurr.

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NEWS

ACA welcomes new members Corporate Platinum Rezitech www.rezitech.com.au Rezitech is a 100% Australian owned, private company having commenced trade in the industrial maintenance market in 1968. As sole Australian distributor for Belzona Polymerics, Rezitech offers a vast range of metal, rubber and concrete repair/protection materials to Australian industry, such as off shore oil and gas; power; sugar and petrochemical. Rezitech are also the Australian distributor for Sponge Jet low dust abrasive blasting technology. World leaders of clean, dry, low dust, reusable surface preparation media and equipment.

Corporate Gold ITW Polymers & Fluids www.itwpf.com.au ITW Polymers & Fluids is a leading Australian manufacturer of quality

branded products such as Galmet, Devcon, Rocol, Molybond and Epirez which support the industrial, consumer, mining, and construction markets. Complemented by corrosion protection solutions through to Food Grade Lubricants, ITW Polymers & Fluids has a wide range of products to suit industrial needs.

Corporate Bronze AGC Industries www.agc-ausgroup.com AGC is celebrating 25 years of operation in the oil and gas and resources sectors.

With decades of experience as a Western Australian based company, they have grown to become a leading supplier of construction services including mechanical construction, painting and insulation and fabrication. They help both large and small clients to build, maintain and upgrade some of the world’s most challenging oil & gas and mineral resource projects.

CCM Group Australia www.ccmgroupaus.com.au CCM Group is a concrete remediation, structural strengthening and industrial maintenance company with well over 50 years of combined experience in diagnosis, design and execution of remedial solutions. They specialise in the repair and protection of reinforced concrete assets in the commercial, industrial and resources sectors.

Mattioli Bros www.mattiolibros.com.au Established in 1974, Mattioli Bros is a Melbourne based company with extensive experience in the commercial and industrial protective coatings & linings painting sectors. They offer a broad range of specialty pre-treatments and coating technologies covering a spectrum of industries from food & beverage, petrochemical & mining, heavy industrial & manufacturing, automotive to pharmaceutical and chemical industries.

Individual/Student/Retired Members Name

Company/Institution

Location

Tristen Lewis

QLD

Davi Abreu

Deakin University

VIC

Andrew Martin

Meghdad Abdi

Ottoway Engineering

QLD

Sam Marden

Nathan Allen

Forgacs Engineering Pty Ltd

Newcastle

Ting Miao

VIC

Andrew Mullins

QLD VIC

Nathan Bahre Robert Callant

Melbourne Water

VIC

Sugan Naidoo

James Canty

Thomas Contracting

VIC

Al O'Brien

NSW

Clinton Pedruco-Lind

Robert Casey

Kerneos

NSW VIC

Monash University

VIC

Steffel

NZ

Glen Pendlebury

Modern Panel Works

VIC

Origin Energy

QLD

SA

Atef Cheaitani

Remedial Technology

NSW

Steven Christie

Aluminium Boats Australia

QLD

Sajee Rayaroth

QLD

Steven Ridling

VIC

Jan Skrip

Cake Commerical Services

New Zealand

Select Solutions

VIC

Jay Cumner Ravin Navneet Deo

University of South Pacific

Rachael Devine

Resene Paints

NSW

Bradley Slocum

Mike Dryden

MG Engineering

SA

Paul Smith

William (Bill) Dunn

Minecoat Plus

QLD

Stuart Smith

Agus Effendy

Select Solutions

VIC

Shaun Spohn

QLD

Ron Stephensen

Peter Eldred Angus Ferrier

New Zealand

QLD Melbourne Water

VIC

Hunter Irrigation and Water Solutions

NSW QLD

QLD

QLD

Rhys Strand

Murphy Pipe and Civil

Yiming Fu

Monash University

VIC

James Taylor

Kulin Group Contractors

WA

Anthony Goldsack

Napier Sandblasting

NZ

Riagan Trease

Pro Co

VIC

John Hannah

JCJV QCLNG

QLD

Philip Vimpani

Port of Melbourne

VIC

Philip Hart

Melbourne Water

VIC

John Watson

PQR

WA QLD

Dean Harvey

Pneumatic Contractors

New Zealand

Andrew White

Powerblasting

Callan Herron

RGH Consulting Group

NSW

Wayne Williamson

New Plymouth District Council

NZ

Geoffrey Hutcheson

NDE Technical Services Australia

QLD

Mark Wood

Direct Access Services

VIC

Stephan Iskowicz

Axiom Construction Consultants

NSW

Christopher Wylie

Nick Jaeger

John Holland Group

QLD

Jianzhong Yang

Linda Lee

CH2MHill

NSW

Jodie Yuwono

QLD SA Monash University

VIC

BRANCH & YCG EVENTS

Good Coatings Selection and Practices The ACA Tasmanian Branch held a successful event on the 20th June in Launceston where Dulux Protective Coatings gave a generic presentation aimed at architects, engineers and asset owners regarding correct coating selection.

The event attracted a strong showing with over 35 attendees which showed that there is great interest in the protection of our assets against corrosion here in Tasmania said Brendan Lichendonk of Dulux Protective Coatings who also provides an insight into the event: Daniel McKeown from Dulux Protective Coatings presented a

discussion on various coating selection issues including: orrosion Basics C Environments & Relative Corrosivity Generic Coating Types How Do Systems Work Where to go for Good Advice What a Specification Looks Like QA / 3rd Party Inspection Case Histories of Projects Problems that have been Encountered Coating Systems for Galvanized Steel Refurbishment & Maintenance of Systems References to AS2312:2002

and some usable products and the event gave attendees a valuable evening to network and also gain more knowledge in the coatings industry.

There was a mix of existing ACA members present and a proportion of prospective members also, whom we would encourage to sign up for ACA membership.

Attendees were offered a free event bag which included technical information

XXXX Brewery Tour The XXXX Brewery Tour conducted by the ACA Queensland Branch on 5th June 2013 was both insightful and enlightening said ACA member Josh Logan. The Site Visit to learn about the processes involved in producing one of Australia’s favourite beers is summarised below by Josh: It started with a stern warning about no photography on the tour and my reluctance to leave my camera behind.

A comical history video was projected onto a circular platform on the floor from which we were all then surprised to find out that beer has been around since 8000 B.C and many great building achievements throughout the past involved payment with the liquid gold.

system saves the brewery 7% on their gas bill!

The brewery always tries to automate every system in order to gain greater efficiency for producing their beer. In the past, the brewery used 10 L of water for every 1 L of beer. Now they only use 2.2 to 2.4 L of water/beer depending on the style. Total water storage at the Brewery is 20 Million litres. The pipe networks are all stainless steel and from what I observed had very little welded joints whereas the platforms and steps surrounding the brewing processes were all galvanised steel. The average pH of the beer XXXX produces is 4.2 and the pipe and tank cleaning chemicals

mainly used consist of caustic soda. Beer is filtered through a fibered filter which each cost $5,000. Each batch of beer is tested over 200 times with various techniques consisting of pH, clarity and taste testing. Where does it all come from? Barley from Tamworth, liquid sugar from Mackay and hops from Tasmania. The yeast I’m told doubles in size every 5 days and produces the CO­2 which carbonates the beer.

What is most amazing is that XXXX sponsors over 100 sporting events and the first State of Origin game was no exception. They had it on the big screen, which made the best BBQ and samples of beer go down just that bit sweeter.

We were taken outside the factory to where the gas tanks are stored for heating processes. Paul, our outstanding tour guide, pointed out that they once used coal for the heating process but that had to be replaced due to new standards and complaints about air quality in the local area. The brewery has large cooling towers that are subject to corrosion and require constant maintenance. Just past the fuel tanks there is a system that uses “Reverse Osmosis Membrane Filtration” and this produces a biogas which is fed back into the gas heating tanks. This filtration

August 2013 www.corrosion.com.au p.19

BRANCH & YCG EVENTS

Riviera Factory Tour The ACA Queensland Branch organised a factory tour of Australia’s largest luxury boat builder on Thursday 23rd May. Providing an insight into the Riviera tour is Joshua Logan who arranged the visit: The tour through the factory began where hulls are made by using a vacuum bag technique which is one of the two techniques in use at Riviera.

Fiber is laid out over the hull and resin is pumped through the vacuum bag at a constant rate for 24 hours. If there is a mistake with the temperature of the resin being too hot or too cold, the making of these hulls could cost Riviera up to $50,000.

The second technique for making the hull is the manual application of carbon fiber and Kevlar over the mould and the rolling of the epoxy resin by hand.

This technique gave off a very strong smelling chemical odour that we all agreed would be too much for us to handle for a long period. Our tour guide

Chris recommended that if we starting feeling faint, we must leave the shed immediately. Next we had a tour of the carbon fiber moulding for the boats roofs, decking and doors and finally we stopped off at the wood working section of the factory which I thought it was interesting how they only use plywood for their furnishings. Riviera also use large CNC machines to get the exact dimensions for certain tasks and Chris also mentioned that their boats have the option of using tractor driven propellers or the opposite and can result in an increase of over 35% efficiency if you get it right.

of the boats. So if you have a spare $1.8 million, why not buy one of the grandest boats in the world!

The boats are assembled in pieces with all different subsystems put together to form the final boat some 3-6 months down the track since starting the process (depending on the size). It is an outstanding factory that enables teams to work together under a strict time schedule. Electricians, plumbers, mechanics, cabinet makers and interior decorators all play a role in the making

Corrosion Forensics The second technical night in 2013 for the NSW YCG was held on Tuesday 4th of June at The Ranch Hotel, Eastwood, Sydney and attracted 28 registrations.

William Ward of PCTE gives his account of the Corrosion Forensics event: The evening began with William Ward presenting on Steel Corrosion with various case studies detailing the procedures involved in identifying the cause of corrosion. David Sunjaya presented next on the Direct Current Voltage Gradient (DCVG) technique, a method of locating and sizing coating defects on buried pipelines.

After a short break, William Ward explained the process of locating corrosion on concrete structures and Alan O’Connor concluded the evening discussing corrosion on the internal surface of a tug boat and the strategies involved in recognising the source of corrosion.

The night was a success considering there were last minute changes to the program due to unexpected circumstances with an original presenter. However attendees still

p.20 CORROSION & MATERIALS

found the event interesting with new things learnt and after the technical presentations, there were plenty of

people staying behind for a few more drinks and some catching up which was quite positive.

BRANCH & YCG EVENTS

Coatings in the Real World The historic Royal Society of Victoria building was the venue for a joint technical meeting presented by the Australasian Corrosion Association Victorian Branch and Surface Coatings Association Australia Victorian Section on 22nd May 2013. The event ‘Coatings in the Real World’ provided real insights to the 60 attendees into the real world of application of protective coatings used to protect Australia’s infrastructure.

The presenters demonstrated some of the trials and tribulations that have to be considered and overcome in the course of applying a quality protective coating systems and follows is a recollection of these presentations by Peter Dove: Justin Rigby from Commercial Industrial Painting Services shared a Challenge in Logistics on painting the Westgate Freeway Signage Gantries.

The project required a 200 metre lane closure with 750 metres of advanced warning signage and speed restrictions.

Works could only be conducted Monday to Friday during the night from 9.00pm to 5.30am. The freeway had to reopen after every shift.

Other aspects of the project involved protecting the road from damage by fuel, paint spills and foreign objects, containment of dust, working with weather restrictions while considering public asset and road closure. A breakdown of the cost of the project told a real world story with only 40% of the costs being for surface preparation and application. The remainder comprised 40% for traffic management and 10% for additional mobilization and demobilization, management and deliveries.

The Immigration Museum building which was originally used as the Melbourne’s Customs House was built in in the mid 1800’s and the existing façade dates back to the 1871-1876 period. The property is registered with the Australian Heritage Commission so any works to the parapet areas and associated building fabric could not detract from the overall cultural significance of the building.

This project involved the removal of approximately 15 to 20 layers of paint including lead based primers as well as carrying out repairs to cracked render façade. Adam Mattioli explained how Mattioli Bros undertook the challenge of working on this landmark project in Melbourne’s CBD with the Museum remaining fully operational while attracting hundreds of visitors each day.

After lead paint testing, asbestos testing, soil testing and an arborist survey to protect plants Mattioli Bros took a month establishing the scaffold, containment and waste management systems as well as ensuring protection of the general public throughout the project. The old coatings took up to several applications of paint stripper which was held in place with a paper backing. After reacting, it was manually scraped off.

After surface preparation, a breathable silicate based primer, intermediate and top coat system was applied resulting in a stunning heritage building for future generations to enjoy.

McElligott Partners then took us out of town, (way out of town!) with Michael Harrington presenting on the protective coating of the gates on the Ord River Diversion Dam near Kununurra in the

far North of Western Australia. The dam is 3,040 km from Perth, 37 km from NT and approximately 3,900 km from Melbourne.

Four full semi-trailer loads of gear from Melbourne and two of scaffold from Darwin were needed for the erection of access platforms, scaffolding and handrails, containment and dehumidification. To allow the roadway to remain fully open, barges carried all of the necessary equipment and materials for the project, including the blast pots, dust extractor, airless sprays, garnet and paint which returned to shore each day for refuelling and reprovisioning.

The containment for the removal of hazardous coal tar created a “hot house” internally with temperatures reaching 58°C. This was controlled using a refrigerated dehumidifier, to achieve a workable 28°C. After surface preparation to AS1627.4 Class Sa 2 ½, an epoxy holding primer preceded the application of a stripe coat of polyamine adduct cured epoxy to rivet heads and all edge. Then a full coat of polyamine adduct cured epoxy was applied to all surfaces. To maintain the aesthetics of the project a coat of two pack polyurethane was applied to downstream surfaces.

One concern that McElligotts had to cope with which that no one in the audience expected, was an “in house” 6 metre salt water crocodile.

The presentations from these PCCP accredited applicators demonstrate the diversity of projects they undertake and our thanks go to the sponsors for the event; Dulux, International and Jotun.

August 2013 www.corrosion.com.au p.21

BRANCH & YCG EVENTS

ACA Auckland June Meeting Report The Auckland Division annual midyear dinner meeting was held at The Landing Hotel on June 19th with guest speaker Liz Yuda, a Director of Artifacts Conservation Ltd. Liz has been involved with artefact conservation in Auckland for the past 20 years working mainly for museums and City Councils on key heritage projects. The presentation was entitled “Ashes to Ashes – Rust to Rust”, in which Liz gave an account of remediation work on weathering, corrosion and vandalism of 150 yearold graves and headstones in the Heritage-registered Symonds Street Cemetery situated in Grafton Gully, Auckland.

NZ Branch President, Les Boulton provides a summarised version of Liz’s presentation: The Symonds St Cemetery was established at Grafton Gully about 1840 on the then fringe of the new town of Auckland by the English colonists. Governor William Hobson, the first Governor of NZ, was interred here in 1842 along with many early settlers of all religions. The cemetery was declared to be full in 1886, but a few family burials continued until about 1950. During the period 1907-1910 the largest steel reinforced concrete bridge in the world (at that time) was built right over the top of the cemetery across Grafton Gully. The heritage-listed and refurbished Grafton Bridge is still in service today.

The six hectares of Symonds St Cemetery were neglected for many

years until Auckland Council established a Cemetery Management Division in 1983 and restoration work commenced. The work involved maintenance and repair to the many of the old graves and headstones. Liz has supervised much of the conservation work in the cemetery over the last seven years. After years of neglect and vandalism, restoration involves repairs to: old headstones with embedded lead lettering; weathered limestone and marble; cast iron and wrought iron grave fences; flooding and storm damage, along with general tidying up work. Some old headstones (granite, marble, limestone) that have fallen are reinstated by stone masons using stainless steel rods embedded into the headstone and matching plinth sealed with epoxy resin. About 12 damaged graves and weathered headstones are reinstated every month by a team of Council workers.

Auckland City has a management plan in place for Symonds St Cemetery with grave mapping being a high priority,

Governor William Hobson’s grave (1792-1842) at Symonds St Cemetery . carried out by the Auckland Historical Society. Presently controlling corrosion on cast iron and wrought iron structures around graves is not a priority. The management plan is to do the work required to stabilise the plots and gravestones but do no more than necessary in order to maintain the cemetery in its original state. As a Heritage Site the Symonds St Cemetery is now a valued historical place which is pleasant to walk through and make an acquaintance with Auckland City’s colonist forbears.

After an extensive discussion session, Chair Wayne Thomson thanked Liz for her fascinating presentation and a number of the attendees stayed for fellowship and dinner with Liz Yuda in The Landing Restaurant.

Liz Yuda (front) with ACA members at The Landing.

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p.22 CORROSION & MATERIALS

BRANCH & YCG EVENTS

Pipeline Corrosion including Research Update & Remote Monitoring The 19th June ACA Victoria Branch event was held at the Geebung Hotel in Hawthorn with a capacity crowd of over 40 people. Victoria Branch Committee Member Richard Brodribb of M. Brodribb Pty Ltd provides an insight into the presentations provided on the night: Mike Tan presented first, discussing on Current Issues in Energy Pipeline Research. Mike gave an overview of the EPCRS Research Program 2, which is research aimed at the Extension of Safe Operating Life of New and Existing pipelines. Mike discussed the campuses where research is carried out, which include Wollongong University, Deakin at Geelong and Burwood and University of Adelaide.

Mike then discussed researchers carrying out work at Deakin, Maria Forsyth, Peter Hodgson, Bruce Hinton and Mike Tan himself and followed this with a detailed discussion of the causes of corrosion and loss of durability in pipelines. Mike explained how RP2 was targeting these issues and listed the 9 major areas of the research projects. Mike then discussed industry involvement in research and showed some corrosion industry notables in odd positions investigating pipe defects. Mike concluded by summarising the value that EPCRC provides to Industry, Public and Commonwealth and showed the RP2 projects and research work carried out at Deakin University.

The second presentation was on the Aegis DataCell CP monitoring system, discussing its design philosophy, the logger itself and field results and case studies. This presentation was given jointly by Alireza Kouklan from Select Solutions (a division of Singapore Power), Steve Watt from Aegis and Max Fraser, from Select Solutions.

Ali discussed how Select Solutions had chosen the Aegis monitor from an investigation of the market and from field trials and now had 23 Aegis dataloggers installed. Steve presented the next section, showing the system components of the logger and the specific monitor features designed for cathodic protection applications.

Steve then discussed how the logger

provides alarms and data back to the user and showed how a web browser interface could be used to extract useful data. Max concluded with examples of installations in cable pits, direct outdoor mounting, complete integrated test points and even what appeared to be some species of transformer rectifier. Max showed data gathered from sites around Victoria and concluded with a summary of the challenges overcome and features implemented in this system.

The evening concluded with lively discussion and the event’s sponsor M.Brodribb Pty Ltd was formally thanked.

WA Branch July Meeting On Thursday 18th July 2013 at The Atrium Theatrette in Perth, Ted Riding of Jotun presented on ‘The Challenges in Developing and Delivering New Technology’ at the WA Branch July meeting.

Ted mentioned how historically the development of new protective coating technology was a simple matter of utilising available polymer and pigment systems that were known to be effective

in mitigating corrosion. However, Ted continued that today there are many regulatory and pre-qualified performance requirements that impact on the selection of suitable materials.

Ted’s presentation then discussed some of the past technologies that have now been deemed inappropriate as well as the current controls applied to coatings that are able to be used in the global market.

August 2013 www.corrosion.com.au p.23

BRANCH & YCG EVENTS

Field Joint Coating systems The ACA Western Australia Branch hosted another technical event with an international guest speaker on Thursday 16th May 2013.

International Guest Speaker David Bell of PIH (United Kingdom) started his presentation with a look at the history of pipelines, including an original video (courtesy of YouTube) describing the development of the PLUTO Pipeline, built across the English Channel to supply fuel to allied forces during the Second World War.

welded joint area. The benefits in the use of automated equipment for the application of a range of field joint coatings were highlighted, both for onshore and offshore pipelines.

The presentation concluded with a case study in the application of MCL Epoxy field joint coatings, to large diameter onshore pipelines, by the use

of automated, rotating, on-pipe spray machines and a video taken at site.

David represented PIH Ltd, based in the UK who is a field joint coating contractor, specialising in the use of automated equipment for the installation of field joint coating systems.

Vahid Afshari of GHD gives a description of the presentation: The presentation summarised the different factory applied pipe coating systems and compatible field joint coating systems that are used today.

Application of field joint coating systems was the main theme of the presentation, outlining the importance of repeatable quality to each and every

YCG Victoria Site Visit to ETP The YCG Victoria Committee arranged a Site Visit on the 4th of June 2013 at Melbourne Water’s Eastern Treatment Plant in Bangholme. Candice Blackney of Melbourne Water gives an account of the site visit: 15 eager youths attended the tour which ran from 8:30am to 11:00am. In this time, attendees were shown around the sewage treatment plant by following the flow of sewage from the influent

p.24  CORROSION & MATERIALS

pumping station where everything gets pumped in, to grit and screenings, then onto primary treatment, briefly passing aeration and sedimentation tanks. With a short stop at the tertiary treatment upgrade, attendees then moved to the south eastern outfall pipe where the treated water is pumped out. Additional stops were provided along the way to the interconnecting tunnels that run under the whole plant as well as the odour control plant.

At each stop Yvonne Earnshaw, a Melbourne Water Educational Officer explained the process and purpose behind the infrastructure. Then Ulf Kreher, Senior Materials Technologist at Aurecon and Robert Callant, Project Coordinator at Melbourne Water followed up with an in depth explanation of the corrosion problems and mitigation techniques specific to that part of the plant.

BRANCH & YCG EVENTS

Industrial Tour at Samaras Group, Port Adelaide On Tuesday the 2nd July the ACA South Australian Branch had the privilege of touring the Samaras Group complex at their main headquarters in Port Adelaide.

are able take steel, make fabricated sections, prepare the surface and apply protection coatings all in the same facility on the same day ensuring the best possible protection for the customer.

On behalf of the ACA South Australian Branch a big thank you to both Darryl Secomb (Surface Treatment Manager ) and George Samaras (Quality Control Manager ) for sharing their knowledge and time for this tour.

SA Branch committee member Neville Smith provides a summary of the tour: The tour started in the fabrication area where the steel for the new foot bridge across the Torrens River (from the Festival Centre to the Adelaide Oval) was being fabricated.

Neville Smith says the Samaras Group is a very well equipped company, not only in the design, fabrication and construction but also in application of the protective coatings. They have grit blasting facilities with an extremely large booth but also a state the art spot peening machine. Samaras

Auckland Division July Meeting Report ACA NZ Auckland Division held a joint meeting with SCANZ in July which was well attended and addressed by an overseas speaker from Axalata Coating Systems (formerly DuPont Performance Coatings) based in Switzerland. Marcel Melis is a polymer scientist and he is the Axalata Sales Manager (Europe & MEA) specialising in the range of Abcite thermoplastic powder coatings. Marcel’s presentation was entitled “Thermoplastic Coatings for Corrosion Protection – one coating for a lifetime solution” and the meeting was sponsored by Dulux Powder & Industrial Coatings in Auckland. Below is a recap of the event from Les Boulton: The presentation commenced with an outline of the Abcite thermoplastic coating technology which has been successfully utilised in Europe on steel power poles for the past 17 years. The Abcite powder coating range has been developed specifically for enhanced long term corrosion protection, high impact strength and its good weathering

properties. The Kulourthene series Abcite powder coatings have been tested to ISO Standards. During application onto metal surfaces the thermoplastic powder melts and flows to form a very hard, flexible and impervious coating which gives long term corrosion protection to the substrates.

Marcel then described various applications of Abcite coatings, such as street and garden furniture, fencing and balustrading, in the water industries, in the marine industry including dredge boat piping, for battery boxes on electric fork lifts, and in many other industrial applications above ground and underground. He emphasised that powder coatings can only be applied in the factory and if maintenance was required in the field then the repairs have to be carried out with liquid-applied paint coatings. After the extensive Q&A session that followed, Marcel was thanked for his interesting talk by the ACA Auckland Chairman Wayne Thomson.

A large audience was present at The Landing to hear Marcel Melis speak.

Marcel continues the discussion with attendees after the meeting concluded.

August 2013 www.corrosion.com.au p.25

ACA STANDARDS UPDATE

ACA Standards Update This is the fourth corrosion related standards report for 2013 prepared by ACA Standards Officer, Arthur Austin.

This Issue is for the Cathodic Protection Technical Group.

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 ACA technical Groups, with this editions group focus being the “Cathodic Protection” Technical Group.

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 21 May 2013 to 24 July 2013, using the key words and key word groups:

‘durability’. ‘ corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’. ‘ paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’. ‘ galvanize’ or ‘galvanized’ or galvanizing’. ‘ electrochemical’ or ‘electrolysis’ or ‘electroplated’. ‘cathode’ or ‘cathodic’. ‘anode’ or ‘anodic’.

Summary 1. T hrough SAIGLOBAL Publications at https://infostore.saiglobal.com/store there were 362 Titles for search on “Cathodic”, with 8 from AS/ASNZS; as shown in Table 1 below.

2. A cross SAIGLOBAL online Standards Publications there was a total of 36 listings of new standards, Drafts and Amendments, found issued from to 21 May 2013 to 24 July 2013; with 0 from AS/ASNZS; as shown in Table 2 below.

A copy of this report can be downloaded from the ACA’s website www.corrosion.com.au

‘ corrosion’ and ‘concrete’ or ‘concrete’ and ‘coatings’.

Stage 1 Report on SAIGLOBAL Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “Cathodic Protection” for the Cathodic Protection Technical Group.

Table 1. Title search by publisher with keywords ‘Cathodic’ – 362 publications found A total of 362 Publications were found with 8 references to AS, AS/NZS publications..

Results by publisher Italian Standards

27

Association Francaise de Normalisation

23

NACE International

23

British Standards Institution

21

German Institute for Standardisation (Deutsches Institut für Normung)

21

Nederlands Normalisatie Instituut

20

Comite Europeen de Normalisation

19

Osterreichisches Normungsinstitut

19

Polish Committee for Standardization

18

National Standards Authority of Ireland

17

Standardiserings-Kommissionen I Sverige

16

Asociacion Espanola de Normalizacion

15

Belgian Standards

15

Norwegian Standards (Norges Standardiseringsforbund)

15

Swiss Standards

15

International Organization for Standardization

11

Standardization Administration of China

8

Standards Australia

8

Bundesamt F. Wehrtechnik unk

7

Bureau of Indian Standard

6

US Military Specs/Standards/Handbooks

5

Brazilian Standards

4

Korean Standards Association

4

p.26 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Wirtschafts und Verlagsgesellschaft Gas und Wasser

4

Det Norsk Veritas

3

South African Bureau of Standards

3

American Petroleum Institute

2

American Society for Testing and Materials

2

American Water Works Association

2

Norsk Sokkels Konkuranseposisjon

2

American Association of State Highway and Transportation Officials

1

Anstat Legislation

1

Energy Networks Association (UK)

1

International Telecommunications Union

1

Japanese Standards Association

1

UK Ministry of Defence standards

1

Underwriters Laboratories

1

Results by subject - Metallurgy – 259 results Corrosion of metals

241

Iron and steel products

13

Non-ferrous metals

3

Products of non-ferrous metals

1

Testing of metals

1

Results by subject - Fluid systems and components for general use – 86 results Pipeline components and pipelines

67

Fluid storage devices

19

Results by subject - Shipbuilding and marine structures – 66 results Shipbuilding and marine structures in general

66

Results by subject - Manufacturing engineering – 55 results Surface treatment and coating

54

Industrial automation systems

1

Results by subject - Petroleum and related technologies – 22 results Petroleum products and natural gas handling equipment

17

Equipment for petroleum and natural gas industries

5

Results by subject - Civil engineering – 21 results Construction of waterways, ports and dykes

11

Earthworks. Excavations. Foundation construction. Underground works

10

Results by subject - Construction materials and building – 9 results Structures of buildings

7

Installations in buildings

2

Results by subject - Generalities. Terminology. Standardization. Documentation – 2 results Graphical symbols

1

Vocabularies

1

Results by subject - Electronics – 1 results Semiconductor devices

1

Results by subject - Energy and heat transfer engineering – 1 results Hydraulic energy engineering

1

Results by subject - Metrology and measurement. Physical phenomena – 1 results Electricity. Magnetism. Electrical and magnetic measurements

1

Results by subject - Services. Company organization, management and quality. Administration. Transport. Sociology – 1 results Law. Administration

1

August 2013 www.corrosion.com.au p.27

ACA STANDARDS UPDATE

Results by Publication AS 2239-2003

Galvanic (sacrificial) anodes for cathodic protection

AS 2832.1-2004

Cathodic protection of metals - Pipes and cables

AS 2832.2-2003

Cathodic protection of metals - Compact buried structures

AS 2832.3-2005

Cathodic protection of metals - Fixed immersed structures

AS 2832.4-2006

Cathodic protection of metals - Internal surfaces

AS 2832.5-2008

Cathodic protection of metals - Steel in concrete structures

AS 4832-2007

Cathodic protection - Installation of galvanic sacrificial anodes in soil

RUL ML.1-2008

Rulings to metal Standards - Cathodic protection interference levels - Ruling to AS 2832.1-2004

NS EN 12068 Ed. 1 (1999)

Cathodic Protection - External Organic Coatings For The Corrosion Protection Of Buried Or Immersed Steel Pipelines Used In Conjunction With Cathodic Protection - Tapes And Shrinkable Materials

PN EN 15257:2008

Cathodic Protection - Competence Levels And Certification Of Cathodic Protection Personnel

PN EN 12068:2002

Cathodic Protection - External Organic Coatings For The Corrosion Protection Of Buried Or Immersed Steel Pipelines Used In Conjunction With Cathodic Protection - Tapes And Shrinkable Materials

NF EN ISO 12696:2012

Cathodic Protection Of Steel In Concrete

PREN ISO 13174:2010

Cathodic Protection Of Harbour Installations

ONORM EN 13174:2001

Cathodic Protection For Harbour Installations

NF EN 14505:2005

Cathodic Protection Of Complex Structures

EN 16222:2012

Cathodic Protection Of Ship Hulls

NBN EN 16222:2012

Cathodic Protection Of Ship Hulls

SN EN 16222:2012

Cathodic Protection Of Ship Hulls

BS EN 16222:2012

Cathodic protection of ship hulls

XP A05 674:2007

Cathodic Protection - Cathodic Protection Of The Underwater Parts Of Ships/vessels

NACE 01102:2002

State-of-the-art Report: Criteria For Cathodic Protection Of Prestressed Concrete Structures

Table 2. Corrosion related standards for as, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and standards and amendments for ISO & IEC published from 21 may 2013 to 24 july 2013 for: Key word search on ‘durability’.- 2 citations found related to corrosion, none from AS, AS/NZS UNE 83993-1:2013

Durability Of Concrete - Test Method - Measurement Of Carbonation Penetration Rate In Hardened Concrete - Part 1: Natural Method

UNE 83993-2:2013

Durability Of Concrete - Test Method - Measurement Of Carbonation Penetration Rate In Hardened Concrete - Part 2: Accelerated Method

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 1 citation in all – none from AS, AS/NZS UNE EN 626971:2013

Test Methods For Quantitative Determination Of Corrosive Sulfur Compounds In Unused And Used Insulating Liquids - Part 1: Test Method For Quantitative Determination Of Dibenzyldisulfide (Dbds)

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 19 corrosion related Publications found; None from AS, AS/NZS; ISO/FDIS 16474-1

Paints and varnishes - Methods of exposure to laboratory light sources - Part 1: General guidance

ISO/FDIS 16474-2

Paints and varnishes - Methods of exposure to laboratory light sources - Part 2: Xenon-arc lamps

ISO/FDIS 16474-3

Paints and varnishes - Methods of exposure to laboratory light sources - Part 3: Fluorescent UV lamps

ISO/FDIS 16474-4

Paints and varnishes - Methods of exposure to laboratory light sources - Part 4: Open-flame carbon-arc lamps

DIN EN ISO 1524 (2013-06)

Paints, varnishes and printing inks - Determination of fineness of grind (ISO 1524:2013)

UNE EN ISO 32331:2013

Paints And Varnishes - Determination Of The Percentage Volume Of Non-Volatile Matter - Part 1: Method Using A Coated Test Panel To Determine Non-Volatile Matter And To Determine Dry Film Density By The Archimedes Principle (Iso 3233-1:2013)

p.28 CORROSION & MATERIALS

ACA STANDARDS UPDATE

TT P 645 Revision C

Paint, Alkyd Type, Formula Number 84 - Revision C

UNE EN ISO 118902:2013

Paints And Varnishes - Determination Of Volatile Organic Compound (Voc) Content - Part 2: GasChromatographic Method (Iso 11890-2:2013)

13/30263194 DC Bs En 16623

Paints And Varnishes - Reactive Coatings For Fire Protection Of Metallic Substrates - Definitions, Requirements, Characteristics And Marking

UNE EN ISO 1524:2013

Paints, Varnishes And Printing Inks - Determination Of Fineness Of Grind (Iso 1524:2013)

BS EN 927-1:2013

Paints And Varnishes - Coating Materials And Coating Systems For Exterior Wood - Part 1: Classification And Selection

FORD WSS M2P195 A:2013

Engineering Material Specification - Interior Parts Painter Approval Process

ISO/DIS 16145-5

Ships and marine technology - Protective coatings and inspection method - Part 5: Assessment method for coating damages

I.S. EN 13603:2013

Copper and Copper Alloys - Test Methods for Assessing Protective tin Coatings on Drawn Round Copper Wire for Electrical Purposes

AWWA C209:2013

Cold-Applied Tape Coatings For Steel Water Pipe, Special Sections, Connections, And Fittings

13/30271594 DC Bs Iso 16145-5

Ships And Marine Technology - Protective Coatings And Inspection Method - Part 5: Assessment Method For Coating Damages

BS EN 13603:2013

Copper And Copper Alloys - Test Methods For Assessing Protective Tin Coatings On Drawn Round Copper Wire For Electrical Purposes

QPL 19565 Revision May 2013

Qualified Product List Of Products Qualified Under Performance Specification - Mil-Prf-19565 - Coating Compounds, Thermal Insulation, Fire, And Water-Resistant, Vapor-Barrier - Revision May 2013

BS EN ISO 9717:2013

Metallic And Other Inorganic Coatings - Phosphate Conversion Coating Of Metals

Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ – 3 Standard Publications found - none from AS, AS/NZS. I.S. EN 12496:2013

Galvanic Anodes for Cathodic Protection in Seawater and Saline mud

MIL DTL 32266:2008 Notice 1 Validation

Wire Rope, 1.5 Inch Diameter, Galvanized, Compacted Strand, For Aircraft Elevator - Notice 1 Validation

BS EN 12496:2013

Galvanic Anodes For Cathodic Protection In Seawater And Saline Mud

Key word search on 'corrosion' with examination for concrete related standards - 4 Standard Publications found, none from AS, AS/NZS. DIN EN 1504-5 (2013-06)

Products and systems for the protection and repair of concrete structures - Definitions, requirements, quality control and evaluation of conformity - Part 5: Concrete injection

UNE 83993-2:2013

Durability Of Concrete - Test Method - Measurement Of Carbonation Penetration Rate In Hardened Concrete - Part 2: Accelerated Method

BS 1881-210:2013

Testing Hardened Concrete - Part 210: Determination Of The Potential Carbonation Resistance Of Concrete Accelerated Carbonation Method

UNE 83993-1:2013

Durability Of Concrete - Test Method - Measurement Of Carbonation Penetration Rate In Hardened Concrete - Part 1: Natural Method

Key word search on ‘cathode’ or 'cathodic' - 4 corrosion related Standard Publications found; none from AS, AS/NZS I.S. EN 12496:2013

Galvanic Anodes for Cathodic Protection in Seawater and Saline mud

DIN EN 16299 (2013-06)

Cathodic protection of external surfaces of above ground storage tank bases in contact with soil or foundations

UNE EN 16222:2013

Cathodic Protection Of Ship Hulls

BS EN 12496:2013

Galvanic Anodes For Cathodic Protection In Seawater And Saline Mud

Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 2 Standard Publications found – None from AS, AS/NZS I.S. EN 12496:2013

Galvanic Anodes for Cathodic Protection in Seawater and Saline mud

BS EN 12496:2013

Galvanic Anodes For Cathodic Protection In Seawater And Saline Mud

Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 Standard Publications found Keyword Search on 'anodize' or ‘anodized’ - 1 Publications found - none from AS, AS/NZS. FORD WSS M4P13 B:2013

Engineering Material Specification - Anodized Aluminum Performance, Bright/Colored Interior Trim

August 2013 www.corrosion.com.au p.29

NEW PRODUCT SHOWCASE

SHOWCASE Epigen 1311 Ultra

Epigen 1311 Ultra = rebuilding Hydrogen Sulphide damage concrete quickly.

Dating back to the mid 1970’s, there is no doubting the Epigen 1311 track record in protecting assets, be they steel or concrete from the harsh effects of corrosion. Sewers, waste water or severe marine environments; it has stood the test of time.

Badly corroded concrete has application in over 10mm thick spray applied – protection installed, concrete preserved.

Minor tweaking allows Epigen to announce the 1311 Ultra which is able to be applied in one coat, without complex plural systems and without heated lines making it more versatile in treating badly damaged assets. With the Epigen 1311 Ultra, an easy refurbishment has emerged.

Nick Subotsch, Technical Director

For further information, please contact:

Peerless Industrial Systems HP +61 (0)408 949 368 FAX +61 (0)3 9553 1286 www.peerlessindustrialsystems.com

Olympus 45MG Thickness Gauge Simple, rugged, and reliable thickness gauge from Olympus.

An innovative, all-in-one solution that is suitable for virtually every thickness gauge application is now available from Olympus, a world-leading manufacturer of optical, electronic and precision engineering products.

The 45MG is an advanced ultrasonic thickness gauge packed with standard measurement features and software options that is compatible with the complete range of Olympus thickness gauge transducers.

Olympus 45 MG Thickness Gauge.

p.30 CORROSION & MATERIALS

According to Graham Maxwell, National Technical & Key Account Manager at Olympus, the 45MG is designed for easy operation via a simple keypad that can be used by

both right- or left-handed technicians and has a rugged, sealed construction meeting the IP67 standard, which has also been shock and vibration tested using MIL-STD-810G. For further information contact: Australia www.olympus-ims.com Dorthe Svarrer, Sales & Marketing Coordinator Industrial Business Division Telephone: +61 (03) 9265 5467 E-Mail: IBDinfo@olympus.com.au New Zealand www.olympus.co.nz Faizal Sahib Ph (+64) 9 836 9993 E-Mail: info@olympus.co.nz

NEW PRODUCT SHOWCASE

SHOWCASE Elcometer 130 Salt Contamination Meter Phillro are pleased to announce the launch of the new Elcometer 130 Salt Contamination Meter.

Available in two versions, Model S & T, the new Elcometer 130 offers significant features and functionality.

Features include: Automatic temperature compensation function

The new Elcometer 130 Salt Contamination Meter.

ompatible with ElcoMaster™ 2.0 C and ElcoMaster™ for Android™ alibration offset function - corrects C the reading value when non-pure water is used for testing old-plated measurement electrodes G to protect against oxidisation and corrosion from salt solutions.

Automatic paper size detection

For further information, please contact:

emory capacity of up to 150,000 M readings in 2,500 batches

www.phillro.com.au Phone: 1300 503 610

CAA Revamped Website & Product Guide Cathodic Anodes Australasia

ZINC ALLOY ANODES

ZINC ALLOY ANODES www.cathodicanodes.com.au

Galvanic anodes the comPlete Guide

Cathodic Anodes Australasia

Keeping MAnUFACTURing jobs in Australia

CAA catalogue 21 MAY 2013 ReViSeD pReSS.indd 1

21/05/13 2:38 pM

Following their recent change of name from Cathodic Diecasting to Cathodic Anodes Australasia (CAA) to better reflect the business focus, CAA are now pleased to announce the launch of their revamped website (www.cathodicanodes.com.au) and Product Guide.

(over 600 anode types) in both online and print format. Both versions offer clear and concise information in an easy to search format. Please visit the website or contact CAA if you would like a copy, or to discuss your corrosion protection needs.

CAA are proud to be able to present such an extensive range of products

Telephone +61 7 5476 9788 Email sales@cathodicanodes.com.au

The new CAA website and Product Guide.

Sonatest Thickness Gauges with Waveform Sonatest Ltd has released new models in their line of ultrasonic thickness gauges. Their range now includes the new Sonagage IV, T-Gage V, Microgage III and Steelgage II (unchanged).

The Sonatest The Microgage III.

The Microgage III is ideal for precision applications which require greater accuracy & capability.

The Microgage III is available in 7 different configurations including basic, datalogging, with & without waveform in colour or monochrome.

All of Sonatest’s gauges weigh only 230 g & have a battery life of up to 200 hours. They come with a limited 2 year warranty, couplant & carry case as standard.

Russell Fraser Sales stocks these gauges and with so many options, it’s easy to get confused, but the team at Russell Fraser Sales is prepared to help you choose the right gauge for your application. Contact Russell Fraser Sales, Tel: (02) 9545 4433 or Email: rfs@rfsales.com.au

August 2013 www.corrosion.com.au p.31

PLENARY SPEAKER ABSTRACTS

Major Sponsor:

Proudly Presented by:

The Corrosion & Prevention 2013 technical committee has reviewed and accepted 110 abstracts of which have been allocated either as an oral or poster presentation. All abstracts can be viewed at www.acaconference.com.au and below are the abstracts for the conference plenary speakers.

Corrosion & Prevention 2013 Plenary Speaker Abstracts Arthur Austin ALS Industrial Pty Ltd Australia Where Theory Meets Practice; some Demonstrations and Case Histories This ACA Conference 2013 PF Thompson memorial lecture is presented to honor both Percival Faraday Thompson (1886-1951) and the first presenter of the PF Thompson lecture, Dr Edmund C Potter (-2005). Both Percival and Edmund excelled in practical demonstrations of corrosion; Edmund’s corrosion clock is a continuing reminder at every conference. We will look back on PF Thomson and Ed Potter and experimentally examine some typical forms of corrosion including, uniform attack, galvanic corrosion, stress corrosion cracking and oxidation. We will also show some case histories showing examples of where theory and practice have conflicted.

Fikry Barouky Anti Corrosion Technology Pty Ltd Australia Sustainable Corrosion Management Program is the Tool to Maintain Pipeline Integrity and Reliability in Oil & Gas Industries In major oil & gas operating companies, Pipeline is considered as the “Artery” of the operational processes. Understanding differences in the processes, equipment, human resources competencies, and the overhaul strategies are the main parameters to help the asset owner to identify critical equipment, damage mechanisms, and

p.32 CORROSION & MATERIALS

key performance indicators to develop a comprehensive Plant Integrity & Assessment Framework (PIAF) throughout the service life expectancy.

Corrosion Management Program (CMP) is an essential tool in PIAF, which helps in achieving a reliable performance within the overall asset integrity framework. CMP objective is to set a sustainable methodology of material selection and corrosion control from the design to decommission of the asset life conforming to PIAF needs.

This paper focuses on how corrosion specialists can develop CMP for a specific operating condition with interactive flowcharts and guidelines to; 1) identify the operational gaps, 2) define inspection and monitoring levels and intervals, and 3) feedback findings into a loop for improvement where the Excellence model can be adapted to enhance the pipeline integrity, introduce new technologies and innovative solutions.

The success of the CMP is achieved through a systematic and structured awareness program to help the asset owners understanding the basic goals, roles, responsibilities, and the benefits of applying CMP. CMP implementation starts from a pilot pipeline, and gradually includes all pipeline networks subject to budget planning and conclusive performance review.

Graeme George Queensland University of Technology Australia Sensitive Methods for Studying the Environmental Performance of Protective Coatings The safe working lifetime of a structure in a corrosive or other harsh environment is not limited

by the material itself but rather by the integrity of the coating material. Advanced surface coatings are usually crosslinked organic polymers such as epoxies and polyurethanes which must not shrink, crack or degrade when exposed to environmental extremes.

While standard test methods for environmental durability of coatings have been devised, the tests are more towards the end of life rather than in anticipation of degradation. We have been developing prognostic tools to anticipate coating failure by using a fundamental understanding of their degradation behaviour which, depending on the polymer structure, is mediated through hydrolytic or oxidation processes. The useful lifetime of a polymer does not extend much beyond the end of the oxidation induction period (which is controlled by sacrificial stabilizers added to the coating) so lifetime determination requires the most sensitive methods for studying the incipient degradation at the shortest times where the rate of oxidation approaches zero.

Fourier transform infrared spectroscopy (FTIR) is a widelyused laboratory technique for the analysis of polymer degradation and with the development of portable FTIR spectrometers, new opportunities have arisen to measure polymer degradation in the field. We have been investigating the use of fielddeployable reflectance FTIR for the non-destructive real-time analysis of paint degradation.

For reflectance sampling, both diffuse (scattered) and specular (direct) reflections can occur. For matte paints reflectance spectra can show a mixture of diffuse and specular features, which may change during weathering. The complexity in these spectra has

PLENARY SPEAKER ABSTRACTS

provided interesting opportunities to study surface physical changes during paint weathering, but has required the use of advanced statistical analysis methods such as chemometrics to follow surface chemical changes. Results from our studies using this and related techniques and the technical challenges that have arisen will be presented.

Srdjan Nesic Ohio University USA Multiphase Flow Effects on Internal CO2 Corrosion of Mild Steel Pipelines The key effects of multiphase flow on CO2 corrosion of mild steel pipelines are covered. The significance of mass transfer in turbulent flow is discussed first. The mechanical interaction of the flow with the pipe walls is covered next, as the wall shear stress is often blamed for removal of protective surface layers, such as iron carbonate or inhibitor films. Using macroscopic as well as atomic scale measurements [atomic force microscopy (AFM)], it was found that it is very unlikely that truly protective surface layers can be removed by shear forces alone.

The other multiphase flow effects on corrosion, such as the effect of condensation on the top of the line corrosion (TLC) in wet gas pipelines, the effect of water settling and wetting in oil-carrying lines, and the effects of sand on erosion−corrosion and underdeposit corrosion in production pipelines, are outlined at the end.

Jack Tinnea Tinnea & Associates, LLC USA Corrosion Testing in Concrete: Better Have More Than One Arrow in Your Quiver Corrosion is an electrochemical process that occurs at the surface of a metal exposed to a surrounding electrolyte. The surrounding electrolyte can be a thin film of moisture from rain or dew as occurs with atmospheric corrosion.

The electrolyte can be the Pacific

Ocean, where pier pilings in Brisbane and in Juneau, Alaska are exposed. An electrolyte can also be soil and even concrete. Within a common electrolyte, local variations can impact the corrosion rate. A pier piling in Brisbane is exposed to warmer water than a pier piling in Juneau, Alaska. Although the warmer water in Brisbane will accelerate the corrosion, the pile in Juneau is exposed to tides almost three times those in Brisbane which accelerate corrosion. When trying to conduct corrosion rate testing it is good practice to directly measure metal loss or have coupons installed that allow measurements that can be converted into corrosion rates.

With existing reinforced concrete structures, absent spalls, direct inspection of the embedded steel is destructive. When performing electrochemical tests it is helpful to be able to separate the anode from the cathode (i.e., working electrode and counter electrode), minimize IR drop error (i.e., instant off readings, or Luggin bridges), and minimize reactant transport impediments (i.e., bubbling oxygen and stirring the surrounding solution). In concrete bubbling oxygen, stirring the solution, using Luggin bridges, and even instant off readings are typically not possible.

This paper will discuss the significant impediments concrete presents to corrosion testing and how different techniques can avoid some of these problems. Further examples will be provided on how employing multiple techniques can improve the aggregate accuracy of a survey. It will also discuss that within a single structure you may have conditions that are as different as Brisbane and Juneau pilings that are exposed to the same ocean.

repair is completed and then dissolve without leaving harmful byproducts. The dissolution of biodegradable metals is based on corrosion in the human body.

Implant corrosion should be usually prevented when designing permanent metallic implants like joint prosthesis (hip, knee) or pace makers. In this sense, biodegradable metals are changing the current paradigm to avoid implant corrosion. However, the intended use of biodegradable metals in humans is different from permanent implants. They will be just implanted where a temporary support is needed, thus avoiding a removal operation.

Biodegradable metals consist mainly of essential and trace elements of the human body, thus the implants and byproducts provide a high biocompatible capacity. Even though first implants have proven the concept in 19th century, first implants are now about to receive clearance of regulatory agencies. The main challenges are predictable, controlled corrosion behavior in a dynamically changing environment. Even more challenging is that the implants are placed into a disturbed human physiological environment, since implants are usually placed during operations and/or after accidental tissue destruction. However, there are several empirical ways to control corrosion in-vivo but the basic concepts of biodegradable metals corrosion are still not fully uncovered.

Frank Witte Charité Universitätsmedizin Berlin Germany

Early Bird Registrations

In this lecture, the past and current approaches to biodegradable metals, especially based on magnesium alloys and current basic concepts of corrosion in-vivo and invitro will be discussed.

Register now for the discounted early bird registration rate by 30th August at www.acaconference.com.au

Biodegradable Metals: The Healthy Aspect of Implant Corrosion Biodegradable metals are temporary biomaterials which are intended to support the healing tissue until the regeneration or

August 2013 www.corrosion.com.au p.33

MEET THE…ACA SECRETARIES

Meet the: Newcastle Please provide your Name, Company, Job Title Karen Swain, ALS Industrial - Power Services, Senior Metallurgist Tell us about your day to day employment and how it relates to corrosion prevention ALS Industrial Power Services specialise in metallurgy/engineering, NDT and pressure vessel/risk based inspection primarily for the Energy Sector as well as general industry.

At the moment I am working on pressure vessel and tank risk based inspection strategies for a chemical plant. Corrosion related mechanisms account for a significant proportion of vessel issues, so mitigating these and predicating possible corrosion scenarios forms a large part of my average day. Investigating plant failures and applying the appropriate

Victoria

inspection regimes to monitor corrosion is paramount to ensuring vessel availability and safety. After 20 years as a metallurgist, I’d like to experience a day of boredom – just to know what it feels like!

How long have you been volunteering for the ACA? I have been involved with the ACA for 4 years – this is my third year as secretary of the Newcastle Branch.

I started regularly attending a few local functions when I changed jobs, enjoying the social aspects of the evenings as much as the networking and then moved on to join the committee.

How does your involvement with the ACA help you achieve your own personal and professional goals?

Our membership base is spread across many industry sectors from academic research to those practicing in the field, so the ACA is provides a forum to speak personally with people involved with all aspect of corrosion. Our events are a

Please provide your Name, Company, Job Title

basis to coatings manufacturers ie: Peerless Industrial Systems Pty Ltd and importers, and assisting an industrial coatings applicator, when projects required my services.

John Tanti, JFT Consulting Services, Sole Trader.

How long have you been volunteering for the ACA?

Tell us about your day to day employment and how it relates to corrosion prevention I have been involved in the marketing & sales of Protective Coatings since 1972. The most significant portion of my 41 years in the Protective Coatings Industry, was my 20 year association with Denso (Australia) Pty Ltd, which resulted in management positions in Victoria, Queensland and Houston Texas. I have in the past few years operated on an as required support

p.34 CORROSION & MATERIALS

My volunteering for the Victorian Branch of the ACA spans 38 years, serving as Committee Member, Treasurer, President and Secretary.

The latter tenure has been for the past 20 years.

How does your involvement with the ACA help you achieve your own personal and professional goals?

I have enjoyed the companionship through membership, and being able to meet and speak with influential

great place to exchange ideas, network and learn more about corrosion in other industries. On a committee level, it has been an opportunity to see how a technical organisation of this size operates and to be part of generating and maintaining local interest in the branch activities. It has certainly improved my organisational and persuasive skills.

What do you hope to achieve in your term as Branch Secretary?

In Newcastle we aim to foster awareness of the ACA and promote its activities to both members and non-members.

Whilst we always aim to increase membership, it is just as important to have local functions that are relevant to existing members and to encourage local involvement. We are always looking to provide events each year that cover the majority of member interests by getting everyone to at least one local technical evening each year.

people within industries, Government and the Corrosion field because of the high standard of recognition which the ACA holds within these sectors. I have also enjoyed participating and assisting in the successful running of ACA Conferences.

What do you hope to achieve in your term as Branch Secretary?

My hopes for achievements as Branch Secretary are to assist in the successful operation of Branch Technical Meetings, to accurately report the running of Branch Committee Meetings through the provision of Branch Minutes and to assist Branch Members when and where required.

MEET THE…ACA SECRETARIES

NZ Please provide your Name, Company, Job Title John Duncan; Building Research Association of New Zealand Inc.; Secretary to BRANZ Inc Board and the Building Research Advisory Council.

Tell us about your day to day employment and how it relates to corrosion prevention

SA Please provide your Name, Company, Job Title Dennis Richards, DMRichards Consulting, Principal Consultant Tell us about your day to day employment and how it relates to corrosion prevention My work involves the provision of technical support to government and industry, specifically related to the corrosion management of structures.

The work involves inspection, structure assessment, asset management

Tasmania Please provide your Name, Company, Job Title Grant Weatherburn, Zintec Corrosion Solutions, General Manager Tell us about your day to day employment and how it relates to corrosion prevention Our core business is promoting the maintenance of steel infrastructure utilising Zinga Liquid Galvanising.

The process is particularly well suited

It is a 20% FTE appointment and has no direct relationship to corrosion prevention whatsoever.

How long have you been volunteering for the ACA? Since 1978, with varying degrees of intensity over that time.

How does your involvement with the ACA help you achieve your own personal and professional goals?

plans, dealing primarily with large structure inventories. The delivery of training specifically to the corrosion management industry is also a key function of DMRichards Consulting.

How long have you been volunteering for the ACA? I have been a member, either corporate or individual, since 1982, and a member of the SA Branch committee since 1992.

I have also been technical convenor and Chairman of the committee for the 2002 and 2010 ACA conferences.

I believe that you must contribute to get back. I have had a lot out of my ACA involvement over the years, and I put back.

What do you hope to achieve in your term as Branch Secretary?

To leave NZ Branch in at least as good a shape administratively as when I took up the role.

The ACA is the industry association which most closely relates to my core business, and provides invaluable support for my business goals.

Committee involvement provides the opportunity to work with a committed group of like-minded professionals, in an environment of camaraderie.

What do you hope to achieve in your term as Branch Secretary?

My goal is to positively contribute to the efficient operation of the Branch committee, whilst satisfying the primary goals of the ACA as a whole.

How does your involvement with the ACA help you achieve your own personal and professional goals?

to assets with depleted hot dipped galvanising where maintenance projects require in-situ treatment and there is a focus on life cycle costs.

How long have you been volunteering for the ACA? I have been actively involved with the Tasmanian branch of ACA for 3 years.

How does your involvement with the ACA help you achieve your own personal and professional goals?

Networking with ACA members has been very helpful in improving my own technical abilities. Contacts made

through ACA have been helpful in opening new business opportunities.

What do you hope to achieve in your term as Branch Secretary?

I would like to see the Tassie branch with a greater number of members actively involved, combined with input from the local engineering community to provide a forum where local case studies could be presented. This would also assist in fostering interest in developing more participation in the Young Corrosion Group.

MEET THE…ACA SECRETARIES

Meet the: NSW Please provide your Name, Company, Job Title Jim Galanos, Corrosion Control Engineering (NSW) P/L, Engineering manager Tell us about your day to day employment and how it relates to corrosion prevention As the Engineering manager at CCE I am responsible for cathodic protection system design and inspection/audit work, as well as project management of cathodic protection system supply and

installation works. I also get out and about and assist with the marketing side of our business.

How long have you been volunteering for the ACA? 13 years and have enjoyed every minute of it. I am also a past president of the NSW branch.

How does your involvement with the ACA help you achieve your own personal and professional goals?

It’s always good to put something back into the industry and being part of the ACA helps promote the industry in general. Corrosion mitigation involves

WA

durability, and remediation of existing steel reinforced concrete structures.

Please provide your Name, Company, Job Title

How long have you been volunteering for the ACA?

Gary Bennett, Parchem Construction Supplies, Specification Manager

Since 2011. Initially as a general committee member and then as secretary for the past two years.

Tell us about your day to day employment and how it relates to corrosion prevention

How does your involvement with the ACA help you achieve your own personal and professional goals?

I support Engineers and Architects with product solutions in new build

Involvement with ACA has been a great learning opportunity both in work and

Queensland Please provide your Name, Company, Job Title Cathy Sterling, ACA Qld Branch Secretary, Treasurer & Membership Officer.

Tell us about your day to day employment and how it relates to corrosion prevention I am employed part-time by The ACA Qld Branch in the above roles. As Qld Branch Secretary, I am the first point of call for the Qld Branch and attend to all incoming and outgoing mail, emails and telephone calls. My role includes marketing ACA’s suite of training courses and providing

p.36 CORROSION & MATERIALS

administrative support to the wonderful group of volunteers. I am also employed as a part-time bookkeeper for a local accounting firm and currently studying for a Certificate IV in Accounting.

How long have you been employed by the ACA? This is my 13th year with The ACA Qld Branch, having commenced employment in March 2000 which makes me the longest standing employee of the Association.

How does your involvement with the ACA help you achieve your own personal and professional goals?

As ACA Qld Branch Secretary, I have had the opportunity to meet interesting people from all walks of life. I have

a number of disciplines and having some understanding of each discipline certainly helps make me a better Engineer.

What do you hope to achieve in your term as Branch Secretary?

The membership needs to be aware of events and information that is available via the ACA. As branch secretary, ensuring members are suitably notified is important, as well as listening to members advise on event formats. From a branch committee perspective it is important all committee members have up to date information to assist with branch decision making.

non-related areas. It has been personally enriching to learn about the work and experiences of other members.

What do you hope to achieve in your term as Branch Secretary?

To support the President and Committee in achieving a more effective engagement and in providing a range of diverse and engaging technical events for the WA membership.

achieved a greater understanding of corrosion and appreciate that “rust” doesn’t just happen, it is a process and it can be quite a complex task to determine what causes corrosion in certain atmospheres. While the “technical” jargon involved in corrosion is overwhelming, I am always keen to meet the people involved in such a diverse discipline.

What do you hope to achieve in your term as Branch Secretary?

Continue to let people know that “corrosion” is an interesting topic and it can occur in various settings.

Encourage “younger” folk to become more interested in and support the ACA (Boat Tours and Brewery Tours seem to be a good start).

COATINGS GROUP MEMBER PROFILE

Tincone Pty Ltd Q: In what year was your company established?

Q: Is the business yard based, site based or both?

A: We were established in 1997.

Q: How many employees did you employ when you first started the business?

A: We have all-weather blast facilities both in Mackay and Gladstone, boasting a 2000m2 underroof facility in Mackay. We also offer site services throughout Australia.

A: Three blast coaters and an office administrator.

Q: What is your monthly capacity or tonnage that you can blast and prime?

Q: How many do you currently employ?

A: With both facilities we could handle 560 tonne per month.

A: We currently employ 24 people.

Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.)

Q: Do you operate from a number of locations in Australia?

A: We currently operate all throughout Queensland, but will work anywhere we are required.

Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.)

A: Abrasive blasting, protective coatings, industrial cleaning, concrete rectification, scaffolding and access, industrial tiling, line-marking and floor demarcation.

Q: What markets do you cover with your products or services? eg: oil & gas, marine, chemical process, general fabrication, tank lining, offshore etc.

A: Oil, gas, marine, mining (maintenance and construction), ports (off and on shore) & general fabrication.

A: We have NACE qualified staff in our management team and offer corrosion surveys, priority listing and budgeting requirements for corrosion control programs. We also offer coating inspections and recommendations.

Q: What is the most satisfying project that you have completed in the past two years and why?

A: We have recently completed a lot of off shore piles and on shore piles for the Bechtel APLNG project with tight time constraints and strict paint specifications. We met the tight time frame and passed all inspection 100%.

With other competitors struggling with the requirements, it showed our process and commitment to quality and timely delivery. We believe we shone compared to our competition.

Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job?

A: Commit to the process you are working to and communicate well the expected outcome to your staff, clients and client’s representatives.

Q: Do you have an internal training scheme or do you outsource training for your employees?

A: We do internal training on a continuous basis and external training for any specialised needs that arise.

Tincone Pty Ltd Abrasive Blasting, Protective Coating & Concrete Rectification.

Darren Beale Managing Director: 0417 767 291 Arran Fletcher Workshop Supervisor: 0458 767 291 John Learoyd Area Mgr, Site Supervisors: 0400 471 773 Address: 247 East Boundary Rd, Paget QLD 4740, Australia Phone: (07) 4998 5290 Fax: (07) 4998 5212 Email: tincone@mcs.net.au Web: www.tincone.com.au

August 2013 www.corrosion.com.au p.37

TECHNICAL EVENT REVIEW

Reinforced Concrete Performance for Water and Wastewater Assets - Sharing Experience through Case Studies: Technical Event Review THE AUSTRAL ASIAN CORRO SION ASSOCI ATION INC S EMINAR

Reinforced Concrete Perf ormance for Water and Wastewa ter Assets

– Sharing Experience

Through Case Studies

Date: Thursday 13th June

2013 • Venue: Brisbane Marriott

The Concrete Structures & Buildings and the Water & Water Treatment Technical Groups of the ACA have together to produce a technical come program that will appeal all stakeholders that are to affected by corrosion.

This event will focus on case studies of new and existing reinforced concrete structures within the Water and Wastewater industries.

The experience and the lessons presenters will share their they successful and unsuccessful), have learnt (both particularly the history asset performance and of how this has and/or could durability planning. inform To ensure this event is a success and to bring the industry together, we will have two speakers from each of the

Time

Session

8:30 – 9:00

Registration

The Concrete Structures & Buildings and the Water & Water Treatment Technical Groups of the ACA held a joint technical event on Thursday 13th June at the Marriott Hotel in Brisbane.

PROUDLY PRESENTED BY:

Hotel - 515 Queen Street,

Brisbane

following industry groups presenting various case studies on new and existing projects;

This full day technical event had 50 delegates from a broad cross section of the industry

Asset Owners Consultants Contractors Suppliers This one day event will help bring together all stakeholders to discuss and learn about various corrosion issues range of projects. To end across a the day we will engage the audience to participate in an open forum to discuss corrosion with the panel of speakers. issues Speaker

9:00 – 9:05 Welcome and Seminar Opening Chairpersons – Frederic Blin, Matthew Dafter Performance of Water 9.05 – 9.45 & Warren Green and Wastewater Reinforced – An Asset Owners Perspective Concrete Structures 9.45 – 10.25 Condition Sheikh Uddin, Queensland Assessment & Life Extension Urban Utilities of Reinforced Concrete Water Reservoirs 10.25 – 11.00 Morning Tea Luke Menefy, SMEC Australia 11.00 – 11.40 Case Studies of Waste Water Structure Rehabilitation – Products, 11.40 – 12.20 Innovative Methods and Outcomes Techniques to Provide Nicholas Critchley, SAVCOR Long Term Protection of Water and Wastewater Assets 12.20 – 13.00 Specificity of Reinforced Concrete Andrew Dickinson, Parchem Construction Supplies – An Asset Owners Perspective Structure in Bulk Water Supply 13.00 – 13.50 Lunch Russell Uy, SEQ Water 13.50 – 14.30 Residual Life Assessment and Repair Design of Wastewater Structures 14.30 – 15.10 Diagnostics Gavin Chadbourn, GHD – How to Determine the Health of Your Water and Wastewater Assets 15.10 – 15.40 Afternoon Mike Rutherford, Freyssinet Tea Australia 15.40 – 16.20 Protection of Water and Wastewater Concrete Structures Pitfalls & Common Site 16.20 – 16.55 Open Floor Issues Grant Dowling, Speakers Forum and Discussion Sika Australia 16.55 – 17.00 Seminar Close Forum Chairs & All Speakers 17.00 – 18.30 Cocktail Function Chairperson

from around Australia in attendance. This event focused on case studies of new and existing reinforced concrete structures within the Water and Wastewater industries. Two presenters from each of the following industry groups presented case studies on new and existing projects; Asset Owners, Consultants, Contractors & Suppliers.

At the conclusion of the event an open floor forum was held and chaired by Warren Green. Some of the key areas of discussion were: rotection Systems performance P & monitoring epair systems performance R & monitoring ife extension of assets – L requirements and predictions redictions of performance P of materials ngineering involvement during E repair contracts erformance differences between P systems The ACA would like to thank all the speakers and delegates who attended this event and for making the day a success!

Following is an overview of the presentations: Performance of Water and Wastewater Reinforced Concrete Structures – An Asset Owners Perspective Sheikh Uddin, Queensland Urban Utilities This presentation covered the problems Queensland Urban Utilities generally

p.38 CORROSION & MATERIALS

encounter in the condition assessment and refurbishment of its concrete structures comprising water reservoirs, sewer maintenance holes and pump stations. Sheikh also shared the design enhancements and repair methods Queensland Urban Utilities has adopted over the years to increase the life of their concrete structures.

Condition Assessment & Life Extension of Reinforced Concrete Water Reservoirs Luke Menefy, SMEC Australia This presentation focused on the engineering assessment and design process undertaken as part of a major refurbishment of a reinforced concrete reservoir. The key issues covered were: ey deterioration mechanisms K of reinforced concrete in water reservoirs. ey findings - localised corrosion K issues uncovered on submerged sections of reinforced concrete columns, combined chloride and carbonation induced corrosion on RC elements at and above water line.

I nvestigation approach and diagnostic techniques to confirm damage extent and assess residual life (durability plan). emedial strategy & the R lessons learned

Case Studies of Waste Water Structure Rehabilitation – Products, Methods and Outcomes Nicholas Critchley, SAVCOR Concrete structures in the waste water environment are often subject to high concentrations of H2S gas above ‘normal’ flow levels. Over time H2S can cause deterioration of concrete cover (because it is oxidised to sulphuric acid by bacteria) and if left untreated can cause major structural issues. As waste water structures are generally difficult to access in terms of confined space and flow control requirements, protection of these concrete surfaces is a high priority to asset owners. This presentation looked at some of the products, methods and outcomes for waste water structures rehabilitated in recent times.

Innovative Techniques to Provide Long Term Protection of Water and Wastewater Assets Andrew Dickinson, Parchem The presentation covered case studies of reinforced concrete structures, both new and old, which have benefited from the use of new and innovative technologies to achieve long term durability and protection to water assets. The technology covered in this presentation included the use of formwork liners, new acid resistant lining system, calcium aluminate mortars and epoxy coatings.

TECHNICAL EVENT REVIEW

Specificity of Reinforced Concrete Structure in Bulk Water Supply – An Asset Owners Perspective Russell Uy, SEQ Water Reinforced concrete is a versatile product that is extensively used in the water industry. However even with use in contact with treated drinking water there are a range of failure mechanisms that can occur that can give rise to water quality, structural integrity and leakage issues. Solutions are generally available within the corrosion and coating industries but it can be difficult to identify products that are suitable for treated water contact and provide the required service life to minimise future maintenance.

Residual Life Assessment and Repair Design of Wastewater Structures Gavin Chadbourn, GHD This presentation described the common deterioration mechanisms associated with wastewater structures.

Considerations for the investigation of these structures were discussed, including access and safety. A discussion on the different non-destructive and

partially destructive testing methods used to assess the degree of damage and residual life of the structures was given and their merits and limitations.

An overview of repair techniques commonly available and adopted for wastewater structures were described and illustrated with case studies.

Diagnostics – How to Determine the Health of Your Water and Wastewater Assets Mike Rutherford, Freyssinet Australia The presentation covered the capabilities of diagnostic testing of concrete structures. Case histories were presented where diagnostic testing was employed to assist assessment of concrete structural components within the following areas: water treatment plant underground a pipe network, bove ground water storage a reservoirs; and

Protection of Water and Wastewater Concrete Structures - Pitfalls & Common Site Issues Grant Dowling, Sika Australia This presentation discussed some of the different processes that take place before a protective coating system is installed and how these processes in the early stages can impact on the end result. Also discussed were the coating application issues that can arise causing a defective coating application and how these can be prevented for future reference. Grant also briefly mentioned some of the Australian Standards that may be referenced during the project and finally showed some case studies on project related issues.

For further information on the ACA Technical Groups or to provide suggestions & or comments for future events please contact Brendan Pejkovic in the ACA office on bpejkovic@corrosion.com.au

elow ground sewerage main and b manholes.

August 2013 www.corrosion.com.au p.39

PROUDLY PRESENTED BY:

SPONSORED BY:

The ACA Coatings Technical Group conducted a two day meeting in Melbourne on the 18th & 19th July 2013 with 75 attendees. This event explored the protective coatings industry by looking at case studies, new technologies, environmental considerations and industry qualifications, standards and training.

Below is a synopsis of a selection of the presentations. If ACA members would like an electronic copy of a particular presentation, please contact Katherine Webber at kwebber@corrosion.com.au Getting it Right – The First Time Daniel McKeown, Dulux Protective Coatings This presentation discussed the importance of ensuring things are done properly the first time. It showcased some real time examples of projects where this may not have been the case, looking at issues that have arisen from a variety of stages of the project. It also examined the impact of corrosion or coating integrity issues raising their heads earlier than expected, including financial costs and the inconvenience of having an asset that has to be taken out of service. The value of preventative maintenance was also discussed.

The Development of a Long Term Maintenance System to Increase the Life of Grange Resources Port Latta Ship Loading Facility Dean Wall, Jotun This presentation was a case study looking at the development of a long term maintenance system to increase the life of the Grange Resources Port Latta Ship Loading Facility. It discussed the rationale behind the maintenance system that was implemented and the challenges associated with the project.

It’s Not Just About Dry Film Thickness Shane Jimmink, Inspec Consulting It’s Not Just About DFT – Typically when people talk about ensuring longevity for a protective coating, the first thought is “Did the Applicator achieve the required Dry Film Thickness?” Although obtaining the specified total Dry Film Thickness is important to achieving the required longevity of a protective coating, relying solely on this Quality Control process by the Applicator and/or Coating Inspector is fraught with danger. Typically the cost and time penalties involved are significantly greater when coating defect (damage, deficient in film thickness etc.) are detected at the latter stage of the process as rework and rehandling is required to

rectify these problems. Most defects and non-conformance of Quality Control measures detected in the latter stage of the process by a Coatings Inspector have root causes originating from deficiencies within Quality Assurance processes earlier.

This presentation discussed the key requirements to ensuring longevity in a protective coating – Quality Assurance.

Zinc Flake Technology and Trends Dennis Guendel, Atotech Australia For decades there has been corrosion resistance as a requirement in various industries. Year by year the importance of corrosion’s resistance is rising. Especially in industries like automotive, construction or wind energy the demand for corrosion protection and end appearance experienced a significant change during the last decade.

Additionally advanced materials like high tensile steel, which need suitable corrosion protection solutions, are applied more and more.

For this demanding environment the Zinc Flake technology was developed to offer flexible and cost effective solutions.

Zinc Flake Coatings in general consist of two components: base coats and top coats. Base coat products provide the best corrosion protection with lamellar shaped zinc particles. The top coat product ranges provide additional properties such as defined coefficient of friction ranges, chemical resistance, color etc. The combination of top coats and base coats forms multifunctional coating systems which can be a modular approach to the wide range of requirements in the diverse industries. Different application methods are available for Zinc Flake coatings which enable a wide variety of parts to be treated in bulk or rack application. In line with Atotech’s sustainable and green surface treatment technologies the Zinc Flake coatings do not contain heavy metals or toxic substances. A wide range of OEMs in miscellaneous industrial sectors is already convinced of the advantages of Zinc Flake coatings and there are more to come in the future.

Innovations from Nanotechnology Provide New Solutions to Prevent Corrosion and CUI (Corrosion Under Insulation) Graham Carlisle, Inovas Asset Integrity Nanotechnology has been a buzz word for a number of years and for some, it has been a fantastic discovery, but for others, it instills a fear of impending doom from the ingestion of minute particles. Whilst the previous statement

p.40 CORROSION & MATERIALS

needs context, one cannot discount the fact that elements or compounds exhibit more novel and valuable characteristics when evaluated at an atomic level than say when evaluated in the form of a billet or extruded rod. This presentation introduced nanotechnology and how nanotechnology can also cause a water-based acrylic latex coating to perform better in corrosion resistance testing than previously imagined. It presented the data from the testing regime, which saw the system being tested to: M9540P Cyclical Accelerated Corrosion Test G BC/BP/JC Testing for Resistance to CUI BC/BP/JC Testing for Thermal Conductivity ASTM D3359 Cross-Hatch Adhesion ASTM D4541 Pull-Off Strength The presentation then discussed the ‘adoption rate’ of nanotechnologies and the potential uses for the above technology in everyday applications. Various case histories are then investigated to establish the ‘in process’ performance of the applied coatings.

Increasing the Longevity of Assets by Providing Planned Coating Solutions Jim Mackay, International Paint This presentation showed how to increase the longevity of assets by providing planned coating solutions to mitigate corrosion, within a computerised maintenance plan, as part of overall Asset Performance Management. This presentation included ideas on improving the maintenance of coatings economically, improving efficiency and promoting safety.

True costs of coatings, maintenance scheduling and planning, inspection and critically of specifications, were highlighted. Examples from industries including Oil and Gas, Mining and Water/Waste Water were used to show how to develop a maintenance plan for coatings from a reactive to predictive status.

Improving the Durability of Hot Dip Galvanized Coatings Peter Golding, Galvanizers Association of Australia This presentation featured a number of short case studies illustrating the general principles of design to avoid corrosion, with real world successes and failures of coatings focusing on hot dip galvanizing. These included how good fabrication practice can increase the life of a structure; the effects of steel composition and surface condition on the quality of hot dip galvanizing; the influence of thermal cutting processes; why it’s a good idea to cut, weld and fabricate prior to coating; and what happens to the coating in different environments.

Force Cured 100% Solids Liquid Epoxy and PE Backed Heat Shrinkable Sleeve with Co-Polymer Adhesive System Used for Field Joint Coating on Iconic QSN3 Pipeline Project John Frith, NACAP / Universal Corrosion Coatings & Peter Thomas, AusPipe Pty Ltd The QSN3 Project extending 940km from Wallumbilla to Moomba and undertaken by Epic Energy represents one of the largest Pipeline Construction projects undertaken in Australia.

5 separate markets are now supplied by the QSN3 Pipeline risbane via Roma Brisbane Pipeline B Gladstone via Queensland Gas Pipeline Mt Isa via Carpentaria Pipeline Adelaide via Moomba – Adelaide Pipeline Sydney via Moomba Sydney Pipeline.

The Epic Walumbilla compressor and metering station is a now a critical junction and trading hub receiving gas from 3 major gas fields, Fairview, Spring Gully and Berwyndale.

It is with some pride that Universal Corrosion Coatings Pty Ltd report that Canusa HBE HT High Build Epoxy Coating was used exclusively for Field Joint Coating on this critical piece of new pipeline infrastructure. Some 53,000 Field Joints were coated with the HBE HT Epoxy and in addition, 200 Hot Induction Bends. Any joint coating undertaking of this size requires a highly collaborative approach from the material supplier, owner, constructor and designer to effect successfully and this project highlighted that the alliance type approach adopted by Canusa CPS, Universal Corrosion Coatings Pty Ltd, Epic Energy Pty Ltd, Nacap pty Ltd delivered a win win outcome for all participants.

Challenges Ahead for Contracting Companies Justin Rigby, Commercial Industrial Painting Services Australian asset owners, private & public tend to plan for long term maintenance but then break the work into a series of smaller projects. However our experience is when asset owners allocate longer term contracts, we have the ability to invest in; - Further training - Staff development - and modern equipment.

Long term contracts provide surety for asset owners. From a contractors view point; Owners benefit best from developing a small group of contractors and allocating groups of works together under a single contract (even if it requires spreading the work over multiple years).

The Newcastle Coal Infrastructure Group Coal Export Terminal Project - Case Study and Lessons Learnt Frank Brown, Jotun This presentation looked at a large CET (Coal Export Terminal) in Newcastle that was built in three stages running into each other. It was built to handle the overload at the existing Port Waratah Coal Services loading facility. The scope of work included kilometres of conveyors, 4 Stacker Re-claimers and two ship loaders & and a wharf extension.

The SR’s & SL’s were fabricated in Korea, the bogeys for the machinery in Turkey, the wharf in Indonesia, the structural steel in Thailand & the idlers for the conveyors in China. It looked at the actual challenges faced in dealing with so many different cultures and languages and ‘practices’, especially the constant battle to get the high spec adhered to in places where they do what is ‘inspected’ not what is ‘expected’. It also covered the interpretation of Jotun’s role in the final product and warranty implications.

Spray Applied Monolithic Coatings – An Australian perspective on Polyurethane/Pure Polyurea Protective Coatings with Case Studies Denis Baker, Rhino Linings This presentation covered the use of Monolithic spray applied elastomers in the waste water, water storage and mining industries.

Spray applied elastomers offer real advantages both during application and finish as a surface protection agent particularly in large concrete and steel structures. These advantages include rapid setting, seamless coverage, high elasticity, durability and a dense impermeable structure. An overview of Polyurethane (PU) and Pure Polyurea (PP) was discussed and case studies were presented.

August 2013 www.corrosion.com.au p.41

TECHNICAL NOTE

Pipelines and Polyurethane Coatings: A Winning Combination When it comes to the lining and coating of pipelines for the water industry, polyurethane is very often the most efficient and cost-effective coating system for both new pipeline construction and pipe rehabilitation. Water pipelines have a very important role throughout today’s world; they are basically pipeline highways transporting water over long distances from the source to the consumer. With the help of Jim Cairns and Jeff Stewart of ITW Polymers Coatings-Futura, we take a look at the role polyurethanes play in the water pipeline industry and how the characteristics of these coatings meet the unique needs of steel water pipes.

©2011 Northwest Pipe Company. Photo by Lincoln Barbour.

The essential use of polyurethanes on steel — or most other protective coatings for that matter — is to protect the substrate from corrosion by forming a barrier, thereby eliminating the corrosion cell.

The tougher, less permeable, and more chemically resistant the coating system is, the better. “These pipelines are put into difficult environments and need to last a long time. Polyurethane coatings help them do just that,” said Jim Cairns.

He added, “Polyurethanes exhibit many characteristics that have led to their extensive use in the pipeline industry.

For example, they are chemical- and abrasion-resistant, they can be applied directly to steel to form a very high-build system in a single application, and they have good corrosion resistance.” These properties, among many others, are the reason that fast-setting, high-solid polyurethane coating systems have been used to line and coat steel pipe since the 1980s. In 1999, the first American Water Works Association (AWWA) standard for polyurethane lining and coating of steel pipe was published (referred to as ANSI/ AWWA C222), with an update published in 2008. As stated by Jeff Stewart, in recent years, the use of polyurethane linings and coatings has grown substantially.

p.42 CORROSION & MATERIALS

The chemistry behind polyurethanes To understand why polyurethane coatings and pipelines are such a good match, you must first understand how the chemical composition of polyurethane defines its properties and characteristics. In terms of chemistry, polyurethane is the result of a reaction between an isocyanate and a hydroxyl terminated polyol group.

Isocyanate is nitrogen-, carbon-, and oxygen- (NCO) based, and the polyol, which is often referred to as the resin, is a carbon chain molecule terminated with a hydroxyl group that is composed of oxygen and hydrogen (OH) together.

When these two reactive groups come together, they form polyurethane.

Despite this complex sounding chemistry, understanding polyurethane coatings is relatively simple. The word polyurethane literally means more than one urethane, which describes the polymer composed of repetitive carbon groups connected by urethane linkages. The characteristics of the polyurethane are determined by the chemical makeup of the carbon-based groups that comprise the polymer’s backbone. For example, depending on the particular polymer backbone, a polyurethane coating may be hard and

©2011 Northwest Pipe Company. Photo by Lincoln Barbour.

TECHNICAL NOTE

In-plant surface preparation procedures include the sandblasting of pipe sections. Although the photo above shows the hand sandblasting of this small fitting, original equipment manufacturing (OEM) plants also have large automated sandblasting equipment. rigid or soft and flexible. This explains why a roller blade wheel, Lycra running shorts, “leather” car seat coverings, and the protective lining on the interior of a water pipeline can all be polyurethanes. Although polyurethanes can be flexible or rigid, can be spray- or brush-applied, and can cure (i.e., create polymer linkages) through various mechanisms, they all display certain common characteristics. For example, they can show high impact, abrasion, and chemical resistance. Because polyurethanes are able to tolerate harsh chemicals, they are smart choices for projects such as the protection of the interior and exterior of potable and waste water pipes and tanks as well as steel and concrete in water and waste treatment facilities. “Polyurethanes are also used for secondary containment, both direct to the substrate and on a geotextile. They can be structural stand-alone liners or molded products, and they can be applied to such diverse substrates as steel, concrete, fiber-glassreinforced paneling, and wood,” said Stewart.

Convenience, cost, and cure Polyurethanes exhibit great resistance to chemicals, corrosion, impact, and abrasion, but this is only part of the story when it comes to polyurethane coatings and water pipelines.

According to Cairns, coatings are typically applied to pipes in original equipment manufacturing (OEM) plants. “Spraying in the field requires both surface prep equipment and plural spray equipment, which also require a generator and compressor.

In addition, environmental controls for temperature and humidity, along with containment and protection of the pipeline, may also be required to support the application. While welded joints and touch-ups may be done

easily in the field, most coatings are applied in-plant to preserve quality and consistency,” said Cairns. Given this circumstance, polyurethanes have many characteristics that make sense for OEM application. Polyurethanes are fast-setting, are applied directly to metal without a separate primer, and are typically applied in a single highbuild coat, which means that process equipment and storage areas are not tied up waiting for the coating to cure or to be quality checked. “They also offer great physical flexibility, which easily allows for 50- or 60-foot-long (15.2 or 18.3 m) pipes and fewer joints to field-apply,” explained Cairns.

Polyurethanes are also light-weight in comparison with other coating systems, which allows for easier (and less expensive) transportation inside the plant and also to and at the job site. This factor, especially when

combined with the other characteristics of polyurethane coatings, makes it a cost-effective choice for steel water pipelines. “Because polyurethane coatings are light in weight, they allow for less expensive and smaller equipment at the installation site,” said Stewart.

It must also be mentioned that the polyurethane coating systems used on steel water pipelines do not contain volatile organic compounds (VOCs) and are referred to as ambient cure. “Ambient cure in this instance refers to the fact that, because of the formulation, no external heat is required to cure the coating, and the material also may be applied in lower ambient and surface temperatures,” stated Cairns. These characteristics make polyurethane coatings an environmentally friendly, or green, option for pipelines.

Measuring the dry film thickness of a coating is another vital step in the quality control process. For the Provo Reservoir Canal Enclosure project, both the interior and exterior of the pipes were coated with a dry film thickness of approximately 35 mils (889 microns).

August 2013 www.corrosion.com.au p.43

TECHNICAL NOTE

The surface preparation and coating application for pipes typically occur in OEM plants.

While welded joints and touch-ups may be done in the field, coatings are usually applied in-plant to preserve quality and consistency, as well as for cost and convenience reasons.

Polyurethane coatings can be spray applied to the exterior of large water pipes with a traveling spray gun in OEM plants. During this process, the pipe rotates in place.

Adhesion tests are an important part of the quality control process. Pull-off adhesion tests, as shown here, measure the tensile strength of a coating system.

In these tests, a loading fixture, or dolly, is affixed with an adhesive to the coating on the pipe.

A load is increasingly applied to the surface of the pipe until the dolly is pulled off.

p.44 CORROSION & MATERIALS

excellent adhesion properties and are very resistant to soil stress,” explained Stewart. Polyurethane coatings also work well with the heat shrink sleeves that are used on the external joint completion out in the field.

As far as the interior of a steel water pipeline is concerned, it must be chemical- and abrasion-resistant and maintain a smooth low friction surface. The smooth surface created by a polyurethane lining provides energy savings in both long- and short-term water flow in the pipe. The Hazen©2011 Northwest Pipe Company. Photo by Lincoln Barbour.

Inside and out Another important aspect of applying polyurethane to water pipelines is the ability to use the material on both the interior and exterior of the pipe.

When it comes to the exterior of a pipeline, the coating system needs to protect it from abrasion from soils, chemicals, and impact from handling during transportation and during installation. “Polyurethane coatings are tough and impact resistant, and, once installed, they protect the exterior of the pipeline in high chloride or low pH environments. They also have

Williams “C” value associated with polyurethane linings is typically 150, the same as that for thermoplastic pipes such as high density polyethylene (HDPE) and polyvinyl chloride (PVC). According to Cairns, polyurethane linings used inside steel pipes are compliant with the NSF/ ANSI Standard 61, which establishes minimum health effect requirements for materials, components, products, or systems that come into direct contact with drinking water, drinking water treatment chemicals, or both.

The longest pipeline The best way to demonstrate the advantages of polyurethane coatings on steel water pipelines is to take a look at a recent extremely large — and extremely successful — project. The Provo Reservoir Canal Enclosure Project, known as PRCEP, was the longest and largest diameter polyurethane-lined and coated steel water transmission pipeline in North America and one of the longest in the world. The installation of the 21-mile-long (33,796.2 m), 126-inch-diameter (320.0 cm) pipeline will result in the prevention of approximately 2.6 billion gallons (9.8 billion L) of water loss annually through evaporation when compared with the previous open canal design.

The pipeline, which has a projected service life of 75 to 100 years, is spirally welded steel pipe with a polyurethane lining on the interior and a polyurethane coating on the exterior. Northwest Pipe was the pipe manufacturer as well as the OEM polyurethane lining and coating applicator for the job, and ITW Polymers Coatings-Futura supplied Protec II and Protec II PW for the exterior and interior of the pipe, respectively. Both of these coatings exhibit all the high-performance qualities of polyurethane — they are high solids, fast-setting, light-weight, chemical- and abrasion-resistant, and protective against corrosion.

Prior to applying the Protec II and Protec II PW to the pipeline sections, surface preparation was done in accordance with AWWA C222 as well as the specifications particular to the project. “The surface preparation followed SSPC – SP 5, NACE 1, White Metal Blast with a minimum 3 mil (76.2 micron) angular profile,” explained Stewart.

Once the surface preparation was completed, the exterior coating was spray-applied with the pipe rotating in

TECHNICAL NOTE

On a project this large, the lightweight pipe sections and the fact that the flexibility of the polyurethane coating allowed for 40-foot (12.2 m) sections was extremely cost-effective.

“Using steel pipe with polyurethane was a huge cost benefit during the transportation and installation of the pipeline. It was more economical to transport the pipeline than if another coating and lining system had been used. The longer sections allowed for fewer field joints, and the impact resistance of the Protec II meant that

coating touch-ups were rarely required in the field,” stated Cairns.

It must also be noted that the PRCEP was originally scheduled to be a threeyear job, but the project was finished one year ahead of schedule in the spring of 2012. According to Cairns, much of the time saved on the job can be attributed to the characteristics of the polyurethane coating and lining system and the ease with which they can be applied in-plant. And because time is money, the year saved on the project was a huge cost savings as well.

A great match According to Cairns, the PRCEP project is just one of many examples of how polyurethanes are a costeffective, time-saving, and long-term solution for the protection of both the interior and exterior of steel water

pipelines. “Polyurethanes offer many of the characteristics necessary for water pipelines. In addition to the time and money saved during the application and installation process, polyurethane coatings do an excellent job of protecting the pipeline and extending its service life. This adds up to even more savings in the long run,” said Cairns.

By Jennifer Frakes Photos courtesy of ITW Polymers Coatings — Futura and Northwest Pipe Company.

This article was originally published in the March 2013 issue of CoatingsPro (www.coatingspromag.com). Reprinted with permission. ©NACE International.

©2011 Northwest Pipe Company. Photo by Lincoln Barbour.

place and with a traveling spray gun.

For the interior lining, the pipe was also rotated in place, and a spray lance was extended along the entire inside length of the pipe. Both the Protec II on the exterior and the Protec II PW on the interior were applied at a 35-mil (889 micron) dry film thickness

August 2013 www.corrosion.com.au p.45

INDUSTRY INSIGHT

Overcoming Corrosion Challenges Faced in Alumina Processing Introduction Over the past 6 years Buel has performed a significant number of inspection, maintenance and repair projects associated with tank corrosion of various types in the Alumina processing industry. The majority of this work has been specifically focused around flat bottomed and cone bottomed precipitator tanks and their associated structures. The precipitator tanks are large, open topped tanks and either conical or flat bottomed and are used to generate alumina seeds from pregnant liquor by means of agitators of various design. The process requires these tanks to be cleaned at regular intervals with a strongly alkaline product to remove scale that builds up during precipitation. Over time these processes contribute to a loss of structural integrity that results in a number of generic failure mechanisms including; wall thickness loss / erosion, corrosion of floor (flat bottom tanks) and caustic embrittlement cracking.

catastrophic cracking, often leading to devastating and unexpected failure.1 Wall Thickness Loss The loss of parent metal thickness on the tank wall or ‘shell’ can occur as a result of abrasion, erosion (usually localised) and corrosion.

Internal Tank Inspection Process Once a tank has been identified for inspection it first requires cleaning with a chemical wash to remove the remaining caustic solution. The

tank is then ‘handed over’ to the inspection and maintenance team to initiate the internal process procedure.

Usually the first step is JSEA (Job Safety and Environmental Analysis) sign-on followed by isolations and establishment of access. Access by rope allows rapid deployment of personnel to ensure ‘tool time’ is maximised and the NDT technicians can start working through scope as soon as possible. The inspection and NDT scope varies. However, it primarily involves a combination of visual, magnetic

Due to the nature and size of these tanks, the safest and most time and cost effective method to deploy inspection and maintenance is with Industrial Rope Access.

Primary Corrosion Issues: Stress Corrosion Cracking (SCC) SCC is the growth of cracks in a corrosive environment. It can lead to unexpected sudden failure of normally ductile metals subjected to a tensile stress, especially at elevated temperature in the case of metals. SCC is highly chemically specific in that certain alloys are likely to undergo SCC only when exposed to a small number of chemical environments. The chemical environment that causes SCC for a given alloy is often one which is only mildly corrosive to the metal otherwise.

Hence, metal parts with severe SCC can appear bright and shiny, while being filled with microscopic cracks.

This factor makes it common for SCC to go undetected prior to failure. SCC often progresses rapidly, and is more common among alloys than pure metals. The specific environment is of crucial importance, and only very small concentrations of certain highly active chemicals are needed to produce ASM International, Metals Handbook (Desk Edition) Chapter 32 (Failure Analysis), American Society for Metals, (1997) pp 32-24 to 32-26

1

p.46 CORROSION & MATERIALS

INDUSTRY INSIGHT

NZ Standards. These procedures allow personnel to be certified to Inspect, Test, Repair and Maintain while ‘in suspension’. The various certifications allow the client the confidence, to ensure the variety of works can be performed with the same level of quality outcome (if not better) as they can on ground. The result is a cost effective solution, with a faster turnaround on tank maintenance and ultimately increased uptime in processing. With the current climate in the resource sector being one that is focused on increased productivity, this clearly demonstrates that the Alumina industry is taking steps in that direction.

particle inspection (MT) and ultrasonic weld scanning (UT - NATA NDT scope 6.50.01 – Ultrasonic A-Scan) for weld integrity (SCC and other) and ultrasonic thickness testing (UT – NATA NDT scope 6.51.01 – Material thickness – spot or grid measurements only). The deployment of these test methods gives the raw data / inputs to ultimately provide engineers with the ‘NATA endorsed’ reports required to help assess the condition

of the tank (note: other tests can also be performed) to determine possible remedial solutions.

Repair / Remedial Solutions In order to conduct the repairs efficiently, a series of specific procedures have been developed in conjunction with NATA (National Association of Testing Authorities), ASME (American Society Mechanical Engineers) and AS/

Conclusion The corrosion related inspection, maintenance and repair challenges that are faced in alumina processing are both technically and physically challenging.

To ensure safe, accurate and efficient delivery a well-integrated, technically experienced team is paramount to success. The team must bring together NATA accredited technicians and specialist tradesmen that operate under IRATA guidelines to ensure zero harm.

The environment is high risk and the work is technically challenging.

Buel

August 2013 www.corrosion.com.au p.47

PROJECT PROFILE

Sydney Desalination Pipeline Cathodic Protection System Performance Review after 3 Years Introduction As part of a NSW State Government initiative to provide Sydney with a long term drought proof water supply solution, a desalination plant was built in Kurnell. The delivery point for the desalinated water was Erskineville, a Sydney suburb approximately 4 km from Sydney CBD. This required the construction of a 16.8km pipeline (see Figure 1).

This study assesses the performance of the cathodic protection system and other corrosion mitigation and monitoring systems over the 3 year period following commissioning.

Design Brief The pipeline was designed and constructed by the Water Delivery Alliance, which was made up of a number of consulting and construction companies and Sydney Water.

The main design requirements for the Alliance included the delivery of up to 550 million litres of water per day and an operating life of 100 years.

This required the construction of a large diameter pipeline. The Alliance prepared the basis of design and a project brief (Table 1).

The pipeline design and construction was an engineering challenge and had to take into consideration; a high water table, sub-sea crossing, pipeline tunnelling in high density residential areas and traversing contaminated soils, all requiring different construction techniques.

Pipeline Construction The water delivery pipeline has the following characteristics The trenched, mounded, above ground and the concrete encased micro tunnelled pipe sections are all carbon steel DN1800 mm, 12 mm (minimum) wall thickness and internally cement lined. The trenched pipe sections are bell and spigot joint with a full circumferential weld internally and externally while the tunnelled sections utilise full butt welds.

The pipeline external coating is ultra high build 2-pack epoxy or HDPE. All field joints were either mastic lined heat shrink sleeve or petrolatum tape.

The sub-sea section consists of twin carbon steel DN1400mm pipelines 17.5mm wall thickness, internally cement lined. A tri-laminate external coating was applied along with a cementitious weight coat. All field joints were coated using a mastic based product.

The tunnelled pipeline sections are all DN1800mm with internal cement lining as previously stated. Externally, the tunnelled pipeline sections are uncoated except for a few select areas, but have been concrete encased.

The pipeline has been electrically isolated at numerous locations. These locations include the extremities (to provide electrical isolation from foreign structures at the pump station and tie-in point) and at each transition

Table 1: The design brief [2] given to the corrosion consultants included: 1.

The minimum operating life of the pipeline is to be 100 years.

2.

The pipeline is to be protected from corrosion failure over this period using a combination of coatings and cathodic protection systems.

3.

The pipeline corrosion levels were to be monitored over the life of the pipeline.

4.

Any DC stray current effects are to be mitigated.

5.

The pipeline route to be checked and mitigated from High Voltage AC induced/fault currents.

p.48  CORROSION & MATERIALS

from cathodically protected to noncathodically protected pipe sections.

Cathodic Protection System Overview The pipeline has been divided into sections, due to the mixture of construction techniques. Each section was looked at separately with the most suitable cathodic protection system selected. Both impressed current and sacrificial anode CP systems were installed to protect the pipeline against external corrosion. The CP systems were designed to complement the external pipeline coating system.

Gypsum bentonite packaged magnesium sacrificial anodes were installed at all mounded and trenched pipeline sections which are relatively short in length and an impressed current CP system was installed to protect the 7.1km twin pipe sub-sea crossing.

Monitoring of the CP system is via test points, located both above and below ground. At a number of locations within the tunnelled sections, LPR corrosion monitoring probes have been installed to monitor corrosion rates.

CP And AC Mitigation System Operation & Performance Commissioning of the CP systems was undertaken following installation of each pipe section between 2008 and 2010. Final commissioning was undertaken in 2010. This confirmed all cathodically protected pipe sections shifted to fully protected potentials, in accordance with Australian Standard AS 2832.1 and the design report, which stipulated a minimum potential of -0.85 Volts vs Cu/CuS04 free of significant voltage gradient error.

Since commissioning, the pipeline potentials have remained stable at all test points. As expected, the impressed current CP system output has decreased as the pipeline polarised.

The test results over the past 3 years show the trenched and mounded pipeline sections, which are protected using sacrificial anodes and have an

Desalination Pipeline - Kurnell to Erskineville WATERLOO

ERSKINEVILLE

DULWICH HILL

Sydney’s water supply system

MARRICKVILLE

ALEXANDRIA

Sydney Park

PROJECT PROFILE

ZETLAND

ST PETERS

SYDENHAM

CENTENNIAL PARK

Erskineville

ROSEBERY

Industrial areas

KENSINGTON

Industrial areas TEMPE

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Muddy Creek crossing Cook Park Kyeemagh

BOTANY

ROCKDALE

MATRAVILLE BANKSMEADOW

BRIGHTON-LE SANDS

KOGARAH

PORT BOTANY

MONTEREY

PHILLIP BAY BEVERLEY PARK

RAMSGATE BEACH

Botany Bay

SANS SOUCI

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Silver Beach Kurnell

Captain Cook Drive

Desalination site

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Figure 1: WDA Pipeline Route Kurnell to Erskineville.

Potential (mV)

-200 -300 -400 -500 -600 -700 -800 -850mV -900 -1000 -1100 -1200 -1300 -1400 -1500

At the tunnelled pipeline sections where no cathodic protection has been installed, potential testing to permanent references shows stable potentials exist, with little variation. In addition, the permanent LPR corrosion probes have stabilised and readings indicate minimal corrosion is occurring in these sections.

This stable environment and low corrosion rate is to be expected as the concrete encased pipeline in the tunnelled sections is buried at depth where an oxygen depleted environment exists.

DOLLS POINT

approximate 3.2 km length, require an average of approximately 950 mA to achieve full protection. This equates to a current density of 0.05 mA per m2 of pipe. This is acceptable given the relatively short (6 m) pipe lengths which have field wrapped weld joints and significant soil resistivity variations

of the approximate 13.6 km pipeline length. This equates to a current density of 0.01 mA per m2 of pipe.

This result is expected as the sub-sea pipelines have a thick factory applied cementitious weight coat which protected the tri-laminate during construction. The current required to protect the sub-sea pipelines has decreased by approximately 30% since commissioning, which is to be expected as the pipelines have polarised with time.

along the route. Note there has been little variation in the current demand (less than 10%) and potential variations during this time. The variations noted appear to be related to ground moisture.

The sub-sea pipelines require an average of 400 mA for full protection

Some sections of the pipeline are subject to stray current effects, mostly relating to NSW Railway activity which is DC powered. As can be seen from Figure 2, most activity occurs during the morning and afternoon peak activity with minimal stray current activity during the night when minimal rail activity occurs.

Conclusion During the 3 year period since commissioning, the cathodic protection systems (sacrificial and impressed current) are operating satisfactorily.

The CP system design parameters made during design stage are being met. These parameters include pipeline external coating loss and current density. The decrease in current density, especially in the sub-sea sections, is to be expected as the pipelines have polarised.

The test results also show no corrosion is occurring at the tunnelled pipeline sections where no cathodic protection has been installed. The stable potentials and low corrosion rates again confirm the design parameter assumptions are being met.

For additional information, refer to 18th International Congress Paper No. 359, by J. Galanos and J. Kalis (2011).

7/12 7/14 7/16 7/18 7/20 7/22

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time (day/hour)

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Jim Galanos Engineering Manager, Corrosion Control Engineering

Figure 2: DC Stray Currents Recorded Over a 24 Hour Period.

August 2013 www.corrosion.com.au p.49

PROJECT PROFILE

The Star’s Multi Use Entertainment Facility (MUEF) undergoes final cleaning and inspection after completion. Its complex geometry is supported by a galvanized steel frame that was integral to the successful on-time delivery of a lowmaintenance structure.

Photo: Brookfield Multiplex.

Don’t Gamble on Your Coating Selection Introduction The redevelopment of the Star City Casino (now known as ‘The Star’) beside Sydney’s Darling Harbour is a recent application of HotDip Galvanized (HDG) steel in a high profile project. The use of architecturally exposed structural steel is becoming increasingly popular, and was a key design feature of the new Multi Use Entertainment Facility.

Given the nature of the design and the high building utilization, a resilient coating was required. HDG from Industrial Galvanizers was chosen as the project required a corrosion protection system that would remain maintenance-free for at least 10 years.

The durable nature of the HDG coating ensures it will exceed the warranty period, providing a maintenance-free service you can bet on!

Background Originally completed in Pyrmont, Sydney during the mid-90’s, The Star has recently undergone a significant upgrade. The $760 million redevelopment has produced a 3,000m2 gaming facility featuring a new entrance facing Sydney Harbour, a floor-to-roof glass façade and a 3,000 seat Multi Use Entertainment Facility (MUEF). The MUEF is a 40x60m complex geometric structure that utilizes a 300 tonne steel frame to support internal walls and an external glass façade, which is internally lit at night to spectacular effect. Its 16m height is split into three levels that include a theatre and loading dock.

The structure is located on the roof of the existing casino, which continued operation during construction.

p.50 CORROSION & MATERIALS

Why Hot Dip Galvanized Steel?

The principal builder on the project was Brookfield Multiplex, who engaged ICMP to manage the innovative construction methodology.

Chris Mathews of ICMP says there were a number of challenges and constraints that made the choice of Industrial Galvanizers’ HDG very suitable for this application:Limited Lay-down Area The construction zone was in a culde-sac that also contained the entry to the casino car park and the loading dock for the Lyric Theatre. All building deliveries had to take place in a 30m area that also contained the base of the tower crane, leaving just 16m of useable space. Storage space was limited and available locations were constrained by the load capacity of the concrete slabs.

As a result, the size of prefabricated steel structures was dictated by transport and on-site crane size. The vital erection sequence of the steelwork was split into stages that were erected sequentially to minimise storage and maximize structural stability and safety. Project success depended on:-

was important to the success of the project, which also depended on: Minimising weather interruptions Trading Operations Given the need to minimise disruption and impact on trading, the effect of local environmental issues also become important in project delivery.

Demolition of pre-existing structures was a necessity, as was reconstruction work; but on-site preparation – including painting - needed to be minimised to: essen the potential impact of dust L and fumes A Low-maintenance Corrosion Protection System The Star is on the shoreline of Sydney Harbour, and exposed to a marine environment. This is within one hundred metres of a sheltered coastal

S teel delivery to a schedule, as required. ff-site preparation and storage of O completed, coated steel.

Tight Construction Schedule The Star is a gaming facility, in use for 24 hours every day. Normal operations were to continue during the redevelopment, with minimal disruption and risk to important clientele. Ensuring schedule adherence

The MUEF during final construction phase; the internal sound-proof walls are in place, the stainless steel framework has been fixed to the HDG steel and the first glass panels have been installed.

Photo: Industrial Galvanizers.

PROJECT PROFILE

area with low deposition of chlorides and classified by ISO 9223 as C3, a “Medium” corrosivity environment.

Despite its partially enclosed environment the steel does require a protective coating to prevent corrosion that will either create aesthetic problems (surface rust); require maintenance in a timeframe that is shorter than planned or budgeted; or – in the worst case – significantly reduce the life of the asset through loss of structural integrity.

Aesthetics were a consideration in the selection of HDG steel, as the steel frame is visible through the glass façade as well as at internal locations.

The use of HDG as architecturally exposed structural steel (AESS) has become popular with architects and engineers due to its texture, characteristic surface appearance, speed and ease of erection and long low-maintenance life. Its selection for the MUEF project underlines the growing acceptance of exposed HDG steel in high profile buildings.

The steel framework has a glass façade, which is exposed to sunlight. Despite

the filtering effect of the glass, impact of UV light on the coating must also be considered. HDG is not affected by UV and this was one benefit of its selection.

The need for off-site preparation and lack of on-site storage meant that any protective coating on the steel needed to be tough and resistant to handling damage, as it would be craned directly into position from the back of the transport. The thick alloy layer that coats HDG steel proved highly beneficial in this application. The galvanic protection provided by the HDG coating ensures that scratches have minimal impact on service life or aesthetics.

Finally, there was limited access for maintenance post-completion.

Effectively, the steel frame was sandwiched between the interior soundproof walls of the MUEF and the attractive external stainless-steel and glass façade. In such a structure, the asset owner needs a guarantee that minimal - or no maintenance will be required for an extended period; Industrial Galvanizers was able to guarantee this for a period of 10 years.

The stainless steel framework for the external glass façade was insulated from the HDG steel frame to prevent bimetallic corrosion. The integrity of the insulating barrier was inspected on site before and after installation of the glass.

Summary The particular challenges faced by principal builder Brookfield Multiplex on The Star redevelopment advocated the use of Hot Dipped Galvanized steel. The need for a guaranteed low maintenance corrosion protection system in a marine environment; sequential delivery of off-site prepared steelwork; resistance to on-site handling damage; ability for rapid erection with minimal weather interruptions, and the aesthetic appeal of the industrial galvanized surface all made the choice of HDG steel the best solution for this application. The coating guarantee provided means that low maintenance is a sure bet!

Alex Spillett Industrial Galvanizers (Australia)

The MUEF during final construction phase; the internal sound-proof walls are in place, the stainless steel framework has been fixed to the HDG steel and the first glass panels have been installed.

Photo: Brookfield Multiplex.

August 2013 www.corrosion.com.au p.51

RESEARCH PROFILE

CSIRO’s Environmental Surface Design Team CSIRO’s Environmental Surface Design Team is dedicated to designing the next generation of active surfaces. These surfaces may be applied to materials for the protection of infrastructure or aircraft, winning nutrients from waste-water or enabling ultra-batteries.

The team’s key priorities are molecular scale design, and to work with, rather than against nature. Designing at the molecular level is leading to unparalleled control of chemical and electrochemical processes resulting in long life green coatings for aerospace, new protection systems for high CO2 pipelines, efficient extraction of phosphate and ammonia from waste water etc. Molecular design enables a myriad of design choices but requires ultra fast methods to sort through these choices. Nature has a way of breaking down the barriers we construct so we need to use natural processes themselves to promote autonomous self repair of materials, or to use embedded sensor networks to render our materials ‘aware’ so that they can change their form, enabling a new generation of ‘ageless’ materials and structures.

Projects Building the next generation of Materials include: Self-repair and Green Coatings Inhibitive coatings are undergoing significant advances driven by a need to find less hazardous inhibitors as well building self-healing mechanisms.

CSIRO is at the forefront of these new developments. We have developed a number of different high throughput (HTP) inhibitor testing experiments with which we have scanned hundreds of inhibitors in thousands of test conditions such as varying pH and concentration. HTP testing allows us to find previously undiscovered synergies between different inhibitors thus enhancing performance. In the selfhealing field, most developments have focused on self-healing mechanism in polymers, whereas CSIRO has adopted a novel approach of using inherent structures within coatings to deliver healing effects.

Durable Water Infrastructure and Waste Recovery Australian water pipe networks require $800 million p.a. of maintenance costs, a quarter of which is spent

p.52 CORROSION & MATERIALS

in responding to failures. CSIRO is developing technologies to predict or sense precursors of failure as well as improving pipe-life.

Wastewater, if treated effectively, contains significant value as a source of water, energy and nutrients. Recycling of phosphorus from Australia’s urbanised population could recover 20% of all phosphorus needed for Australian farm produce. CSIRO is developing Hybrid nano-materials for the removal of phosphorus from effluent, with the potential to recover up to 3.5 wt% of phosphorus. In parallel, CSIRO has developed electrochemically-assisted ammonia with high efficiency and more economically than commercial approaches. The technology aims to deliver a low-cost method of recovering ammonia from waste streams.

Self Aware Materials and Nano-Sensing Imagine a material that can senses the environment, predicts how the environment will change and then adapts itself to respond in precisely the right way. This may be rendering itself resistant to degradation or it could be opening up its pore structure to promote absorption into membranes in chemical or biochemical processing. CSIRO’s building networks of nano-sensing and molecular activators to make this vision a reality.

Development of commercially viable self-aware materials may take some years but along the way some exciting technologies are being developed. The first is multifunctional nano-sensing, enabling a wide range of chemical species or properties (pH, redox potential) to be measured on a micron size film and then a unique multi-frequency optical signal generated which defines the exact environmental conditions.

Projects Reducing Materials Development time.

Computational Design and Autonomous Science A major issue faced by the aerospace industry is that the development of new materials takes twice as long as the development of new aircraft (15 versus 8 years). CSIRO is developing

two technologies to dramatically cut the discovery phase of materials development – Computational Design and Autonomous Science.

Computational design allows molecular level design of materials on a personal computer and lifetime performance for components and structures to be evaluated. It will thus enable rapid sorting of material based on required service performance.

Autonomous discovery builds on HTP testing but replaces the analytical role of the scientists so that the system develops itself and then tests hypothesis of structure/property relationships, dramatically accelerating the rate of discovery.

Data Driven Modelling Data Constrained Materials Modelling (DCM) is a leading-edge methodology for quantitative 3D characterisation of material compositional microstructures to enable quantitative predictive modelling of material properties and performances. DCM requires tomography (CT) datasets taken at distinct x-ray energies and calculates quantitative, high-resolution 3D composition maps, with volume fractions of compositions on each voxel (volumetric pixel). DCM has been used for characterisation of microscopic spatial distribution of corrosion product in relation to corrosion resistant material development and corrosion inhibitor and diffusion paths distribution in aerospace primers for the development of effective and environment friendly coatings.

Climate Sensing and Life Estimation To understand and model corrosion in any system (plane, train, infrastructure) a comprehensive and detailed knowledge of how different protective systems respond to the environment and quantification of critical environmental factors is required. Such factors may cover geographic levels (global, continental) to micro-levels.

We monitor environmental conditions such as weather, pollutants and the response of surfaces to these conditions.

Environmental factors and the response of metals to these factors are used to estimate life expectancies of current protective systems and design testing regimes to evaluates novel systems.

RESEARCH PROFILE

Corrosion map of Australia.

DFT modelling of inhibitors.

Wastewater Treatment

Corrosion monitoring in Antarctica.

Phosphorus Recovery

1:0 Quantity of P

100% 0 0% Wastewater influent Variable [Mg]:[Ca]

Mainstream Treatment

0:1 1:0

Recovery via Precipitation

Struvite

Anaerobic Digestion Variable [Mg]:[Ca] High [PO43-] High [NH4+]

Digester Centrate

0:1 1:0

Purity of Product

Sidestream Treatment

[Mg]:[Ca] Ratio

Mg addition

Hydroxylapatite

Ca addition

0:1 5

pH

11

Focussed Ion Beam Cut of pitting at S phase in aluminium.

Electrochemical recovery of phosphorus.

Instrumented samples on a mast at the Italian Base at Terra Nova Bay Antarctica.

Corrosion with and without inhibitors on aluminium 2024.

DCM reconstruction of chemical topography of corroded zinc wire.

Capped quantum dots for nano-sensing.

Dr Tony Hughes is a Chief Research Scientist with 32 years experience as a surface scientist specialising in surface characterisation.

He has 24 years experience in protective coatings and 5 patents based on cerium coatings for Al-alloys.

Dr Sam Yang is a Senior Research Scientist in CSIRO and has led the development of DCM methodology.

He has researched on complex systems science including signal based performance monitoring of machines and process, statistical physics and phase transitions.

Mr Wayne Ganther is a Senior Experimental Scientist in the fields of Atmospheric Corrosion, Environmental monitoring, Microclimate instrumentation and Corrosion Mapping and Modelling.

He has 20 years of problem solving in research and industrial projects.

Prof. Ivan Cole is a Chief Research Scientist at CSIRO and team leader with over 20 years experience in fundamentals of corrosion and microclimate, life prediction, sensor systems and the development of IT tools.

Dr Tim Muster is a Senior Research Scientist with over 15 years experience in colloidal, surface and electrochemical systems. Recent focus areas include: physical methods for nutrient recovery from wastewater and embedded sensing technologies.

Contact: Dr Ivan Cole Chief Research Scientist CSIRO Division of Materials Science and Engineering Normanby Rd, Clayton 3168 Ivan.cole@csiro.au 03 95452054

August 2013 www.corrosion.com.au p.53

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