ACA C&M October 2012

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Vol 37 No 5, October 2012 ISSN 1326-1932

corrosion & prevention

ISSUE Inside this Issue: Corrosion & Prevention 2012: Sponsor and Exhibitor Profiles Technical Introduction: Designing with Steel for Corrosion Protection – Common Issues University Profile: James Cook University Project Profile: Rio Tinto Dampier Salt Operations Mistaken Island Mooring Dolphin Repair Project Project Profile: Thinking Laterally (and vertically) for Woodside Research Paper: Acts of Secrecy: the DC-3 that Disappeared

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CONTENTS

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

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

The ACA is a founder member of the World Corrosion Organization Front Cover Photo: The Melbourne CityLink Gateway is protected with one coat of Dulux Durebild STE surface tolerant epoxy White and one coat of Dulux Weathermax HBR high build recoatable two pack polyurethane in special formula “CityLink Cherry Red”. Image supplied by Dulux Protective Coatings.

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ISSN 1326-1932 Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257 Publications Director Mohammad Ali – GHD, MAli@ghd.com.au Editor Brian Cherry – Monash University, brian.cherry@monash.edu Associate Editors Research: Bruce Hinton – Monash University bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants, willie.mandeno@opus.co.nz News: Ian Booth – The Australasian Corrosion Association Inc, ibooth@corrosion.com.au

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President’s Message

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Chief Executive Officer’s Message

10

Letters to the Editor

12

News

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ACA Branch News

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ACA Standards Update

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Event Report: 68th meeting of the Australian Electrolysis Committee

26

Technical Group Review: Mining technical group meeting review

29

Young Corrosion Group Update

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ACA Certification Program

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Corrosion & Prevention 2012: Program

Reviewers Andy Atrens – University of Queensland Nick Birbilis – Monash University Frederic Blin – AECOM Lex Edmond – Monash University Harvey Flitt – Queensland University of Technology Maria Forsyth – Deakin University Rob Francis – Aurecon Australia Warren Green – Vinsi Partners Doug John – Curtin University of Technology Graeme Kelly – Corrotec Services Nick Laycock – Shell Grant McAdam – Defence Science & Technology Organisation David Nicholas – Nicholas Corrosion John Robinson – Mount Townsend Solutions Paul Schweinsburg – Queensland University of Technology Raman Singh – Monash University Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science & 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

Corrosion & Prevention 2012: Sponsor Profiles

50

Corrosion & Prevention 2012: Exhibitor Profiles

67

Coatings Group Member Profile

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Technical Introduction: Designing with Steel for Corrosion Protection – Common Issues

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University Profiler: James Cook University

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Project Profile: Rio Tinto Dampier Salt Operations Mistaken Island Mooring Dolphin Repair Project

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Project Profile: Thinking Laterally (and vertically) for Woodside

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Research Paper: Acts of Secrecy: the DC-3 that Disappeared

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Suppliers and Consultants

ACA Operations Board President: Peter Dove

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 brian.cherry@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 Branches & Divisions Auckland Division: Sean Ryder

64 9 261 1400

ACA Technical Groups Cathodic Protection: Bruce Ackland

61 3 9890 3096

Coatings: Matthew O'Keeffe

61 437 935 969

Chief Executive Officer: Ian Booth

Newcastle: Karen Swain

Operations Chairman: Paul Vince

New South Wales: Denis Jean-Baptiste 61 0 404 646 272

Finance Director: Brad Dockrill

Queensland: Cathy Sterling

Senior Vice President: Allan Sterling

South Australia: Erwin Gamboa

Junior Vice President: Andrew Hargrave

Tasmania: Grant Weatherburn

61 0 418 120 550

Immediate Past President: Ian MacLeod

Taranaki Division: Ron Berry

64 27 671 2278

Research: Nick Birbilis

61 3 9905 4919

Technical Director: Graham Sussex & David Sloan

Victoria: John Tanti

61 3 9885 5305

Research: David Young

61 2 9385 4322

Education Director: Geoffrey Will

Wellington Division: Monika Ko

Water & Water Teatment: David Mavros

61 419 816 783

Membership Director: Fred Salome

Western Australia: Gary Bennett

Communications Director: Matthew Dafter & Mohammad Ali Events Director: Dean Wall Advocacy Director: John Duncan

61 0 418 854 902

61 7 3821 0202 61 8 8303 5473

64 4 978 6630 61 0 408 413 811

Concrete Structures & Buildings: Frédéric Blin

61 3 9653 8406

Mining Industry: Peter Farinha

61 8 9456 0344

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

Welding, Joining & Corrosion: Graham Fry 61 409 698 968 Young Corrosion Group: Erwin Gamboa

61 8 8303 5473

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

PRESIDENT’S MESSAGE

to it while enjoying the support of our major conference sponsor Dulux Protective Coatings.

Talking with Ian Booth in his office about ideas for this President’s message he pointed to a series of volumes of back issues of Corrosion & Materials. I grabbed a few random editions and here are some interesting points of what I discovered.

The current manifestation of our publication was first published in April 1996 with the title “Corrosion & Materials” which David Whitby, the then publication director, said ‘is succinct and encompasses both the problem we have and the materials with which we are involved”. This still holds today.

Peter Dove President Have you registered for Corrosion & Prevention 2012 in Melbourne on November 11 to 14? If Not, Why Not? I wouldn’t like it to end in tears when you hear what great technical and social programs you missed out on from all the delegates who had a great time there. I’m booked in and I look forward

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Before C&M, the publication was called “Corrosion Australasia”, with the first edition of 19 pages out and about in October 1976 with a mandate described by Peter Thorpe of being “published at two monthly intervals, and will contain original technical papers, technical notes, and case histories, selected to make each issue provide something of interest for all readers.” With C&M running at some 60 odd pages we have something for everyone.

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p.6 CORROSION & MATERIALS

Of the original Editorial Committee we have to thank Brian Cherry for his long and dedicated service who is retiring from editing C&M with this issue. Long servicing and dedicated volunteers like Brian are the backbone of our association. We are fortunate to have them. THANKYOU Brian, at least now C&M is one less thing to think about while you and Miriam are racing LENA around Port Phillip Bay. Speaking of a long standing relationship with the ACA, on the cover of Volume 1, Edition 1 of Corrosion Australasia are photos of the 1976 handbook from Denso who still actively support us, as do many others that make up our platinum and gold members.

On Corrosion Australasia’s cover in October 1981 there is a guy standing on the top of a ladder in a lab coat, so we are talking real science here, nailing metal coupons to a lamp post on a busy four lane road with the promise of results at the next ACA conference. While the picture may raise a few eyebrows as we’ve learnt to work more safely these days, this was the ground work for the CSIRO corrosion mapping of Melbourne and then development of the corrosion maps of Australia we use today.

It was 1982 that Brian Cherry reported to our Council that a feasibility study ordered by the Minister of Science and Technology was underway to determine the true cost of corrosion in Australia, to delineate specific research and development programs for Australia’s needs and to determine how, when and where a corrosion centre should be developed. The report was published in June 1983 and resulted on the corrosion centre being established, which has developed into our head office with a staff of 11 administering the needs of over 1,700 members. Something else to blame thank Brian for.

I found a photo from June 1996 of the first class of ACA Coating Inspectors in New Zealand. How time flies. The ACA has now trained over 1,000 coating inspectors since those humble beginnings, not to mention running courses on cathodic protection, concrete, protective coatings and corrosion technology.

Let’s not forget our history, and the efforts of those many selfless volunteers in getting our association to where it is today, and like them work together to grow and maintain the ongoing relevance and contribution of the ACA in the fight to mitigate corrosion.

Time to start painting… again.

If only they had hot dip galvanized in the beginning.

Completed in 1932, the Sydney Harbour Bridge is a national icon, but its anti-corrosion maintenance program is also part of Australian folklore.

Compared to any other protective coating for steel, hot dip galvanizing is unmatched in its superior corrosion resistance, strong and tough coating, proven performance, and lifetime cost benefits.

Hot dip galvanized steel also has very high sustainability credentials.

Zinc and steel are 100% recyclable and can be recycled an unlimited number of times. Hot dip galvanized steel contains no volatile organic compounds (VOC’s) and does not emit ozone depleting gases.

Hot Dip Galvanizing – First and last line of defence For further examples of the durability of hot dip galvanizing please visit www.gaa.com.au

October 2012 www.corrosion.com.au p.7

CEO’S MESSAGE

Future Fund, policy development and benchmarking deliver for ACA members In July 2009, during Brad Dockrill’s presidency, ACA created a Future Fund designed to ensure the future financial viability of the association and to create a pool of funds outside of budget which would give ACA the flexibility to allocate additional expenditure to improve the delivery of new member benefits and to supplement resources to speed up the implementation of other important activities.

evelopment of corrosion kits for D use as educational resources in the secondary and undergraduate education systems

At its August 2012 meeting, after having consulted with Branches, ACA’s board released $100,000 from the Future Fund to provide funding for five activities.

The five projects which have received funding are:

The updated Corrosion Technology Certificate resource material will allow ACA to make this resource to members via the ACA web site. Print and electronic versions will also be made available to universities and other educational institutions so that there is a better awareness of corrosion issues amongst students before they complete their courses.

cceleration of the review A and updating of training and education courses onsultations and legal drafting C expenses for a revised constitution onations to support the activities of D ACA Foundation Limited Production of technical guides

Already work is underway with the review of courses – the on-line training of the Coatings Inspector Refresher program will commence by year’s end, the suite of Cathodic Protection courses is being developed so that they are fully up to date, better articulate with each other and can be easily modularised to give greater flexibility in delivery. The resource material for the Corrosion Technology Certificate is similarly going through a review and this project will be completed in 2012.

protect ACA financial assets and to ensure ACA continues to observe best practice in financial management and protection of funds.

ACA has led the creation of a group of associations which together benchmark their financial and operational performance. This “first” in the association management sector in Australasia will assist ACA to continue to develop and will provide reliable data from which ACA can accurately assess its performance when compared with other leading technical associations.

ACA’s board and staff continue to develop ACA as an efficient, value focused organisation. The Future Fund, policy development and benchmarking activities are all designed to ensure ACA continues to develop for the benefit of members and the industries it serves.

Ian Booth Chief Executive Officer ibooth@corrosion.com.au

The board has also approved the introduction of a reserves and investment policy designed to further

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Embedded Zinc Anodes

Anode embedded in repair concrete to protect the surrounding areas. High output gives cathodic protection not just low polarisation for cathodic prevention. Use in conjunction with galvanised reinforcement in new structures for long term protection with low cover in severe exposures.

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ZincTape’s pre-applied conductive adhesive is unique and ensures continuous active corrosion protection. Applied insitu on new or old steel it provides better corrosion protection than hot dip galvanising.

The Camur II is a complete system for monitoring structures and controlling cathodic protection systems.

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Steel surface can be dried and ZincTape applied between tides to enable protection to over lap with water anodes.

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Force’s ERE 20 manganese dioxide half cell has 30 years of proven performance monitoring CP systems. No drifting of results preventing long term data comparisons.

Protector’s CM2 continuity tester is used to test reinforcement connections and continuity across the ground bed in CP applications.

Test under load is essential.

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corrPRE’s Current Limiters avoid excessive current outputs in ICCP systems. Models 5-50, 50-500 & 2502000 mA (latter is AC powered).

October 2012 www.corrosion.com.au p.9 Stand 9, ACA Corrosion and Prevention 2012. Nov 11-14, Melbourne

LETTERS TO THE EDITOR

The Importance of Prequalification Testing and Verification of Competencies in the Application of Protective Coatings In today’s industrial workplace, mistakes and product failures can cost companies thousands or perhaps hundreds of thousands of dollars when it comes to rework or the unforseen extension of a particular project schedule. However while delays can be reasonably expected with any large scale project, they can also be reduced if not eliminated by adopting proper planning and using proven methods or techniques in whatever area of construction, maintenance or refurbishment that is being undertaken.

and remain compliant within the specification boundaries, otherwise serious delays can occur and be likely to cause a domino effect on scheduled works that follow.

I refer mainly to the prequalification of protective coatings in petrochemical and offshore facilities and the verification of competencies of those persons who apply them.

Similarly low film thickness coatings such as Inorganic zinc (IOZ) or arc spray aluminium can cause time consuming delays if applied at higher than specified DFT. In the case of IOZ, if proper cure is not achieved the entire coating system may fail prematurely and could be very expensive to repair.

For many, many years all welding processes and personnel who carry out welding in an industrial application, are subjected to vigorous prior testing to ensure that they can adequately meet the required specifications and standards. This is usually done by replicating the proposed processes in a workshop environment and subjecting them to destructive testing, to both verify the process itself and the skills of the technicians applying them. However only relatively recently has this idea been adopted by some companies in the application of protective coatings, which form the first line of defence in contributing to the longevity of structural steel and concrete in any industrial or marine environment.

When an engineer decides to use a particular product (protective coating in this example) on a certain structure or pipework via research of the chemical constituents or proven case history in a similar environment, sometimes the application methods of such a product are not given the same consideration as selection of the product itself.

For example if a tight construction window only allows for 1 coat of an ultra high build epoxy at 2500µm around a jacket leg in this instance, the construction manager needs to have faith that the person applying the product can achieve that goal

p.10 CORROSION & MATERIALS

Destructive testing in this example is also advantageous prior to mobilization, to validate that the adhesive / cohesive strength of the coating is satisfactory compared to say 2 coats at 1250µm and to verify that the applicator can achieve a holiday free layer in 1 coat.

To give this some perspective, if original application cost = $1k, repair of a failure can be $2k, $5k even up to $10k depending on complexity of structure, location and when the failure becomes evident.

The most common causes of failure are usually as follows: A) Inadequate surface preparation — a degree of cleaning substandard to that specified, or coating over dust, dirt, soluble salts and/or debris contaminates on the surface after surface preparation.

B) Poor or deficient surface preparation is probably the number one cause of coating failures.

C) Inadequate mixing or mis-mixing — prior to application. Coating material should be mixed properly (in sequence) to ensure that the curing agent, pigment and resin are blended to a homogeneous consistency, and if need be inducted for sufficient duration to develop the required thixotropy. Some heavily pigmented coatings (such as zinc rich primers) will require an in-pot agitator in order to maintain homogeneity.

D) Deficient coating thickness — this is perhaps the second most common cause of coating failures.

E) Lack of or inadequate inspection can also be jointly responsible for the scenarios above.

Therefore, when coating systems are selected and approved for the application it is in the best interest of the client and the project manager to stipulate that the applicator undergo prequalification testing which should be overseen by an experienced coating inspector.

A typical example for these tests would involve each painter producing a test panel, usually 1000mm x 1000mm with some sort of angular protrusion, or pipe work of a similar diameter representing that which is to be coated in the field, for each coating system in the specification.

Quality inspectors should record and document as a minimum that the following are adhered to in accordance with the specification: perators should be trained in the O safe use of the equipment which they are using and all equipment used throughout prequalification process should be identical to that which is intended to be used in the field. here is a quality management plan T in place with a comprehensive ITP (inspection & test plan) which has been reviewed & approved by both applicator and Client. mbient conditions are recorded A throughout the prequalification process.

S urface treatments have been prepared to the specified class of blast. nchor profile is angular and within A the specified range of depths. ixing & application of primer is M completed within the post blast window before oxidation of the clean surface begins.

LETTERS TO THE EDITOR

pplications of subsequent coats are A within the recoat windows and wet film thicknesses are observed. inal coats are free from runs, sags, F dry spray, holidays and conform to the system’s specified dry film thickness.

I f necessary destructive testing should be conducted to verify the paint system for adhesion/ cohesion and coupons retained for future reference.

In comparison to the total capital expense of a construction project the surface treatments in general roughly represent only 1% of the overall cost.

If this is further broken down into the 3 separate components, on average: Surface preparation= 45% Labour= 35% Materials= 20% However delays to a project can cost far more and perhaps have a negative impact on the reputation of a company.

As with many things in life, prevention is always better than the cure. So with a little effort; planning, prequalification and strategic use of quality professionals, coating projects can have a higher chance of success without incident or injury and clients can be confident in their end product serving its purpose.

Jonathan Gilfillan QA/QC

Salt Fog Testing Dear Brian, I refer to the Technical Note – ‘Salt Fog Testing’ published in Volume 37, No 4 (August 2012) edition of Corrosion & Materials. The Technical Note included a number of photographs of articles after salt fog testing and noted that salt fog testing is not an exact replication of natural environment exposure.

However, I feel it is important to remind your readers that these tests should not be used as a comparison of performance of one material to another, unless those materials are near identical in nature. This is especially important in metallic coatings which often rely on the formation of passive films. As stated in the Scope of ISO 9227:2012 (Corrosion tests in artificial atmospheres — Salt spray tests): “The salt spray methods are all suitable for checking that the comparative

quality of a metallic material, with or without corrosion protection, is maintained. They are not intended to be used for comparative testing as a means of ranking different materials relative to each other with respect to corrosion resistance.”

In addition, ISO 14713-1:2009 (Zinc coatings — Guidelines and recommendations for the protection against corrosion of iron and steel in structures — Part 1: General principles of design and corrosion resistance) passes further comment the matter in Section 8 of that standard, where it states “ASTM Committee G-1 on Corrosion of Metals has jurisdiction over the salt spray standards ASTM B117 and ASTM G85.

The Committee passed the following resolution regarding the use of ASTM B117: “ASTM Committee G-1 on the Corrosion of Metals confirms that results of salt spray

(fog) tests, run according to ASTM standard designation B117, seldom correlate with performance in natural environments. Therefore, the Committee recommends that the test not be used or referenced in other standards for that purpose, unless appropriate corroborating long-term atmospheric exposures have been conducted”.

Members of the ACA may be interested to know that other standards related to accelerated corrosion of metals are under development by ISO and they may have an opportunity to comment on Drafts through the relevant Australian Standards Committee.

Yours Sincerely Peter Golding Chief Executive Officer Galvanizers Association of Australia

October 2012 www.corrosion.com.au p.11

NEWS

Corrosion Control Directory update The ACA Corrosion Control Directory is designed to assist members in locating a service provider in the various fields of corrosion prevention. The ACA is updating the Corrosion Control Directory on its website to be more user friendly and searchable by category, keyword or country. It will be easier to find just the right company as each listing will have a short description of the services provided and a link to the company’s website.

Categories have also been reviewed and will now include: athodic and Anodic Protection C Cathodic and Anodic Protection Consultants Coating Inspectors Composites and Plastics Concrete & Concrete Structures Consultants Corrosion Inhibitors Fasteners Marine

etals & Alloys M Protective Coatings & Linings Repair, Rebuild & Maintenance Specialist Corrosion Control Surface Preparation & Cleaning Testing & Research Training & Education For further information or if you’d like your business listed, please contact Renata Fularczyk on rfularczyk@corrosion.com.au or on +61 (0)3 9890 4833.

Corrosion Matters improves on regular communication ACA has reintroduced electronic newsletters as a service to members and the broader Australasian corrosion community.

Corrosion Matters is now published every two weeks, generally on Tuesday mornings.

The focus of Corrosion Matters is to provide up to date information on upcoming ACA events, opportunities

for training and education, conference updates, links to job listings and other information which doesn’t easily meet the deadlines or have the “print life” of material which would normally appear in Corrosion & Materials.

To ensure you receive your copy of Corrosion Matters, ACA’s domain name corrosion.com.au should be set as a friendly source in your email filter.

Importantly, Corrosion Matters also enhances ACA’s ability to recognise the level of support received from platinum corporate members towards the ongoing development of ACA.

Jacquie Martin at ACA’s Melbourne office is available to assist with any enquiry regarding Corrosion matters - +61 3 9890 4833 or jmartin@corrosion.com.au.

Technical events return to Brisbane In addition to hearing from three expert presenters, the audience enjoyed the networking opportunities, catching up with industry colleagues and making new contacts.

Coal Processing Industry; Mike Rooney from Contract Resources challenged the audience with his presentation which posed and addressed the question Industrial Coatings – Are We Expecting Too Much? The Human Element and Paul Vince from SA Water revisited ACA’s Corrosion Challenges Project with an overview of The Cost and Impact of Corrosion of Infrastructure in the Australian Urban Water Industry.

Brad Dockrill from Vinsi Partners presented on Case Studies of Concrete Repair Methods and Approaches in the

It is expected that by the time this edition of Corrosion & Materials is distributed a further event will have

More than 50 ACA members and industry stalwarts gathered recently in Brisbane at what was the first of a new series of technical events planned for one of ACA’s major membership bases.

p.12 CORROSION & MATERIALS

been conducted and a schedule for events through to the beginning of 2013 will be settled.

ACA’s Queensland Branch will host Corrosion & Prevention 2013 in Brisbane at the Brisbane Convention and Exhibition Centre from 10th to 13th November 2013.

Further information on ACA events in Queensland is available via ACA’s web site at www.corrosion.com.au or by contacting Cathy Sterling at the Brisbane office on +61 7 3821 0202.

NEWS

Foundation receives substantial donation ACA Foundation Limited has received a $50,000 donation from The Australasian Corrosion Association Inc (ACA).

Paul Vince, ACA Chairman recently received approval from ACA’s board to make the sizeable donation as a demonstration of ACA’s commitment to the Foundation’s activities. Funding for the donation came from ACA’s

opportunities which benefit the industries which both the Foundation and ACA serve.

Future Fund which was created to ensure ACA has the funds necessary to support its own growth into the future and to fund special projects which might otherwise not be able to receive the financial support they deserve.

The Foundation is focussed on providing financial support for education

Information on Foundation activities is available from Jacquie Martin at ACA’s Melbourne office - +61 3 9890 4833 or jmartin@corrosion.com.au.

New appointment at Vinsi Vinsi Partners Consulting Engineers are delighted to announce that Tony Zheng has joined them as a Senior Structural Engineer.

Tony has over 25 years of experience in the consulting fields of Structural, Civil and Remedial Engineering coupled with Materials Technology.

Since 1998 he has focused on the investigation and repair of various civil, infrastructure and

building structures as well as durability assurance.

He has hands on consulting experience with advanced non-destructive testing and evaluation of reinforced, prestressed and post-tensioned concrete structures at mine sites, desalination plants, reservoirs, railway stations, road and railway bridges. This experience has included the publishing of technical papers in international journals and conferences.

Tony has undertaken durability consulting including thermal analysis and early age concrete crack control, advice on concrete mix and cast sequence for thick and large volume pours. Such consulting has translated through into the construction phase with site supervision for concreting, quality control and non-destructive evaluation at various sites within Australia as well as in Asia and South America.

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NEWS

BP pledges $100 million to UK-led universities to create industry-changing materials BP is to establish a $100 million international research centre, known as the BP International Centre for Advanced Materials, or BP-ICAM. This centre will lead research aimed at advancing the fundamental understanding and use of materials across a variety of energy and industrial applications.

The BP-ICAM will be modelled on a “hub and spoke” structure, with the ‘hub’ located within The University of Manchester’s Faculty of Engineering and Physical Sciences, which has core strengths in materials, engineering, characterisation, collaborative working, and a track record of delivering breakthrough research and engineering applications that can be deployed in the real world. The “spokes” and other founder members, all worldclass academic institutions, are the University of Cambridge, Imperial College London, and the University of Illinois at Urbana-Champaign.

The ten-year investment programme will fund research into advanced materials and is expected to support 25 new academic posts, along with 100 post-graduate researchers and 80 post-doctoral fellows.

The UK Chancellor of the Exchequer George Osborne said: “This coalition Government is committed to putting innovation and research at the very heart of its growth agenda. We are ensuring the UK maintains it competitive edge in science and we are creating an environment where innovation can flourish. That’s why top businesses such as BP are investing in the UK and supporting our worldleading universities in delivering cutting edge research. And as an MP for the North West of England I particularly welcome the fact that BP’s International Centre for Advanced Materials will be based at Manchester University.”

p.14 CORROSION & MATERIALS

Bob Dudley, BP group chief executive, said: “Advanced materials and coatings will be vital in finding, producing and processing energy safely and efficiently in the years ahead, as energy producers work at unprecedented depths, pressures and temperatures, and as refineries, manufacturing plants and pipeline operators seek ever better ways to combat corrosion and deploy new materials to improve their operations.

“Manchester has world-leading capabilities and facilities in materials and was chosen after a global search to act as the ‘hub’ of the centre, working with other world-class university departments. We look forward to deepening further the very productive partnership that already exists between our professionals in BP and the academic team at Manchester.”

The University of Manchester’s President and Vice-Chancellor, Professor Dame Nancy Rothwell, FRS, said: “We are very pleased that BP has chosen The University of Manchester to be the ‘hub’ for the BP-ICAM, utilising our world-leading breadth of research expertise in advanced materials and their applications to address the current and future challenges facing industry. We also look forward to working closely with the University of Cambridge, University of Illinois at Urbana-Champaign and Imperial College London as the founding “spokes” of the BP-ICAM. This is an excellent announcement for UK science and recognises the excellence of our universities, our research and our willingness and ability to work with global industry.”

BP’s Chief Scientist, Ellen Williams said: “We’re very excited by the vision of taking advanced tools that were developed for fundamental research to the real-world application of materials used for energy production. Our

engagement with these four universities demonstrates the importance both of research and of the innovation which can lead to advanced technologies.”

The BP-ICAM hub will be based in dedicated premises which will use state-of-the-art tools to support this major international collaboration. The BP-ICAM will carry out research into seven primary areas of direct interest to industry – structural materials, smart coatings, functional materials, catalysis, membranes, energy storage and energy harvesting – with the initial focus on: S tructural materials, such as new metal alloys and composites for deepwater production, and high pressure/high temperature reservoirs; S mart coatings, for increased protection from the elements and improving a structure’s usable life, protecting pipelines and offshore platforms from corrosion; embranes and other structures, for M separation, filtration and purification of oil and gas, water and chemicals in production, refining and biofuels processes and petrochemicals.

“This should allow us to change the way we build, operate and maintain our equipment; manufacture cleaner and more efficient products; develop imaginative energy sources and then store that energy for when it is needed most; and increase the use of lighter metals and composites for structures and products,” added Dudley.

NEWS

Agreement furthers oil and gas training and research Charles Darwin University (CDU) has furthered its capacity for education, research and on-job training related to the needs of the oil and gas industry after signing a memorandum of understanding with Incospec and Associates Australia.

The memorandum will see the establishment of collaborative initiatives between CDU and Incospec for specialised training, educational and research services, including training and competency development in areas of corrosion engineering.

Incospec Technical Director Mark Weston said that corrosion remained a huge cost to the oil and gas industry.

“Corrosion-related damage costs the industry between 3 and 5 per cent of GDP,” he said. “It is vital that we improve our research in testing and evaluation of corrosion protection.

Together with CDU we will work towards providing good quality corrosion engineering, specific to the oil and gas industry in North Australia and Incospec globally.”

CDU Vice-Chancellor Professor Barney Glover said the agreement would allow CDU researchers to work with industry to develop research and training initiatives at the new North Australian Centre for Oil and Gas. “The new facility, due for completion toward the end of 2012 will enable the university to provide a range of specialised and generic training requirements in the areas of Higher Education and Vocational Educational and Training for the oil and gas industry,” Professor Glover said.

“Incospec has extensive experience in the provision of corrosion engineering consultancies and services for the oil

and gas industry, other main resource sector industries, maritime operations and infrastructure”.

“Once the new centre is up and running Incospec alongside our CDU engineering staff and students, will be conducting corrosion testing and evaluation research locally for the oil and gas industry.”

Professor Glover said the memorandum would also keep CDU students well connected with the industry while they were studying.

Incospec Technical Director Mark Weston and CDU Vice-Chancellor Professor Barney Glover signing the memorandum.

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October 2012 www.corrosion.com.au p.15 23/01/2012 2:00:05 PM

NEWS

­ athodic Diecasting to Cathodic C Anodes Australasia One of Australia’s leading anode manufacturers is changing its name to more accurately reflect the activities of the company. General Manager Ross Gorfine explains, “We felt that the name Cathodic Diecasting no longer represented what we do. Although die cast anodes are an important part of our product range, they only make up a small proportion of what we manufacture. We cast galvanic anodes of all sizes and alloys using a variety of furnace types and casting methods.

We believe that our new name, Cathodic Anodes Australasia (CAA), more accurately reflects the direction of the company”.

“The Cathodic Diecasting name has become synonymous with the

manufacture of high quality anodes.

Since 1984 our standing within industry has been won through consistently meeting or exceeding our customers’ expectations. We understand the risk involved with the change, but believe that it is necessary to ensure that the company name remains relevant into the future”.

“We are very happy with the design of our new logo, the inverted orange triangle symbolises the molten metal and the space between the two A’s represents the cast iron mould.”

“The ownership and management structure of the company has not changed. We continue to be proudly Australian owned and continue to

manufacture at our Kunda Park plant in Queensland.”

Cathodic Anodes Australasia will continue to have the same telephone and fax numbers. The new web address will be www.cathodicanodes. com.au. The existing website www. cathodicdiecasting.com.au will continue to remain active for the foreseeable future and the same will apply to email addresses.

Cathodic Anodes Australasia (CAA) will continue to offer high quality anodes, backed by an inspection and testing system and look forward to working with their customers under the new name.

Cathodic Anodes Australasia

A Change for the Better It’s an exciting time for us – Cathodic Diecasting is changing it’s name to Cathodic Anodes Australasia (CAA) to more accurately reflect what we do; manufacture anodes. There is no change in ownership or management and we will continue to offer high quality anodes backed by an inspection and testing system that is second to none.

Cathodic Anodes Australasia

T +61 7 5476 9788

F +61 7 5476 8268

www.cathodicanodes.com.au E sales@cathodicanodes.com.au

NEWS

Quest Integrity Group, LLC Announces Acquisition of Digital Insight Limited On August 21, 2012 Quest Integrity Group, LLC announced its acquisition of Digital Insight Limited, a privately held, specialty Remote Digital Video Inspection (RDVI™) company based in New Zealand.

Under Quest Integrity Group’s ownership, Digital Insight’s current management team will continue to lead the company as part of Quest Integrity’s advanced inspection services. The company’s RDVI™ technology will be branded as Digital Insight™ under the Quest Integrity Group name. All other operational and administrative business functions will be integrated with Quest Integrity.

“We are excited to welcome this market leader in a rapidly growing inspection technology area to Quest Integrity Group. The synergies with our existing business portfolio, particularly in advanced inspection and engineering assessment, align strongly with our core strategic growth aspirations in the energy sector,” said Andy Saunders-Tack, Vice President Asia-Pacific, Quest Integrity Group.

Quest Integrity Group, a TEAM Industrial Services company (NYSE: TISI), is a global leader in the development and delivery of asset integrity and reliability management services and solutions for its clients.

Solutions consist of technologyenabled, advanced inspection and engineering assessment services and products that help companies in the refining and chemical, pipeline, syngas and power industries increase profitability, reduce operational and safety risks, and improve operational planning. Quest Integrity Group is headquartered in Seattle and has offices in Houston, Denver, Canada, The Netherlands, United Arab Emirates, Australia and New Zealand.

For more information, visit www.QuestIntegrity.com or call +64 (0)4 978-6630.

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October 2012 www.corrosion.com.au p.17

NEWS

ACA welcomes new members Corporate Gold Insight Global Solutions www.insight-global.com.au Insight Global Solutions (IGS) have over 25 years of field and technical experience and can offer a full range of services including third party inspection, asset surveys, project management and client representation.

IGS are constantly looking for new and innovative ways to help clients control their maintenance programs and are currently working on a software solution. Their independence is a valuable asset, enabling IGS to offer their clients totally unbiased advice, free from commercial supplier restraint.

Corporate Silver Atteris www.atteris.com.au Atteris offers Pipeline Engineering Solutions to offshore development projects, from the early concept phase through to the design engineering phases, including subsequent field engineering and project management support. Their areas of expertise include; Design of Pipelines from Offshore Fields/ Platforms to Onshore Gas Treatment Plants, Design of Subsea Pipeline Systems, Risers and Tie-in Spools, Design of Horizontally Directionally Drilled Crossings for Pipelines, Design of Micro-tunnelling for Pipelines and Finite Element Analysis.

Corporate Bronze Anti Corrosion Technology www.anticorrosiontechnology.com Anti Corrosion Technology (ACT) is an engineering company that offers the oil & gas, water, mining and power generation industries full technical

support in materials engineering and corrosion control. ACT is the authorised sole distributor of STOPAQ in Australia offering product & service solutions for external pipeline corrosion protection of field joints, flanges, HDD, etc as well as external corrosion protection of tank bottoms and offshore/submerged structures.

Bluey Technologies www.bluey.com.au Bluey Technologies Pty Ltd is a supplier of construction products for major civil engineering infrastructure works.

Their range of products includes high performance pre-packaged concrete repair products, concrete corrosion protection liners, liquid and sheet membranes and non-metallic ground anchors. All of their products are supported by sound technical advice and on-site support.

Hobson Engineering www.hobson.com.au Hobson Engineering was established in 1935 and is 100% Australian owned.

Hobson is one of the leading distributors of fasteners and is a specialist in the supply of Stainless Steel fasteners through technical knowledge, exotic materials, stock depth, manufacturing, independent heat batch NATA testing, coating and quality control to ISO9001.

Hobson is the master distributor of Bumax® (the world’s strongest stainless steel bolt).

McBerns www.mcberns.com.au For over 20 years McBerns has supplied innovative maintenance products to the Water & Wastewater Industry. Rust Bullet® is a tough, chemical and scratch resistant protective coating for Rust & Corrosion Prevention and Cure and is

used to repair concrete corrosion and rust in sewerage treatment plants, water storage sites, pipe work, valve pits & wastewater infrastructure.

Multicoat www.multicoat.com.au Multicoat has for 15 years, been a leading provider of environmentally sustainable surface finishing solutions.

Multicoat are specification application specialists utilising powder, protective, decorative, commercial, industrial and automotive coatings to give products a professional finish and provide the required level of corrosion protection.

Tincone www.tincone.com.au Tincone management has over 70 years combined experience which has equipped them for work in the Construction and Mining Sector.

Tincone offer services from all their Weathered Blast & Paint Facilities, Full Mobile & Shutdown Services, Abrasive Blasting and Protective Coatings.

Tincone aim to provide an experienced, reliable and honest workforce to clients by delivering value through quality products and services.

Vincent Painting Contractors Vincent Painting Contractors have been applying industrial coatings for the power, paper, water, oil and gas industries since 1995. Prior to that their employees have local industrial painting experience dating back to 1983. Vincent Painting Contractors contracts to supply abrasive blasting, linemarking, signwriting and painting services to Hazelwood Power, TRUenergy Yallourn, Loy Yang Power and Loy Yang B Power stations and mines in the Latrobe Valley, Victoria.

Carboguard®690 is a proven performer in Carboline's range. This coating exhibits outstanding moisture tolerance during application and has a low temperature cure capability. Ideal for industrial or marine environments, 690 can be used in immersion service for salt water, process water and waste water treatment projects. Talk to your local Carboline representative today!

p.18 CORROSION & MATERIALS

NEWS Individual Members Name

Company

Location

David Anderson-Smith

Royal Australian Navy

New South Wales

Adam Andrews

Vertical Services

New South Wales

Pierre Ayoub

McConnell Dowell

Queensland

Dan Buelk

Ask4Dan

USA

Peter Camera

Victoria

Marie Clancy

Monash University

Victoria

Michael Crowley

Blastcoat

Wellington

Alin Finna

Industrial Galvanizers

New South Wales

Anthony Giles

Adelaide Pressure Inspection

South Australia

Tim Gowans

STPM Industries

Tasmania

Wade Guye Andrew Harrison

Victoria Apache

John Learoyd

Queensland

Sarah McCrackon Gerome Macri

Queensland Victoria

Global Painting

Terence Magryn

Western Australia South Australia

Alan Parnell

ICD Asia Pacific

New South Wales

Karl Vogt

Steelink

Queensland

Mark Watson Jonathon Wood

Tasmania SGM

Newcastle

Name

Institution

Location

Izaac Bradley

The University of Adelaide

South Australia

Scott Caddick

The University of Adelaide

South Australia

James Cobbledick

The University of Adelaide

South Australia

Alexey Deev

The University of Adelaide

South Australia

Mali Ding

The University of Auckland

Auckland

Junye Dong

The University of Auckland

Auckland

Mohd Aiza Farid Hasan

The University of Adelaide

South Australia

Christine Head

The University of Adelaide

South Australia

Paul Kinlough

The University of Adelaide

South Australia

Jonathan Lines

The University of Adelaide

South Australia

Yangsi Liu

The University of Auckland

Auckland

Joshua Logan

The University of Adelaide

South Australia

Alejandro Miracle

Monash University

Victoria

Daniel Ong

The University of Adelaide

South Australia

Xin Ouyang

The University of Auckland

Auckland

Thenesh Kumar Rajasekaran

The University of Adelaide

South Australia

Nicholas Reeks

The University of Adelaide

South Australia

Rafael Ritzinger

The University of Adelaide

South Australia

Stevan Rokvic

The University of Adelaide

South Australia

Muhammad Afifi Shakir Mahood Sabri

The University of Adelaide

South Australia

Marzieh Sharifi

The University of Auckland

Auckland

Jay Stevens

The University of Adelaide

South Australia

Juan Su

The University of Auckland

Auckland

See Leng Tay

The University of Auckland

Auckland

Xiaojin Wei

The University of Auckland

Auckland

Mohd Naim Bin Yusof

The University of Adelaide

South Australia

Student Members

October 2012  www.corrosion.com.au  p.19

BRANCH NEWS

WA Branch Technical Event Galvanic Anodes for Protection of Corroding Steel Reinforcement ACA WA branch hosted another technical gathering on the topic of Galvanic Anodes for Protection of Corroding Steel Reinforcement

by Andrew Dickinson of Parchem Construction Supplies on Wednesday, 22 August, 2012.

The evening started at 6pm with refreshments including snacks and drinks with approximately 45 members and non-members attending the event.

Catching up with familiar faces and networking with new attendees made the night that much more memorable for members.

After greeting the attendees, participants were seated for a technical presentation with the welcome and introduction by Branch President, Ben Biddle. In his opening remarks, Ben stressed his appreciation of WA YCG

for their successful effort of arranging a site visit for students and other young corrosion professionals in Kalgoorlie in July.

Andrew gave an impressive presentation describing the latest developments and case studies in the use of galvanic anodes to protect reinforced concrete. He detailed his speech by comparing the different standards requirement for levels of protection and advantages of using the sacrificial anodes to extend the life of reinforced concrete structures.

A description was given of the recent trials and project installations of galvanic anodes that Andrew had seen in his projects. He concluded his interesting presentation showing the beneficial effect of changing the concrete conductivity using additive and how that will increase the galvanic

anode efficiency. The meeting ended with various questions and answers from the audience.

WA Branch thanks everyone who attended this event for their contribution to the meeting including Parchem for their sponsorship.

Andrew Dickinson (left) receives a bottle of wine from WA Branch President Ben Biddle (right).

SA Branch - Wattyl Site Tour The ACA SA Branch held a successful site tour for 20 members of the Wattyl Manufacturing plant on Wednesday the 18th of July. Members were greeted by Wattyl’s’ (Valspar) National Industrial Group Sales Manager, State Industrial Sales Manager, David Morrow who is also a qualified Chemist. David also provided a short technical presentation on the chemical makeup of an Epoxy Coating.

Members then had an informative tour of the factory which produces water based coatings for the national market. The tour included the manufacturing plant (grinding, mixing, and packaging), the QC laboratory, and the waste water treatment plant which returns almost pure water to the sewer.

The factory, at 17 years old, is still one of the most technologically advanced facilities in the Southern Hemisphere producing around 25 million litres of paint per year. After touring the manufacturing plant, members had a brief walk through of gigantic warehouse which holds approximately

p.20 CORROSION & MATERIALS

3,000,000 litres of paint at any one time and distributes 450,000 litres of coatings weekly from this facility.

The evening came to a close after a networking opportunity while the members devoured some gourmet

pizza’s sponsored by Wattyl. A thank you to Wattyl and to committee member Justin Rayner for arranging the site tour. Members had a great night and no one had ever seen such a volume of paint in one building!

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ACA STANDARDS UPDATE

ACA Standards Update ACA Standards Officer Arthur Austin has prepared a schedule of the latest Standards developments. This report will comprise two parts; a search of SAI Global publications at https:// infostore.saiglobal.com/store for new standards, amendments and drafts, and a search for all current publications and standards relating to the Mining Industry Technical Group where results of the search can be found in Table 1.

A search of SAI Global at http:// www.saiglobal.com/online/ for new Standards, amendments or drafts of

AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI, and Standards and amendments of ISO & IEC published from 19th July 2012 to 11th September 2012 was conducted using the following key words and key word groups: durability c orrosion or corrosivity or corrosive; but not anodizing or anodize(d) aint or coating; but not anodizing p or anodize(d) galvanize or galvanized or galvanizing

cathode or cathodic anode or anodic c orrosion and concrete, or concrete and coatings Results of the general search can be found in Table 2, showing 42 new Standards, Drafts and Amendments.

There were 0 new AS or AS/NZS Standards or Draft publications.

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

Table 1. Title search by publisher with keywords corrosion and mining – 3 citations Ford Motor Company – 1 FORD BI 103 01:2001

Ford Laboratory Test Method - Salt Spray Resistance Test For Painted Panels And Parts

German Institute for Standardisation (Deutsches Institut für Normung) – 1 DIN 23320-1 (1998-04)

Flameproof Protective Clothing for Firefighters in The Mining Industry - Safety Requirements and Testing

Society of Automotive Engineers – 1 SAE J 1467:1993

Clip Fastener Fitting

Table 2. New standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards or Amendments for ISO & IEC PUBLISHED between 19 July 2012 to 11 September 2012 Key word search on ‘durability’.- 3 citations found related to durability; one to concrete structure design life ISO 16204:2012

Durability - Service life design of concrete structures

I.S. EN 16122:2012

Domestic and Non-domestic Storage Furniture - Test Methods for the Determination of Strength, Durability and Stability

I.S. EN 1728:2012

Furniture - Seating - Test Methods for the Determination of Strength and Durability

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 10 citations in all – Zero AS/NZS citations ISO 19840:2012

Paints and varnishes - Corrosion protection of steel structures by protective paint systems Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces

IEC 62697-1 Ed. 1.0 (Bilingual 2012)

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)

12/30266655 DC BS SP 139-140 A2

Specification for corrosion-resisting steel crinkle washers

12/30269092 DC BS HC 105 AMD2

Specification for 18% chromium-11% nickel-2.5% molybdenum niobium-stabilized corrosion-resisting steel castings (500 MPa)

BS ISO 14802:2012

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

BS ISO 17752:2012

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

BS EN ISO 4404-1:2012

Petroleum and related products. Determination of the corrosion resistance of fire-resistant hydraulic fluids. Water-containing fluids

BS EN 60811-604:2012

Electric and optical fibre cables. Test methods for non-metallic materials. Physical tests. Measurement of absence of corrosive components in filling compounds

DIN 81249-3 (2012-09)

Corrosion of metals in sea water and sea atmosphere - Part 3: Galvanic corrosion in sea water; Text in German and English

p.22 CORROSION & MATERIALS

ACA STANDARDS UPDATE

DIN 81249-4 (2012-09)

Corrosion of metals in sea water and sea atmosphere - Part 4: Corrosion in sea atmosphere; Text in German and English

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or ‘corrosion’ – 26 Publications found; Zero from AS/NZS; ISO 9117-4:2012

Paints and varnishes - Drying tests - Part 4: Test using a mechanical recorder

ISO 9117-5:2012

Paints and varnishes - Drying tests - Part 5: Modified Bandow-Wolff test

ISO/FDIS 12013-1

Paints and varnishes - Determination of curing characteristics using a free damped oscillation method - Part 1: Starting temperature of the curing reaction

ISO/FDIS 12013-2

Paints and varnishes - Determination of curing characteristics using a free damped oscillation method - Part 2: Glass transition temperature

SR CEN/TS 16358:2012

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Assessment of air Inclusions/microfoam in Coating Films

SR CEN/TS 16359:2012

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Assessment of Knot Staining Resistance of Wood Coatings

SR CEN/TS 16360:2012

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Assessment of Film Extensibility by Indentation of a Coating on a Wooden Substrate

I.S. EN ISO 9117-4:2012

Paints and Varnishes - Drying Tests - Part 4: Test Using a Mechanical Recorder (ISO 9117-4:2012)

I.S. EN ISO 9117-5:2012

Paints and Varnishes - Drying Tests - Part 5: Modified Bandow-wolff Test (ISO 9117-5:2012)

I.S. EN ISO 9117-6:2012

Paints and Varnishes - Drying Tests - Part 6: Print-free Test (ISO 9117-6:2012)

I.S. EN 927-3:2012

Paints and Varnishes - Coating Materials and Coating Systems for Exterior Wood - Part 3: Natural Weathering Test

BS EN ISO 13632:2012

Binders for paints and varnishes. Rosin. Sampling and sample preparation for colour measurement

BS ISO 15181-6:2012

Paints and varnishes. Determination of release rate of biocides from antifouling paints. Determination of tralopyril release rate by quantitation of its degradation product in the extract

PD CEN/TS 16358:2012

Paints and varnishes. Coating materials and coating systems for exterior wood. Assessment of air inclusions/microfoam in coating films

PD CEN/TS 16359:2012

Paints and varnishes. Coating materials and coating systems for exterior wood. Assessment of knot staining resistance of wood coatings

PD CEN/TS 16360:2012

Paints and varnishes. Coating materials and coating systems for exterior wood. Assessment of film extensibility by indentation of a coating on a wooden substrate

BS EN ISO 2812-3:2012

Paints and varnishes. Determination of resistance to liquids. Method using an absorbent medium

BS EN ISO 9117-6:2012

Paints and varnishes. Drying tests. Print-free test

BS EN 927-3:2012

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

DIN EN 4689 (2012-08)

Aerospace series - Paints and varnishes - Two components cold curing polyurethane finish - High flexibility and chemical agent resistance for military application; German and English version EN 4689:2012

ISO 12671:2012

Thermal spraying - Thermally sprayed coatings - Symbolic representation on drawings

BS ISO 12671:2012

Thermal spraying. Thermally sprayed coatings. Symbolic representation on drawings

Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ – 0 Standard Publications found; Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ - 0 Standard Publications found.

Key word search on ‘cathode’ or 'cathodic' -1 corrosion related Standard Publications found; Zero AS/NZS Publications ISO/FDIS 15589-2

Petroleum and natural gas industries - Cathodic protection of pipeline transportation systems - Part 2: Offshore pipelines

Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 0 Standard Publications found – Zero from AS/ANZS Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 Standard Publications found Keyword Search on 'anodize' or ‘anodized’ - 2 Publications found 12/30271191 DC BS EN 4827

Aerospace series. Hexavalent chromium free anodizing of aluminium and aluminium alloys

PD ISO/TR 16689:2012

Anodizing of aluminium and its alloys. Experimental research on possible alternative sealing quality test methods to replace the phosphoric acid/chromic acid immersion test. Evaluation of correlations

October 2012 www.corrosion.com.au p.23

EVENT REPORT

68th meeting of the Australian Electrolysis Committee The following are taken from my notes of the 68th meeting of the Australian Electrolysis Committee (AEC), held 20th July 2012 in Adelaide.

The venue was kindly provided by SA Water and the lecture room featured live fish in tanks around the lecture theatre and the meeting was very well attended with AEC members from both interstate and overseas.

The first presentation was by Bruce Ackland and it discussed the ongoing revision to AS 2832.1. Bruce noted the unique nature of the standard and the amount of effort that had gone into its preparation by a wide range of people.

The revisions to the standard refer to practical aspects such as testing of casings, insulating joints and HDD, interference criteria, competence of personnel, electrical safety aspects and many other changes. The draft will be available for public comment later this year.

The second presentation was by Graeme Gummow and Richard Brodribb. Graeme and Richard gave a presentation on the applicability of the SELV and PELV requirements of AS 3000 with regard to both transformer rectifiers and to connected equipment.

Graeme and Richard also gave an assessment of risk, both physical and legal, to asset owners or operators, and a presentation on how this might be minimised. There was lively discussion

p.24 CORROSION & MATERIALS

after this as to the relevance of some of sections of AS 3000 to CP installations.

Brian Martin then gave a very interesting presentation with many great photographs. Brian’s presentation covered the evolution of pipeline coatings, from black jacket, through to yellow jacket, blue jacket, rock jacket and, finally, multi-layer coatings.

Brian’s involvement with pipeline coatings over many years made this a very interesting talk, accompanied by details of coatings that had worked well and coatings that had not. The coatings that had not worked well also mainly seemed to be accompanied by giant digups.

Geoff Cope gave a presentation on electrical hazards on pipelines. Geoff demonstrated risk analysis software used to create a model for acceptable risks of step and touch potential for CP operators working at CP test points, around substations or in the proximity

of electrical power pylons and for other workers or the general public who may have contact with pipelines subject to electrical hazards. The software could be used to predict the sensitivity of risk to the frequency of event, type of installation, protective clothing, etc.

An acceptable risk at any particular point of exposure was seen to be a probability of 10E-6 fatalities per year.

Geoff also noted that AS 4853 allows for higher risks for skilled practitioners.

Ali Kouklan then made a presentation on monitoring systems. His employer Select Solutions are using a number of brands of monitor for data logging and Ali compared the results that they’ve obtained so far and discussed compatibility and ease of use.

The meeting concluded with the AEC General Meeting chaired by Bruce Ackland and secretary Alireza Kouklan.

Richard Brodribb

ACRA AWARDS FOR EXCELLENCE IN CONCRETE REPAIR AND PROTECTION To acknowledge the many significant developments and high quality projects in the concrete repair and protection area, as well as providing an excellent promotional and publicity opportunity for corporate members, ACRA is now introducing its eighth biennial “Awards for Excellence”. The winners of the "Merit" or "Excellence" awards will be awarded in recognition of their efforts in the field of concrete repair at a prestigious awards evening.

Our panel of judges are: David Mahaffey Mahaffey Associates Pty Ltd

Ian Godson Infracorr Consulting

Sharyn Machin Strata Community Australia (NSW)

The 2012 ACRA Awards have received a record number of entries, and the entrants are: Andersal Project: Lane Cove Aquatic Leisure Centre ACRA Contributor:Parchem

Diagnostech Project: Miramar Apartments ACRA Contributor: Remedial Building Services

Australian Concrete Repair Group Project: Shortland WWTP-Inlet: Concrete Repairs & High Build Protective Coatings (Newcastle) ACRA Contributor: Parchem

Duratec Australia Project: BHP Biliton Kalgoorlie Nickel Smelter Acid Bund Remediation Project ACRA Contributor: Parchem

Australian Concrete Repair Group Project: Mortdale Rail Maintenance Centre – Maintenance Rail Track Refurbishment Joints and Coatings ACRA Contributor: Parchem BASF Australia Project: Fishermans Co Op Wharf-Coffs Harbour NSW ACRA Contributor: Freyssinet Australia BASF Australia Project: West Gate Bridge-FRP Strengthening Upgrade Project Consolidated Quality Projects Project: United Dental Hospital ACRA Contributor: Sika & Hyder Consulting Crest Restoration Project: Concrete Repair of Balconies and Associated Works ACRA Contributor: Parchem & Costin Roe Consulting Dapcor Building Services Project: HMAS Watson Project S5312 Conservation of Gun Emplacements Reinforced Concrete Repairs ACRA Contributor: Sika Dapcor Building Services Project: Marine Parade Remediation, Maroubra ACRA Contributor: Sika

Duratech Australia Project: Rio Tinto Dampier Salt Ltd-Mooring Dolphin Remediation ACRA Contributor: Parchem Fluid Building Services Project: Oceanworld – Sedimentation Tanks ACRA Contributor: Parchem GHD Project: Swansea Bridge Rehabilitation ACRA Contributor: RMS & Marine & Civil Maintenance Marine & Civil Maintenance Project: Brooks Creek & Fairy Creek Bridges (concrete repair & cathodic protection) ACRA Contributor: Parchem Marine & Civil Maintenance Project: HMAS Platypus ACRA Contributor: Parchem & BASF Marine & Civil Maintenance Project: Kamesburgh Mansion-Beams Soffit Repairs & Hybrid Protection ACRA Contributor: BASF Metrocorp Technologies Project: Northern Suburbs Ocean Outfall Sewer Rehabilitation, Manly CBD ACRA Contributor: Parchem

Preservation Technologies Project: Casa Modrona, Neutral Bay-Remedial Facade Works ACRA Contributors: Bellmont Facade Engineering & Parchem RM Watson Project: The Astor Conservation Project ACRA Contributor: Hyder Consulting & Parchem RM Watson Project: St James Centre Remedial Works ACRA Contributor: Hyder Consulting, BASF & Parchem RM Watson Project: Nathan Tower ACRA Contributor: Parchem Savcor ART Project: Cairns Bulk Sugar Terminal – Shed 2 Pile Repair Works ACRA Contributor: AECOM & Parchem Savcor ART Project: Eastern Drop Structure Rehabilitation Project ACRA Contributor: Parchem & GHD Volumetric Concrete Australia Project:Taxiway A1 Trail Slab Replacement, Sydney International Airport, Mascot Water infrastructure Group Project: Rehabilitation of 6MHs. Three MHs on Northern Main Sewer & Three MHs on Southern Main Sewer ACRA Contributor: Sika & Parchem Water Infrastructure Group Project: Cluster Waste Water Pumping Station Upgrade

Winners announced in the next edition of Corrosion & Materials

THE AUST RALASIAN CORROSIO N ASSOCI ATION INC SEMINAR

Corrosion & Infrastruc ture Sustainability in the Mining Industry

TECHNICAL GROUP REVIEW

PROUDLY PRESENTED BY:

Mining technical group meeting review The ACA Mining technical group conducted a one day seminar entitled Corrosion & Infrastructure Sustainability in the Mining Industry on 26th July 2012 in Mackay, Queensland.

The aim of the seminar was to encourage dialogue on the various aspects of efficiently mitigating corrosion, with a special focus on the peculiar demands imposed by mining and mineral processing activities.

Below is a synopsis of each of the presentations. If ACA members would like an electronic copy of a particular presentation, please contact Katherine Webber at kwebber@corrosion.com.au or +61 3 9890 4833.

Environmental Considerations When Specifying for Durability Jaimie Shaw, International Protective Coatings This presentation took a brief look at the practical aspects of specifying performance in different atmospheric corrosivity categories. AS/NZS 2312-2002 provides guidance on a number of generic protective coating systems, along with an indication of their performance expectations (i.e. durability) in different corrosivity categories. Many industrial projects do not fall neatly into these predetermined categories.

The presentation covered: Using AS/NZS 2312-2002 in real life specifications chieving the maximum durability A nominated by the Standard for any given corrosivity category efining durability and how it relates D to asset design life and coating performance warranty Designing for Corrosion and Infrastructure Sustainability...

Can it be Done?

Peter Farinha, Extrin Consultants Corrosion and deterioration of mine-site infrastructure, plant and equipment is a fact of life for most mine sites, Australian and otherwise.

The presence of poor quality water, innately corrosive ores and harsh

p.26 CORROSION & MATERIALS

processing conditions all serve to increase the corrosion risk in mining, be it iron ore, coal, gold, copper and the like. Maintenance activities in many instances are proportional to the price of the product and if prices go south, maintenance activities are one of the first things to contract.

This presentation discussed the importance of designing for corrosion, so working towards long term process sustainability as a critical step in a sustainable mining industry. The design should use the benefits of prior operational experience, both successes and failures of previously used corrosion management programs, to drive the improved asset management of mine site infrastructure. This can be most cost effectively addressed during the design phase and followed up with attention to detail during the fabrication phase to provide longer “time to first maintenance” during the operations phase.

The Importance of Managing Integrity at an Operating Production Facility Wolfgang Mika, Bureau Veritas Plant operators have a common objective of operating the plant in a safe and profitable manner with due consideration for the environment.

Safety aspects are also addressed by State regulations applicable to the site. This presentation discussed the processes of maintaining plant integrity through an understanding of degradation mechanisms and taking the appropriate steps to manage the degradation. As a minimum, this aims to avoid failures and demonstrate due care. However, there are also upsides in cost effectively improving plant availability and managing plant life.

The presentation discussed examples and highlights some of the challenges and opportunities to a plant operator in ensuring on-going success in operating a safe and productive site.

Practical Maintenance of Resource Sector Concrete Structures Frank Papworth, PCTE The paper provided a brief introduction to incorporation of maintenance requirements at the design stage and focuses on condition assessment

Date: Thursday 26th

July 2012 • Venue: Quest Mackay, 38 Macalister Street,

Sustainability has become a fashionabl times and is at risk e of being misused. term in recent core of mining activities However, it is at the and there is an increasing in the industry, particularl trend y at operating mines, proactive program. to have a Corrosion and the subsequent degradatio equipment will work against process and n of plant and sustainability, so environmental corrosion manageme a critical step in a nt strategies are sustainable mining mitigation can be industry. Corrosion addressed at all phases design, fabrication of mining – and operation (and decommissioning) where relevant, – and an integrated ensure a positive approach helps to impact.

Time 8.15 – 8.45 8.45 – 9.00 9.00 – 9.40 9.40 – 10.20 10.20 - 10.50 10.50 – 11.30 11.30 – 12.10 12.10 – 13.00 13.00 – 13.40 13.40 – 14.20 14.20 – 14.50 14.50 - 15.30 15.30 – 16.20 16.20 – 16.30

Mackay

The Australasian Corrosion Associatio Technical Group is hosting a seminar n’s Mining Industry dialogue on the various to encourage aspects of efficiently corrosion, with a mitigating special focus on the peculiar demands imposed by mining and mineral processing activities.

The seminar will be planning through of value to anyone involved in mine to mining operations these activities continue , ensuring that to provide benefit Australian and New to the wider Zealand communit ies.

SPONSORED BY:

Schedule Registration Welcome & Seminar Opening – Peter Farinha, Extrin Consultants Environmental Considerat ions When Specifying for Durability – Jaimie Designing for Corrosion Shaw, Internationa and Infrastructure l Protective Coatings Sustainability...Can Morning tea it be Done? – Peter Farinha, Extrin Consultants The Importance of Managing Integrity at an Operating Production Practical Maintenanc Facility – Wolfgang e of Resource Sector Mika, Bureau Veritas Concrete Structures Lunch – Frank Papworth, PCTE Application of Rubber Lining within the Process/Mining Industry Dehumidification – Cameron Handley, and Temperature REMA TIP TOP Control during Surface Linings – David Dawson, Preparation, Application Dehumidification Technologies and Curing for Coatings/ Afternoon tea Tank Coating - Good Practice – Ted Riding, Jotun Open-floor Speakers’ Forum Summary & Seminar Close

methods, preventative maintenance and repair. In the design stage, the service life is assessed using a simple theoretical deterioration versus life model. In condition assessment surveys the same model is used but the actual deterioration rate and current condition is established using a range of tests. Electrical potentials to determine corroding area, polarisation resistance to assess corrosion rate and the interrelationship between chloride ingress, carbonation depth and cover as probability distributions will be discussed. More advanced NDT methods were briefly outlined and determining a repair strategy based on life cycle cost and required reliability explained. An overview of repair methods including coatings, patch repairs and cathodic protection was given.

Application of Rubber Lining within the Process/Mining Industry Cameron Handley, REMA TIP TOP The application of rubber lining within the process/mining industry is a process that is much like painting; however, there are several key areas throughout the application that differ from the application of traditional protective coatings. Firstly, the fabrication of the items which require rubber lining require a certain radius depending on the type and thickness of the rubber that is to be applied. The preparation of the substrate is one that is predominately the same as the type of preparation that you would normally find in the painting industry, like chloride testing, visual contamination checks, profile testing and welding defects (undercuts, pinholes etc.). The significant differences involved are in the application of the primer and adhesive systems. There are very thin coats of primer, as low as between 10 to 20 microns, applied by brush to obtain penetration of the substrate. The application of the adhesive is completed in a similar fashion. Drying times of the adhesives differ quite considerably from paint coatings and there is not an exact science when it comes to adhesion to the substrate. As with any coating or lining system, there are issues that will require attention when it comes to inspections; blistering, solvent trap, lifting skive joints, and air entrapment.

TECHNICAL GROUP REVIEW

Dehumidification and Temperature Control during Surface Preparation, Application and Curing for Coatings/Linings David Dawson, Dehumidification Technologies The first project discussed in this presentation specified requirement for internal and external tank wall encapsulation following the construction of steel tanks. Temporary climate control systems, which combined dehumidification, heating and cooling, were required to be connected to this encapsulation in order to maintain strict humidity and temperature conditions during the stages of abrasive blasting, industrial coatings application, curing and rubber lining within the encapsulation.

To meet the demanding schedule during winter, an enclosed environment and a means of climate control / climate monitoring was required. This consisted of the total shrink wrap encapsulation of

scaffolding around the external and internal perimeters of the steel tanks, creating a water tight roof between the outer and inner scaffolding. It enabled the connection of desiccant dehumidifiers and industrial heaters which provided the dry warm air needed to convert the desert night conditions into the specified controlled environment conditions.

The final stage of the project was the internal floor rubber lining which required summer climate control. This was achieved with a carefully selected capacity of desiccant dehumidifiers, coupled with cooling units.

Tank Coating - Good Practice Ted Riding, Jotun Applications for Tank Coatings represent some of the most arduous service conditions for protective coatings and there are many factors which determine a successful result where the chosen coating delivers its optimum performance. This presentation looked at some of the environmental, logistic and practical aspects of achieving the desired result.

Sponsored by:

Additional mining applications were also discussed which include internal and external blasting & coating applications and corrosion prevention during maintenance outages for steel vessels, refining process tanks and coal conveyors. The potential to apply dehumidification in underground mining work fronts was also included & identifying & overcoming the associated challenges involved.

ACA Training Courses ACA Training Courses offer the most up-to-date corrosion control information available today, they are lectured by corrosion professionals with many years of practical experience and conveniently rotate around Australia and New Zealand. Training courses being offered in the next 3 months include; October Cathodic Protection Monitoring Adelaide, October 22 – 24 November Coatings Selection & Specification Melbourne, November 8 - 10 Coatings Inspector Refresher Melbourne, November 10 Coating Inspector Refresher Auckland, November 29 Protective Coatings Quality Control Melbourne, November 26 - 28

Introduction to Protective Coatings Auckland, November 30 December Corrosion Technology Certificate Sydney, December 3 - 7 The NACE Coating Inspection Program is the world’s most widely recognised coating inspection certification. The following CIP courses are the last with places available until 2013.

NACE – Coatings Inspector Program CIP Level 2 Melbourne, November 5 - 10 Perth, December 10 - 15

Refer to the ACA website for the full 2012 training schedule, training course details, schedules and registration form, alternatively for further information contact Barry Hodder at ACA on +61 3 9890 4833 or email bhodder@corrosion.com.au

October 2012 www.corrosion.com.au p.27

Come experience ience thee

POWE R of NACE OWER

M a r c h 1 7 - 2 1 , 2 0 1 3 • O r l a n d o, Fl o r i d a , U S A

A World Class Corrosion Conference

2013 Symposia Hot Topics

For 69 years, NACE International has developed corrosion prevention and control standards and grown to be the largest, most trusted organization in the world committed to the study of corrosion.

• Advances in Imaging and Surface Analysis Techniques for Corrosion Monitoring in Industry Applications— NEW! • Advances in Materials for Oil and Gas Production

CORROSION 2013 will provide a multidisciplinary setting

• Assessment and Control of Reinforcement Corrosion in Concrete Structures

to share best practices across key themes influencing corrosion in 14 industries including pipelines, petroleum refining, power generation, maritime, and more.

• CO2/H2S Corrosion in Wet Hydrocarbon-Containing Environments • Corrosion and Corrosion Control of Cast and Ductile Iron Pipe—NEW! • Corrosion and Corrosion Mitigation of Fire Protection Systems—NEW! • Corrosion and Scaling in Geothermal Applications— NEW! • Corrosion in Nuclear Systems • Corrosion Issues Related to Water Systems and the Environment—NEW! • Corrosion Monitoring in Subsea Installation—NEW! • Current Applications in Chemical and Mechanical Cleaning—NEW! • Direct Assessment—The Continuing Dynamic Development of the Processes • High Temperature Issues and Materials for the Process Industry • Microbiologically Influenced Corrosion • Pipe Coatings, Corrosion Control and Cathodic Protection Shielding—NEW! • Pipeline Integrity Symposium • Recent Experiences with Corrosion Resistant Materials • Refining Industry Corrosion • Understanding Coating Failures—NEW!

Read the latest updates from

Visit www.nacecorrosion.org thep.28 OfficialCORROSION Publication of CORROSION 2013 & MATERIALS

YCG UPDATE

YCG SA Industry Visit On the 8th of August, the ACA Young Corrosion Group assisted by the SA Branch conducted an industry visit to Pacific Marine Batteries Pty Ltd (PMB).

The first part of the evening was a presentation from Nick Lukacs on the basics of batteries and how they transform chemical energy into useful electrical energy. Following this introduction, Mr Lukacs described the complex behaviour that batteries can display, and how PMB overcomes these difficulties during their manufacture

and commissioning of batteries for use in the maritime industry.

“Manufacturing 1 tonne batteries is not an easy task and requires careful attention to detail and a good knowledge of electrochemistry” said Mr Lukacs.

The second part of the evening consisted of a tour of the PMB facilities, showing the manufacturing, assembly and testing areas.

The evening concluded with the 18 attendees networking over pizzas. Many thanks to PMB for hosting the YCG event and for sponsoring the catering.

Nick Lukacs fielding a question from Kingsley Brown during the plant tour.

NSW YCG Technical event On Tuesday 14th of August 2012, The NSW ACA Young Corrosion Group held its first technical event for 2012.

The event, “Corrosion in Action” was held at the Sydney CBD Hotel with 22 attendees from a variety of industry and service providers.

The objective of the night was to provide fundamental corrosion theory through real world examples from different industries and environments.

Two separate presentations were delivered as a joint effort by William Ward (PCTE), Blaine McGuiness (Savcor) and James Wu (Jemena).

The first presentation was more theoretical, where James Wu started

the presentation on the basic corrosion cell, factors that affect the corrosion rate and the common types of corrosion. Blaine McGuiness then dealt in more detail on the causes of corrosion of steel reinforcement in concrete and how investigation can be conducted to diagnose the corrosion effect. William Ward then finished off the first presentation on the lesser known mechanisms of corrosion, where he spoke about graphitisation of cast iron, microbiological corrosion, black rust in concrete and stray currents.

The second presentation was more practical, where all three presenters showed pictures of corrosion from various projects and environments

to reinforce the fundamental theory presented earlier in the night.

Overall the night was a great success.

There were some great and interesting questions asked during the presentations and between session breaks and general atmosphere was friendly and casual, with some attendees networking further after the event.

Attendees of the technical night.

ACA Auckland Division YCG Event 2012 The 4th Annual YCG Event organised

by ACA Auckland Division was held at the Drake Hotel in Freemans Bay on 30th August 2012. The meeting was well attended and it was good to see a number of students attending from the Auckland University Engineering School. There was also a visitor from the Ruakaka Oil Refinery and a good attendance of young engineers from several Engineering Consulting Practices in Auckland. The evening started with refreshments and a mixand-mingle session before the YCG Convenor, Sean Ryder, welcomed everyone and introduced the speaker for the YCG evening.

Michel Nieuwoudt from the Chemical Sciences Department, Auckland University, then gave a short presentation on “Some Aspects of Analysis used in Forensic Investigations of Corrosion of Materials”. Michel’s address encompassed the principles of spectrochemical analysis techniques that are used for research and forensic investigation work including infrared and raman spectroscopies. She outlined a number of case studies using these techniques including a recent situation where a well-known oil painting was proven to be a fake following analysis of fragments of the paint used by the artist for the forgery.

evening. The attendees then got together for a further networking session over more refreshments. The evening concluded with a group of the YCG attendees joining in the Drake Hotels’ weekly Quiz Night. Overall, a great YCG evening was had by all attendees.

Sean Ryder thanked Michel for her interesting contribution to the YCG

Some of the attendees at the Auckland YCG meeting.

October 2012 www.corrosion.com.au p.29

YCG UPDATE

YCG Kalgoorlie Site Visit Who in their right mind would wake up at 5am on a Saturday to jump into a van to travel a total of 14 hours and 1,300km to a visit a dusty outback mining town over one weekend?

On 28th - 29th July, 8 young corrosion enthusiast did just that. Organised by the Western Australian Young Corrosion Group they visited an operating gold mine site in Kalgoorlie, Western Australia. The aim of the site visit was to highlight corrosion issues found in the working environment.

The young corrosion enthusiasts were: Emil Rozkoszny, Gary Batts & Associates Luke Robinson, BHP Billiton Mike Oehler, Curtin University Peter Sourivong, Corrocoat Engineering Priya Pandarinathan, Curtin University Rob MacDonald, CBH Giles Harrison, Extrin Consultants Oliver Gasior, Extrin Consultants The group arrived in the famous gold mining town at approximately 2pm and were rewarded with their first ever mining induction. Luckily only a 40 minute visitor’s induction was necessary and the group was admitted access to the mine. The group was ‘kitted out’ with the required personal protective equipment (PPE) and once everyone looked the part the tour started.

The tour focused on the Fimiston processing plant within the gold mine operation which is where, as the name suggests, the gold is processed from its ore form to gold ingots. The tour was originally going to cover only common corrosion issues within concrete and structural steel structures, methods of identification and methods of repair but also ended up covering structure reliability strategy. Squeezing every last bit of light out of the day, the group ended at their hotel at sunset for a well earned rest and recovery before dinner.

Smiles of delight crossed the group’s faces when they learnt they were going to be dining at the Golden India; one of Kalgoorlie’s highly recommended curry houses. A spicy curry and a cold beer seemed to be just what the

p.30 CORROSION & MATERIALS

doctor ordered for the weary corrosion enthusiasts. It is funny what happens when you have a group of people new to the corrosion industry at a dinner together; the conversation rarely strayed from the topic of corrosion!

Subjects included some of the more technical aspects of preventative maintenance strategies and the systematic approach to corrosion control on the mine site. Everyone found it quite refreshing to be able to talk for extended periods of time about the topic without being at risk of boring others at the table that do not share the interest!

After dinner a short tour of the night life of Kalgoorlie was undertaken by a few. A visit to the famous Exchange Hotel for a beer was short lived and everyone was in bed at a reasonable hour. Why such and early night in Kalgoorlie?! There is a zero tolerance policy for alcohol at the mine, so understandably no one wanted to overindulge as they did not want to risk missing out on one of the key aspects of the trip; the dump truck ride.

Early the next morning the YCG group were back on site and were getting prepared for their ride in a 793 dump truck. Kalgoorlie Consolidated Gold Mines (KCGM) organised a ride in the massive machines which are responsible for collecting the ore from the bottom of the super pit and bringing it back up 500m to the surface for stockpiling and crushing. The lucky YCG group members were able to travel right down into the pit and carry out a couple of circuits with the KCGM dump truck driver. “78 tonnes of material were loaded onto the truck in one scoop and you hardly feel it” was the comment from an impressed Mike

Oehler and it is certain that there has never been a bigger smile than that on the face of Priya Pandarinathan when she got out of the dump truck after her circuit. The fantastic experience, not available to the general public, was relished by all members of the group.

The group paid a quick visit to the super pit lookout to gain a bird’s eye view over the whole operation before the 7 hour journey back to Perth.

YCG WA would like to thank the ACA Western Australian Branch for providing the funding and support for the trip. It is clear from the YCG point of view that ACA WA is dedicated to assisting the YCG in reaching and supporting the young and new to the corrosion industry.

YCG WA would also like to thank KCGM; in particular Mick Harvey, Mark Shaw, Phil Edwards, and Shane Morgan for organising the ride in the dump trucks and Jason Gardner for allowing access to the ACA YCG group.

YCG WA would like to thank Katherine Webber, Oliver Gasior, Roger Farinha and Steve Dyer for all their help organising the event logistics.

The next YCG WA event is a technical evening in mid October. If you are interested in attending YCG events please feel free to register your interest for this and any future events. YCG WA are open to any suggestions on the topics you wish to have discussed so please contact the YCG WA through Giles Harrison at g.harrison@extrin.com.au.

Giles Harrison YCG WA Representative

YCG UPDATE

What did you learn from the trip? “ It will take too much space if I write down all that I learnt . The whole 2 days, I accumulated so much new information, especially different aspects of an engineering project. Also, it is in a field event as KCGM visit that I could learn of implementation issues of corrosion. I may never get to know this in laboratory experiments or in conferences”. “ I found the tour guide to be very knowledgeable on multiple facets of the corrosion industry. From the Project management side of planning, budgeting and inter discipline communications to the physical execution of the designs concepts that will be implemented by the site workers”. “ As a designer I’m always looking for a new angle to improve my knowledge base however I can. Seeing the tour guide provide details on the maintenance side of construction due to corrosive factors was fantastic in helping me understand what my designs need to incorporate for the long term to help aid the removal of corrosive elements in concrete, steel work and production costs”. “ The main thing I learnt from the trip was the importance of preventative measures within a highly corrosive environment such as that found at a mining site. I also learnt that corrosion comes in various levels and affects everything in some

way, whether that be structural or mechanical, reducing its performance drastically. Therefore preventative measures are in most situations better alternatives than replacing equipment / machinery etc”.

What was the highlight of the trip? “ Dump truck ride . The real highlight was the TEAM. People coming together to discuss, share ideas and expand the knowledge on what we know of more than just corrosion”. “ The highlight of the trip was the tour Giles took us through the Fimiston Mill. As we wandered through all the various sections of the mill and were provided with information regarding various situations in which corrosion has affected structures and machinery.

I later spoke to many of the other mine workers who have never had the chance of seeing that part of the mine, so we felt very privileged to be able to go there”.

Did the trip change my perspective on the corrosion industry and if so how?

“ You can talk about it all you want in a class room, but until you see a head end configuration (Chute, Bearing housing and pulley with the drive) weighing near 30 tonne on a platform 15m in the air supported by a few welded column and beams with corroded holes big enough to put your leg through and their concrete footing also housing corroded rebar, it doesn’t hit home with the same effect. I can’t stress these site trips enough”. “ Certainly did. For a student like me in the start of my academic career, the trip has diversified my interests.

To be precise, my PhD is on chemical corrosion inhibitors. In addition, I only wanted to stay in academia and wasn’t very curious of industry job. But having seen the mine, I’m left with lot of open questions on concrete corrosion and other internal control measures like coatings, galvanic anodes etc. appropriate for the corrosion issues there. This exposure will sure help me in my research/industry prospects I believe”. “ Yes, seeing everything first hand really gave me an appreciation of how much is involved. From planning, project management, actual works and then maintenance – And then so much more!! There is a lot of exciting opportunities for people to get involved”.

“ Yes. I now appreciate how new, engineering, design and products help to control corrosion and improve asset life. Six months ago I never knew just how much of an industry corrosion control or prevention was”.

October 2012 www.corrosion.com.au p.31

ACA CERTIFICATION PROGRAM

ACA’s Certification Program The ACA’s Certification program for ACA Corrosion Technicians and Technologists recognises those with education and experience in the corrosion industry. A Corrosion Technician has at least 4 years work experience and has attended a number of formal training courses, whilst those awarded Corrosion Technologist have

at least 10 years work experience and have obtained further training. For a more detailed explanation of the eligibility criteria, please consult our ACA Certification Program brochure which is available on our website www.corrosion.com.au. A schedule of current ACA Corrosion Technicians and Technologists appears below and will

Corrosion Technicians

be published in Corrosion & Materials in full each April and October and will be continuously updated on the ACA’s website. All current ACA Technicians and Technologists have been issued a wallet card with their certification number and membership details.

Corrosion Technologists

Name

Cert No:

Expiry Date

Name

Cert No:

Expiry Date

Gary Barber

248

30/06/2013

Bruce Ackland

82

30/06/2013

153

30/06/2013

Heath Boelen

306

4/05/2013

Fred Andrews-Phaedonos

Stephen Brown

263

4/02/2013

Ross Antunovich

214

30/06/2013

106

30/06/2013

Dave Charters

261

21/01/2013

Arthur Austin

Pasquale Chiaravalloti

274

11/07/2013

Derek Avery

295

19/08/2013

264

23/02/2013

Rodney Clarke

206

20/12/2012

Dinesh Bankar

Craig Clarke

246

26/03/2013

Don Bartlett

15

29/06/2013

236

7/11/2012

Venkatesh Coimbatore

192

30/06/2013

Stuart Bayliss

Ross Darrigan

174

14/07/2013

Peter Beckford

187

28/02/2013

74

1/01/2013

Glenn Dean

280

20/01/2013

Tony Betts

Clint Doherty

298

22/02/2013

Rob Billing

12

30/06/2013

10

1/01/2013

Raed El Sarraf

305

21/04/2013

Harvey Blackburn

David Fairfull

179

30/06/2013

Michael Boardman

30

12/07/2014

43

1/01/2013

Geoff Farrant

253

30/06/2013

Les Boulton

Robert Gentry

114

30/06/2013

John Bristow

107

1/01/2013

215

30/06/2013

David Harley

291

30/06/2013

Gary Brockett

Stephen Holt

207

28/02/2013

Kingsley Brown

257

27/09/2013

209

30/06/2013

Bradley Jones

258

18/04/2013

Philip Bundy

Boris Krizman

169

18/02/2013

Wayne Burns

100

1/01/2013

27

1/01/2013

Gary Martin

57

1/06/2013

Brian Byrne

Ian McNair

163

30/06/2013

Bryan Cackett

70

30/06/2013

103

30/06/2013

Terence Moore

125

9/06/2013

Robert Callant

David Morgan

234

16/02/2013

Neil Campbell

38

30/06/2013

281

6/07/2013

Alan O'Connor

303

17/12/2012

Graham Carlisle

David Parravicini

296

2/09/2013

Antonio Carnovale

203

30/06/2013

260

30/06/2013

Rafael Pelli

164

30/06/2013

Luis Carro

Keith Perry

139

31/01/2013

Reg Casling

11

1/01/2013

224

29/06/2013

Sean Ryder

262

21/11/2012

Dylan Cawley

Ian Saunders

251

24/06/2013

Peter Clark

80

30/06/2013

128

30/06/2013

Justin Tanti

238

14/02/2013

Stan Collins

Gavin Telford

244

30/06/2013

Geoff Cope

71

29/06/2013

44

30/06/2013

John Tomlinson

53

28/02/2013

Leon Cordewener

Ben Ward

300

16/07/2013

Robert Cox

14

30/06/2013

8

29/06/2013

Mark Watson

186

3/09/2013

Peter Crampton

Derek Whitcombe

123

30/06/2013

Kerry Dalzell

28

30/06/2013

Roman Dankiw

208

29/06/2013

Rene D'Ath

197

11/03/2013

Robert de Graaf

154

1/01/2013

NB: this list is current as at 21 September 2012

p.32 CORROSION & MATERIALS

ACA CERTIFICATION PROGRAM Mike Dinon

5

30/06/2013

Murry McCormick

196

28/06/2013

Bradley Dockrill

241

15/07/2013

Michael McCoy

109

14/04/2013

Peter Dove

210

29/03/2013

Brad McCoy

178

14/07/2013

Gary Doyle

294

2/08/2013

Bill McEwan

32

1/01/2013

Adrian Dundas

250

1/02/2013

Stuart McLaughlin

299

17/12/2012

Lucas Edwards

273

11/07/2013

Vic McLean

237

30/06/2013

Bernard Egan

20

30/06/2013

Jim McMonagle

56

1/01/2013

Gary Evans

271

30/06/2013

John Mitchell

115

30/06/2013

Wayne Ferguson

242

4/09/2013

Elio Monzu

159

30/06/2014

Peter Ferris

195

30/06/2013

Greg Moore

97

1/01/2013

Gavin Forrester

282

10/02/2013

Janet Morris

256

5/07/2013

Rob Francis

23

1/01/2013

Robert Mumford

33

30/06/2013

Dale Franke

199

30/06/2013

Tony Murray

134

30/06/2013

Max Fraser

283

17/03/2013

David Nicholas

94

1/01/2013

Robert Freedman

147

1/01/2013

Calvin Ogilvie

17

19/01/2013

Jim Galanos

254

17/12/2012

Dean Parker

108

5/07/2013

Barry Gartner

2

30/06/2013

David Pettigrew

297

17/12/2012

Bill Gerritsen

18

30/06/2013

Dennis Richards

180

1/01/2013

Ian Glover

129

30/06/2013

Steve Richards

110

30/06/2013

Frederick Gooder

141

30/06/2013

Gavin Richardson

48

30/06/2013

Chris Hargreaves

292

28/05/2013

Tony Ridgers

36

30/06/2013

Phil Harrison

145

8/05/2013

Bernd Rose

252

1/05/2013

Peter Hart

200

30/06/2013

John Rudd

243

21/06/2013

Frank Hewitt

67

1/01/2013

Fred Salome

231

1/01/2013

Brian Hickinbottom

138

30/06/2013

Ian Savage

259

30/06/2013

Brett Hollis

88

30/06/2013

Ron Scaddan

272

5/02/2013

Marshall Holmes

293

25/08/2013

Philip Schembri

198

30/06/2013

Peter Hosford

216

1/01/2013

Paul Schweinsberg

34

1/01/2013

Peter Hunger

301

4/08/2013

David Scott

173

29/06/2013

Paul Hunter

62

30/06/2013

Mike Slade

175

7/06/2013

Jeffrey Hurst

202

30/06/2013

Brian Smallridge

201

30/06/2013

Craig Hutchinson

249

26/10/2013

Jim Steele

119

17/12/2012

Luciano Ioan

228

11/07/2013

Alan Steinicke

9

1/06/2013

Bruce Jewell

245

30/06/2013

Allan Sterling

191

31/03/2013

Michael Johnstone

230

18/04/2013

Gordon Stewart

68

1/01/2013

Michael Jukes

90

3/03/2013

Ian Stewart

155

18/06/2013

John Kalis

166

17/12/2012

Graham Sussex

136

30/06/2013

Graeme Kelly

102

1/01/2013

Tan Swee Hain

189

30/06/2013

John Kilby

193

30/06/2013

Yongjun Tan

194

30/06/2013

Ulf Kreher

304

28/06/2013

Peter Thorpe

144

1/01/2013

John Lane

188

20/01/2013

Peter Tomlin

120

30/06/2013

Bill Lannen

111

1/01/2013

Nicholas Van Styn

229

25/02/2013

Harry Lee

19

1/01/2013

John Waters

121

30/06/2013

Keith Lichti

133

30/06/2013

John Watson

239

10/06/2013

Verne Linkhorn

39

30/06/2013

Richard Webster

69

30/06/2013

Garry Luskan

117

2/02/2013

Mark Weston

149

1/01/2013

Willie Mandeno

13

30/06/2013

Geoffrey White

182

1/07/2013

Brian Martin

60

1/01/2013

Paul Wilson

290

19/04/2013

William McCaffrey

142

30/06/2013

Rodney Wubben

46

30/06/2013

John McCallum

59

30/06/2013

Morris Young

217

30/06/2013

Daryl McCormick

1

17/12/2012

Nizam Yusoff

302

9/02/2013

October 2012 www.corrosion.com.au p.33

corrosion & prevention

Corrosion Management for a Sustainable World: Transport, Energy, Mining, Life Extension and Modelling Crown Conference Centre • Melbourne, Victoria, Australia • 11–14 November 2012 www.acaconference.com.au

Proudly presented by:

Major sponsor:

registrations now open

see www.acaconference.com.au for details p.34 CORROSION & MATERIALS

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October 2012 Device www.corrosion.com.au p.35BAP1318

p.36 CORROSION & MATERIALS

Corrosion & Prevention 2012 Programme

programme

Proudly presented by: Major sponsor:

Can High Temperature Materials Meet the Future Challenges D. Shifler Office of Naval Research 154 High Temperature Oxidation Behaviour of 2.25%Cr and 9%Cr Boiler Steels in Laboratory and Plant Steam Environments A. Czerwinski HRL Technology Pty Ltd & Monash University 056 The Effect of Carbide-Forming Elements on the Metal Dusting Rate in Refineries G. Slabbert University of the Witwatersrand/ Mintek 064

Multiscale Modeling of Cathodically Driven Corrosion on Aerospace Aluminum Alloys J. Osborne Boeing Research & Technology 174 The Role of Precipitates upon the Electrochemical Stability of Aluminium X. Zhou Monash University 072

Characterisation of the Evolution of Microstructure and Electrochemical Properties for 7xxx Aluminium Alloys R. Gupta Monash University 118

Corrosivity-Sensor Output and Correlation in Hawaii Climates L. Hihara University of Hawaii 134 The Effect Coupon Size for the Determination of Atmospheric Corrosivity R. Jeffrey The University of Newcastle 031

Reactive Wetting in Corrosion: A Mild Steel Example J. Connor University of South Australia 073

Blast Cleaning Standards: Cutting through the Confusion?

R. Francis R A Francis Consulting Services 013

Use of Fiber Reinforced Polymer Linings for Controlling Corrosion in Mineral and Chemical Processing Industries M. Stevens Ashland Performance Materials 040

Seeing Is Believing. A Visual Method of Corrosion Management using Protective Coatings.

J. Mackay International Paint 079

Towards Rendering Steel Reinforced Concrete Immune to Corrosion G. Glass Concrete Preservation Technologies 159

Durability Design and Testing for the Hot Marine Environment D. Wimpenny Halcrow 080

F.E. Modelling of Galvanic Corrosion Currents in Carbonated Concrete A. Castel University of New South Wales 049

11:00

11:30

12:00

Stream E (M13) Research- High Temperature Corrosion Chair: David Young

Morning Tea

10:30

Stream D (M12) Research- AI and Mg Alloys Chair: Nick Birbilis

Plenary 2: Mario Blasco, Dulux Protective Coatings Aquatic Centres: A Case Study in Tailoring Protective Coatings Systems to Specialised Environments

9:45

Stream C (M15&16) Atmospheric Corrosion Chair: Ivan Cole

Plenary 1: Tony Hughes, CSIRO The Impact of Modern Research Tools on an Old Problem – The Devil is Always in the Detail

9:00

Stream B (CCH3) Coatings Chair: Peter Dove

Opening Address and Starting of Ed Potter Clock (CCH 1&2)

8:30

Stream A (CCH2) Concrete and Cathodic Protection Chair: Sarah Furman

Welcome Function Melbourne Aquarium Sponsored by Incospec & Associates Australia

18:30 – 21:30 Monday 12th November 2012

Registration Desk Opens Crown Conference Centre

11:00 – 18:00

Sunday 11th November 2012

The ACA reserve the right to exclude any paper and to alter without notice any of the arrangements, timetables and programmes relating to the conference.

corrosion & prevention

October 2012 www.corrosion.com.au p.37

16:00

Half-Cell Potentials - Useful or Misleading?

U. Kreher Aurecon Australia 146

Concrete and Cathodic Protection Chair: Bruce Ackland

Update on AS 2312 (continued…)

R. Francis, R A Francis Consulting Services Updates in Protective Coatings Application G. Tamone, Graco Inc 20 minutes

Coatings Forum Chair: Matthew O’Keeffe

Research- MIC and Bio Corrosion Chair: Marianne Seter Role of Biofilms of Sulfate Reducing Bacteria in Electrochemical Corrosion of Steel S. Welikala Monash University 060

Research- AI and Mg Alloys Chair: Tony Trueman The Effect of Rare Earth Element Additions on the Corrosion Behaviour of Magnesium Alloy AZ91E A. Sudholz Monash University 069

Marine Corrosion Chair: Les Boulton The Effects of Depth and Time on the Corrosion of Cast Iron in Port Phillip I. MacLeod WA Maritime Museum 116

Afternoon Tea

Cathodic-Limited Corrosion Kinetics on Aircraft Alloys in Aerated Chloride Environments A. Sudholz Defence Science and Technology Organisation 108

Coatings Forum The Case for Single-Coat IZS Coatings in Marine Environments I. Glover, Corrotek 20 minutes Update on AS 2312 R. Francis, R A Francis Consulting Services 20 minutes

Mine Concrete Process Tank Repaired with Hybrid CP System I. Godson Infracorr Consulting Pty Ltd 136

15:00

15:30

Carburisation of Fe-Al Alloys in High and Low Carbon Activity Gases at High Temperatures J. Zhang University of New South Wales 012 Corrosion Resistant Manganese Phosphate Coatings for MG AM-LITE Alloy X-B. Chen CAST & Monash University 112

Corrosion of Materials in a Multitude of Microclimates R. Sugamoto University of Hawaii 132

Thermal Metal Spray: Successes, Failures and Lessons Learned W. Mandeno Opus International Consultants Ltd 167

Electrochemical Chloride Extraction Site Trials of Reinforced Concrete Bridge Substructure Elements M. Moore Roads and Maritime Services 076

14:30

Composition Effects on the Corrosion of Aluminium-Free Magnesium Alloys X. Xia Monash University 142

Oxidation Resistance of Bimodal Fe-Cr Alloys Having Controlled Dispersion of Microcrystalline Grains in a Nanocrystalline Matrix B.V. Mahesh Monash University 039

General Aspects of the Corrosion of Aluminium Alloys N. Sukiman Monash University 130

A Corrosion Map of Australia: Principles and Implications I.S. Cole CSIRO 010

Research- High Temperature Corrosion Chair: Rajeev Gupta

Temperature Effect on Oxidation of Binary Fe-Si and Fe-Al Alloys in CO2H2O Gas Atmosphere H. Li University of New South Wales 011

Developments in Coating Thickness Gauges and Paperless QA D. Beamish DeFelsko Corporation 163

Research- AI and Mg Alloys Chair: Nick Birbilis

Methodology for Producing Intergranular Corrosion on AA7075 T651 M. Salagaras Defence Science and Technology Organisation 120

A Review of Sacrificial Anode and Hybrid Cathodic Protection Systems for the Mitigation of Concrete Reinforcement Corrosion L. Holloway Savcor Group Ltd 062

Atmospheric Corrosion Chair: Robert Melchers

Lunch

Electrochemical Experiments to Determine the Probability of Corrosion under a Droplet S. Knight Defence Science and Technology Organisation 106

14:00

The Stability of Organosilanes in Water for Use as Protective Films I. K. Eriksson-Scott University of Western Sydney 058

Coatings & Coatings Forum Chair: Rob Francis

Concrete Cathodic Protection Monitoring of Port Infrastructure C. Crawshaw & D. Ross AECOM & Savcor ART Pty Ltd 052

Concrete and Cathodic Protection Chair: Frédéric Blin

13:00

12:30

p.38  CORROSION & MATERIALS Morning Tea

10:30

Carbon Dioxide Corrosion Inhibition: An Overview of Recent Research on New Inhibitor Development Y. Tan Deakin University 063 Rare Earth Cinnamates and their Corrosion Inhibition Mechanisms for AS1020 Steel M. Seter Deakin University 085

Characterising the Pit to Crack Transition A. Turnbull National Physical Laboratory 016

Mechanisms of Stress Corrosion Cracking in Single-Phase Alloys S. Lynch Defence Science and Technology Organisation 158

Prediction of Long Term Corrosion in Soils using Electrochemical Tests M. Dafter Hunter Water Australia & The University of Newcastle 014 Long-Term Corrosion of Cast Iron Cement Lined Pipes R. Petersen The University of Newcastle 023

Energy Efficiency of Cathodic Protection Systems R. Brodribb M. Brodribb Pty Ltd 145

Introduction to Design Techniques Used for Hybrid Corrosion Protection Systems L. Thompson Infracorr Consulting Pty Ltd 148

11:00

11:30

Stream C (M15&16) Research- SCC and Fatigue Chair: Gerald Frankel

Plenary 4: Bruce Ackland, Bruce Ackland & Associates Pty Ltd Cathodic Protection – It Never Sleeps

9:45

Stream B (CCH3) Water Chair: Greg Moore

P.F. Thompson Lecture: Graham Sussex, Sussex Materials Solutions Pty Ltd A Journey with Stainless Steel

9:00

Stream A (CCH2) Concrete and Cathodic Protection & Concrete Structures & Buildings Forum Chair: Warren Green

Young Corrosion Group Event Crown Promenade: Tonic Bar Sponsored by Galvanizers Association of Australia

18:30

Tuesday 13th November 2012

Exhibition Opening (Exhibition Hall- Ground Floor)

17:4519:45

Stream D (M12&13) Research- Inhibitors Chair: Maria Forsyth

In Vitro Studying Corrosion Behaviour of Biocorrodible MG Alloys S.S. Jamali University of Wollongong 141

Improving Corrosion Resistance in Amorphous Magnesium Alloys J. Cao University of New South Wales 111

Electrochemical Measurements and Short-term-in-Situ Exposure Testing L. Stockert University of Applied Sciences Wuerzburg-Schweinfurt 100

Coatings Concrete Standard Proposal Update P. Dove, GHD 15 minutes

Technologic Developments in Marine ICCP Systems H. Khosasi Aurecon Australia 143

17:00

AGM: 10 minutes

Ionic Liquid Pretreatment as a Means to Control the Corrosion Behavior of Magnesium Alloys in Simulated Body Fluids Y. Zhang Deakin University 071

Silane Coating for the Corrosion Protection of a Magnesium Alloy ZE41 P. Chakraborty Banerjee Monash University 044

Suitability of Aluminium Alloy AA5083 in Marine Environments K. Kannoorpatti North Australian Centre for Oil and Gas 173

Carbonation and Chloride Attack of Concrete Structures and their Prevention J-P. Marrow, International Paint 20 minutes

Modulus, Chemistry & Microstructure of Aluminium - Zinc Offshore Anodes R. Northey Cathodic Diecasting Pty Ltd 048

16:30

October 2012 www.corrosion.com.au p.39

Open Discussion continued…

15:00

16:00

15:30

Open Discussion

14:30

Corrosion in Renewable Energy Power Production L. Boulton Les Boulton & Associates Ltd 008

Power Chair: Mike Tan

AGM: 15 minutes

Galvanic and Hybrid Concrete CP – Products and Performance F. Papworth, SRCP G. Glass, Duogard

14:00

Concrete Structures & Buildings Forum Chair: Frédéric Blin

Cathodic Protection in Deep and Ultra-Deep Water Production Systems, Some Lessons Learned and New Technologies Available J. Britton 20 minutes Some notes for HDD Testing G. Cope, Geoff Cope & Associates Pty Ltd 20 minutes

Cathodic Protection Forum Chair: Bruce Ackland

Research- Steel, Zinc and Nickel Chair: Geoffrey Will Modeling of Damage Evolution during Crevice Corrosion of Nickel Alloys R.S. Lillard University of Akron 123

Corrosion Management, Buildings and NDE Chair: Christine Crawshaw The Astor - Facade Repairs, Protective Coatings and Heritage Conservation P. Johnsson Hyder Consulting 034

Afternoon Tea- Ground Floor & Poster Session- Level 1

Crack Growth from Etch Pits in 7050-T7451 under Combat Aircraft Spectra R. Jones Monash University 168

WWT Forum Galvanic Corrosion of Vitreous Enamel Coated Steel Tanks B. Ackland, Bruce Ackland & Associates Pty Ltd 15 minutes Victorian Desalination Plant Pipeline CP System Project G. Brewster, Savcor ART Pty Ltd 15 minutes

Synthesis and Characterization of Electroactive Nanostructures Synthesized Using Ozone V. Gelling North Dakota State University 152

Active to Passive Models for the Synthesis of Polarization Curves G. Will Queensland University of Technology 101

In-Vitro Evaluation of Stress Corrosion Cracking Behaviour of ZX50 Magnesium Alloy in a Simulated Body Fluid L. Choudhary Monash University 047

The Economics of Applying Internal Coatings to Pump Casings P. Vince SA Water 122

Research- Techniques Chair: Nick Birbilis In-Situ Synchrotron XRD Studies of CO2 Corrosion of Carbon Steel M. Ko Quest Integrity Group 102

Research- SCC and Fatigue Chair: Stan Lynch

Electrochemical Etching of Aluminium Alloy in Ionic Liquids P. Huang Deakin University 104

Inhibition of Corrosion on AA2024 T3 by Rare Earths & Mercaptoacetate R. Catubig Deakin University 092

Evaluation of S2o32- as a Substitute for H2S in Corrosion Fatigue Studies G. Frankel The Ohio State University 147

Lunch

Role of Bacteria in Corrosion and Assisted Cracking of Mild Steel: A Review A. Majumder Monash University 075

Stress Corrosion Cracking of a Twinning Induced Plasticity (TWIP) Steel R.K. Singh Raman Monash University 061

Assessment of Water Quality in Assets across WA Using Corrosion Indices V. Afshari GHD 155

Water & Water Treatment Chair: David Nicholas

Corrosion of Copper Alloy Assets in Fresh Water S. Furman AECOM 059

CS&B Forum Galvanic and Hybrid Concrete CP – Products and Performance A. Dickinson, Parchem Construction Supplies A. Sarkady, BASF Australia Ltd

12:30

13:00

External Corrosion Protection Options for Ductile Iron Pipelines: A Review D. Nicholas Nicholas Corrosion Pty Ltd 042

Design Consideration and Interfacing Between Onshore to Offshore Pipeline Cathodic Protection Systems J. Grapiglia Corrosion Control Engineering 171

12:00

p.40 CORROSION & MATERIALS Effects of Temperature and Chloride Ion on Electrochemical Behaviours of a Duplex Stainless Steel P. Cho Khalifa University 135 The Influence of Microstructure on the Corrosion of Rolled Zinc T. Muster CSIRO 165

In Situ Study of the Growth and Localized Breakdown of the Passive Film on Iron M.K. Nieuwoudt University of the Witwatersrand 068

Corrosion Management for System Sustainability G. Keller LMI 160 Detection and Mitigation of Electrolysis Corrosion in Major Commercial Centres P. Hosford Ausgrid 037

Pitting Resistance of Candidate Materials for Nuclear-Desalination Plants A. Al Zaabi Khalifa University 129

Novel Concept of Failure of Thin Organic Films K. Habib Materials Science Laboratory,Department of Advanced Systems, (KISR) 009 The Application of Plasma Electrolytic Oxidation (PEO) to the Production of Corrosion Resistant Coatings on Magnesium Alloys: A Review D. Northwood University of Windsor 015 A Study of the Chemical and Electrochemical Conditions beneath Disbonded Coatings using Numerical Modelling M.H. Alkathafi Sirte University 033

The Changing Composition of the Corrosion Products of Mild Steel in Severe Marine Atmospheres R. Jeffrey The University of Newcastle 028

The Effect of Increasing Amounts of Nutrient on the Corrosion Rate of Mild Steel R. Melchers The University of Newcastle 029

Long-Term Corrosion of Grey Cast Iron in Marine Environments R. Melchers The University of Newcastle 032

11:30

12.00

Stream D (M12&13) Research- Steel, Zinc and Nickel Chair: Geraint Williams

11:00

Stream C (M15&16) Corrosion Management, Buildings and NDE Chair: Dimitri Ross

Morning Tea

10:30 Stream B (CCH3) Research- Coatings Chair: Willie Mandeno

Plenary 6: Geraint Williams, Swansea University The use of Electrochemical Scanning Techniques to Elucidate Corrosion Mechanisms in Magnesium

9:45

Stream A (CCH2) Marine Corrosion Chair: Ian MacLeod

Plenary 5: Paul Natishan, US Naval Research Laboratory Enhanced Corrosion Resistance of Stainless Steels Interstitially Hardened with Carbon under Paraequilibrium Conditions

Wednesday 14th November 2010

ACA Annual Dinner & Awards Crown Palladium Sponsored by Denso Australia

9:00

19.0024.00

Developing Self-Repairing Oxides to Protect Zinc S. Thomas CSIRO & Monash University 127

Efficiency of Hydrophobic Impregnation – Site Results M. Donadio Sika Services AG 045

Updates for AS 2832.1 B. Ackland & D. Robertson, Bruce Ackland & Associates Pty Ltd 20 minutes

HVAC Transmission Tower Corrosion Assessment Case History J. Paterson Mears Integrity Solutions 172

17:00

AGM: 10 minutes

“Trigger” Mechanisms for Initiation of Pitting Corrosion of Stainless Steels D. Williams University of Auckland 169

The Art of Corrosion Risk Management N. Tripathi Roads and Maritime Services 095

Some notes for HDD Testing (continued…)

Instant off Potential, Group Discussion 20 minutes

Dissolution Behaviour of Novel Lead Anodes for Copper Electrowinning M. Clancy Monash University 137

16:30

October 2012 www.corrosion.com.au p.41

Wenjie Liang Parama Chakraborty Banerjee

Use of Aqueous Solutions to Simulate Supercritical CO2 Corrosion

Comparison of the Corrosion of Carbon Steel in Natural Seawaters – Evidence of MIC?

Influence of Sulphate Reducing Bacteria in Stress Corrosion Cracking of Mild Steel in Aqueous Solutions

On the Corrosion of 6000 Series Aluminium Alloys

CVD Graphene on Metals for Remarkable Corrosion Resistance

Microstructural Aspects Accompanying Sensitisation in 5xxx Series Aluminum Alloys

054

089

096

128

133

139

Ruifeng Zhang

Sneha Patil

Scott Wade

Samson Sim

Paper Title

Paper no.

Corresponding Author

Farewell Function Crown Promenade: Tonic Bar

15:30

Poster Session

Closing Session (CCH1)

15:00

Understanding welding zone corrosion problems on a duplex steel pipeline M. Tan, Deakin University 10 minutes

Sustainability from an Asset Owner’s Perspective R. Khatri Roads and Maritime Services 161

Inhomogeneity of Organic Coatings and its Effect on Protection S.S. Jamali University of Wollongong 150

Investigation of Severe Corrosion of Mooring Chain in West African Waters A. Potts AMOG Consulting Pty Ltd 175

14:30

Monash University

Monash University

Central South University & Monash University

Monash University

Swinburne University of Technology

Monash University

Organisation

Cost of Corrosion Prof Richard Clegg

Risk based inspection TBC

Standards Arthur Austin

Working Group Reports 20 minutes

AGM: 10 Minutes

Audience discussion & feedback: 15 minutes

Corrosion management in the petroleum & chemical process industries - the role and achievements of the ACA PCPI Technical Group in 2011 – 2012 F. Barouky, Anti Corrosion Technology 10 minutes Research & Development Working Group Forum - Approaches to controlling pipeline corrosion in the oil & gas industry R. Gubner, Curtin University 10 minutes

Petroleum & Chemical Processing Industry Forum Chair: Fikry Barouky

Exploring a Phosphate System for Corrosion Prevention in CO2 Pipelines M. F. Morks CSIRO 046

GPR Array for the Condition Assessment of Concrete Slabs & Pavements R. Barnes PCTE 070

Corrosion Management, Buildings and NDE Chair: Brad Dockrill

Lunch

A Case Study of Pitting Corrosion Assessment of a Pressure Filter Vessel Using Numerical Method V. Afshari GHD 156

Micro-Structural Characterisation of Paint Using Ultra-Microtome SEM A. Trueman Defence Science and Technology Organisation 107

Research- Coatings Chair: Parama Banerjee

Electroless Ni-P-PTFE-Al2O3 Hybrid Nanocomposite Coating for Corrosion Resistance A. Sharma I.I.T. - Roorkee 097

The Use of Electrical Resistance Corrosion Sensors to Assess Infrastructure Protective Systems M. Hales Queensland University of Technology 055

Marine Corrosion Chair: Robert Jeffrey

Reliability Analysis of Long Term Pitting Corrosion of Welded Marine Steel Pipelines I. Chaves The University of Newcastle 036

14:00

13:00

12:30

corrosion & prevention 2012 SPONSOR PROFILES Proudly presented by:

corrosion & prevention

Major sponsor:

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Long term corrosion control has been effectively achieved by the use of Dulux zinc rich epoxy primers, inorganic zinc silicates, high build epoxy intermediates, chlorinated rubber, acrylic and

p.42 CORROSION & MATERIALS

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Call Dulux today on 13 23 77 or visit www.duluxprotectivecoatings.com.au.

Worth doing, worth Dulux®.

corrosion & prevention 2012 SPONSOR PROFILES

Supporting Sponsor International Paint www.international-pc.com

Akzo Nobel, is a market driven, technology based company specialising in coatings and chemicals and serves the Marine and Protective Coatings markets, under the brand ‘International®’.

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Jotun Australia Pty Ltd is a wholly owned subsidiary of the Jotun Group and supplies Protective Coatings, Marine Coatings and Powder Coatings for corrosion control and other specialised applications.

In 1990 Jotun purchased the Dimet business linking the best of European technology with an Australian business that brought innovative products to the world.

International’s Protective Coatings division supplies market focussed, innovative coatings to the Mining, Oil & Gas, Water & Waste, Infrastructure, and Power Generation markets. With tailor made, high performance coating solutions for new construction and maintenance of both steel and concrete substrates International can provide for all your project needs.

Our local manufacturing unit accredited to ISO 9001 is situated in Brooklyn, Victoria, where we maintain a NATA (National Association of Testing Authorities) registered laboratory and a manufacturing facility recognised by Australian Paint Approvals Scheme. In addition the Brooklyn site holds accreditation to ISO 14001 (Environmental) and OHSAS 18001 (Safety) management systems.

Our global presence means that International’s project management and technical service experts can assist with all your project’s coating needs. From specification advice during FEED, to spec optimisation at detailed design, to on site tech service during application (available worldwide), and finally to our Interplan® maintenance planning survey programme at commissioning and operation, International is there to support you every step of the way.

At Jotun, we are able to draw on our vast worldwide experience to provide technical assistance and coating recommendations in Mining, Smelting, Chemical, Petrochemical, Offshore, Water, Sewerage and many other industries where corrosion problems are found.

International is home to some of the best known product names in high performance coatings such as: Interline, Enviroline, Ceilcote and Polibrid for severe chemical environments; Intertherm for high temperature, cryogenic and CUI applications; and Interchar and Chartek for high performance passive fire protection. Add these to the recently released Intercrete™ range for concrete repair and remediation and you have the solutions for all your coating needs.

Jotun Australia’s head office and manufacturing can be contacted on +61 3 9314 0722.

Jotun Australia has activities in all states and is able to provide a high level of local service supported by the global strength of Jotun’s worldwide activities.

Supporting Sponsor Peerless Industrial Systems www.peerlessindustrialsystems.com

International is exhibiting at the ACA Corrosion & Prevention Conference being held 11th -14th November 2012 at the Crown Conference Centre, Melbourne. We are located at stands 7 and 8.

Toll free Australia: 131 474 | Toll free NZ: 0800 808 807 Email: pc-australasia@akzonobel.com

Supporting Sponsor Jotun www.jotun.com.au Standard

Jotun is one of the world’s leading manufacturers of paints, coatings and powder coatings. The group has 74 companies Jotun blue and 39 production facilities on all continents. In addition,

Perth, Melbourne, Brisbane, Singapore, Hongkong Epigen lining & repair composite polymers dominate in water storage & treatment, grouting & backing, linings for aggressive chemical resistance, process tanks, nonskid flooring, pump repair/rebuilding, turbine & motor chocking, joints, adhesives, and metal repair.

Sectors include power, water industry, mining, mineral processing, petroleum, refining, and materials handling with past projects including linings for the Merrimac (Gold Coast), Rosedale (NZ), WA21 in Perth, and lining materials for the Mackay WWTP. Water products are approved to AS4020 successfully date back to the 1970’s. Significant applications include internal linings in FGD and Stacks in

October 2012 www.corrosion.com.au p.43

corrosion & prevention 2012 SPONSOR PROFILES

Power Stations around Asia working closely with Institutes in China, ground breaking over recent years.

The Epigen Chemproof 4000 range of novalac products; lead the field for aggressive chemical resistance; installed at major sites throughout Australia including Nickel West Acid Facility, Murrin Murrin, Tiwest, CSBP, BHP Billiton, for protecting concrete and steel.

Peerless enjoys an excellent reputation in liaising with contract applicators, consultant design engineers and asset owners to qualify protective systems for their particular operating environments. Working with all ensures that the principle receives a system that achieves the maximum service life possible.

has given us an unrivalled heritage and level of technical expertise: experience that guarantees exceptional products, performance and service.

No matter what the size of your organisation, PPG has the scale and resources to deliver outstanding support, with well-established operations in over 60 countries.

Our aim is to become the world’s leading protective and marine coatings company: unrivalled in performance and protection among asset owners, contractors, fabricators and applicators across the globe.

Gala Dinner Sponsor

Peerless – Celebrating 65 years in 2012

Denso Australia

Epigen – Celebrating 40 years in 2010

www.densoaustralia.com.au

Chemproof – Celebrating 21 years in 2010 KIS – New Patented Elastomeric, high elongation – “Keep It Stretchy” Tel. +61 (0)8 9477 3788 Fax +61 (0)8 9477 3766 Email nick@epigen.com.au

Supporting Sponsor PPG Industries www.ppgpmc.com.au

PPG Industries’ vision is to continue to be the world’s leading Coatings and Specialty Products Company.

Through leadership in innovation, sustainability and colour, PPG helps customers in industrial, transportation, consumer products, and construction markets and aftermarkets to enhance more surfaces in more ways than does any other company.

Founded in 1883, PPG operates in more than 60 countries around the world. Sales in 2011 were $14.9 billion.

PPG Protective & Marine Coatings, part of PPG’s Performance Coatings’ business segment, is uniquely placed to offer the highest-quality coatings for the protective and marine coatings industries. Whatever your requirement, our proven products and technologies can safeguard a wide variety of assets in the markets we serve.

The knowledge we have gained throughout the world

p.44 CORROSION & MATERIALS

DENSO NORTH AMERICA INC. Denso (Australia) Pty Ltd are principal manufacturers of long life anti-corrosion products and sealing systems, which service a multitude of industry groups. Denso services, as it’s core markets, Oil & Gas, Marine, Mining, Minerals Processing and Water Industries, throughout Australia and New Zealand and Pacific Islands.

Denso (Australia) Pty Ltd adapts and refocusses on a continuing basis, making certain that as the industries we serve change, Denso, and our products and services remain as not only the internationally recognised standard, but the supplier of preference.

The Denso range comprises a variety of specialist pipe & structural coatings, marine protection systems, concrete and tank coatings, including tapes, brush and spray applied liquid coatings, mastics, primers and sealants based on materials such as petrolatum, butyl rubber, bitumen, plastics, heat shrink sleeves and epoxy resins.

Systems are tailor made for individual anti-corrosion and sealing problems developed with the realities of an onsite application in mind. Denso’s extensive product range is suitable for use in a wide range of highly corrosive environments with operating temperatures from subzero to 250°C. Brand names include Seashield, Archco-Rigidon, Protal, Rigspray, Denso, Densopol, Ultraflex, Densoramic and Polybron.

Associated group companies include Winn & Coales (Denso) Ltd, Archco Rigidon, Premier Coating Ltd, Seashield International, Denso (New Zealand) Ltd, Denso North America Inc and Denso South Africa (Pty) Ltd.

corrosion & prevention 2012 SPONSOR PROFILES

Welcome Function Sponsor Incospec & Associates Australia www.incospec.com.au

Young Corrosion Group Function Sponsor Galvanizers Association of Australia www.gaa.com.au

Corrosion Engineers & Consultants – Independent Advice Established in 1981, Incospec & Associates Australia has grown to be one of the largest Corrosion Engineering Consultancies in Australasia. We provide both independent and authoritative consultancy in the fields of Corrosion Engineering and Asset Management.

Our independence is vital, allowing us to offer our clients totally unbiased optimum advice, without commercial constraints in the following specialised areas:

Asset Integrity Management Surveys – Guardian® Cathodic Protection Coating Selection and Specification Development 3rd Party Independent Coating Inspections and Certification

Failure Analysis Metallurgy & Materials Consulting Welding Inspection, Specification Development and Certification

Concrete Condition Surveys Workforce Training and Competency Certification With offices throughout Australia and in key locations in Singapore, Kuala Lumpur and Hong Kong, Incospec continues to expand its presence and delivery of high value technical corrosion engineering consultancy, research, training and field services to key global clients.

Our continued strategic focus of providing high value asset integrity maintenance management systems through Guardian® directly to key asset owners continues to support our primary Corporate mission – ‘To Assist Clients Protect Their Assets’ Incospec recently announced a key commitment to the continued development of the Northern Australia resource sector with its partnership with Charles Darwin University and the North Australian Centre for Oil and Gas. Proudly In Partnership With

The Galvanizers Association of Australia (GAA) has represented the hot dip galvanizing industry throughout Australia, New Zealand and SE Asia for nearly 50 years.

The Association conducts research and compiles case studies in various areas dealing with corrosion protection, environmental sustainability and hot dip galvanizing. The GAA has established close links with international galvanizing and corrosion protection associations to maintain the latest technical knowledge and keep abreast of emerging industry trends on both a local and global scale.

The GAA provides technical advice on hot dip galvanizing, environmental sustainability and corrosion protection to specifiers, engineers, architects and any other members of industry interested in the corrosion protection of steel.

For further information on the benefits of hot dip galvanizing and to find out more on why HDG is the first choice for corrosion protection of fabricated steel articles, please contact Peter Golding (CEO) on +61 (0)3 9654 1266 or visit our website www.gaa.com.au.

Coffee Sponsor Zintec Corrosion Solutions www.zinga.com.au

Zintec Corrosion Solutions Pty Ltd is the distributor of Zinga in Australia and New Zealand.

Zinga is a unique liquid zinc galvanizing film for the recoating of weathered galvanized surfaces, abrasive blasted new steel or suitably prepared, previously painted steel. It has competitors that can demonstrate some of the benefits Zinga offers, but not all.

Qualities unique to Zinga are that it is a very flexible zinc coating that provides cathodic protection of steel assets, with the ability to rejuvenate the coating in-field with minimal cleaning and surface preparation. If there is no

October 2012 www.corrosion.com.au p.45

corrosion & prevention 2012 SPONSOR PROFILES

rust emerging prior to recoating, the only requirement is a water blast to remove zinc salts and surface contamination. The rejuvenation process can be repeated indefinitely without the need for abrasive blasting, minimising life cycle costs.

Tuesday Morning Tea Sponsor Mears Integrity Solutions www.mears.net

Service life can be predicted on a similar basis to hot dipped galvanizing. It will depend on the coating thickness and the local zinc usage rate.

The flexibility of Zinga enables a broad range of application possibilities. Steel can be coated for protection prior to bending or welding. New fabrications can be shop primed, with a second coating applied after installation in field. Properly applied Zinga will not flake, blister or peel and the cathodic protection qualities prevent under-creep if the coating is damaged.

Zintec Corrosion Solutions can be contacted on (03) 6273 5118.

Monday Morning Tea Sponsor ProDigital www.prodigital.com.au

ProDigital Pty Ltd are the representatives in Australia and New Zealand for two global leaders in the manufacture of electrochemical instrumentation, including potentiostats and galvanostats for research electrochemistry, applied corrosion, battery and fuel cell research, biomedical research, plating and sensor applications.

Princeton Applied Research and The Solartron Group offer world class instrumentation and software for the characterisation and analysis of materials, employing spectroscopy techniques in a wide range of applications including electrochemistry, materials testing and metals analysis.

Both being of a high standing in the industry bring together more than 70 years combined experience under Ametek Corporation.

ProDigital Pty Ltd, now in its 15th year, offers local expertise, service and support for all the product range it offers.

p.46 CORROSION & MATERIALS

Mears Integrity Solutions are a world leading service provider specialising in corrosion control and asset integrity management. We offer superior engineering, technical and construction services to meet the challenges and demands of industry.

Founded in the USA in 1970, the company specialises in delivering customer specific solutions for all types of corrosion integrity problems, including turnkey inspection, remediation and repair services. Mears is a Quanta Services company with over 400 employees and more NACE certified technical staff than any other company in the world.

Mears have the experience and engineering expertise to provide our clients with optimum integrity solutions through corrosion evaluation, corrosion control, and remedial action. Our Senior Vice President of Special Projects is also the current President of NACE International.

Mears specialises in the pipeline and power industries and offers a safe, targeted, turnkey service to assist clients with their integrity management plans. The Mears Service Package includes the following Engineering, Technical, Construction and Field Services:

Cathodic Protection In-Line MFL Pipeline Inspection & Tethered ILI Direct Assessment (ECDA, ICDA, SCCDA) Surveys (DCVG, ACVG, CIS, PCM) LFI - Induced AC current studies and mitigation Linear Anodes Excavation & NDT Pipeline coating removal, remediation and recoating HVAC Transmission tower corrosion assessment & remediation

We’ve got you covered Supporting your projects in Australasia and around the world • Design • Application • Tech Service • Installation • Maintenance Our global presence means that International’s project management and technical service experts can assist with all your project’s coating needs. From specification advice during FEED, to spec optimisation at detailed design, to on site tech service during application (available worldwide), and finally to our Interplan® maintenance planning survey programme at commissioning and operation. International is there to support you every step of the way.

Toll Free Australia: 131 474 Toll Free New Zealand: 0800 808 807 pc-australasia@akzonobel.com www.international-pc.com

October 2012 www.corrosion.com.au p.47

Protective Coatings for the Mining Industry • A world leader in protective coatings • Systems proven across the globe • Innovation, quality and performance • Close by – wherever your project is located • Providing a comprehensive technical support function

Jotun Australia Pty. Ltd., P.O. Box 105, Altona North, Victoria 3025, Australia tel: +61 3 9314 0722 fax: +61 3 9314 0423 email: sales@jotun.com.au jotun.com 55574 Mining Adv Australia 190W x 125H.indd 1

p.48 CORROSION & MATERIALS

06/09/2012 06:36

PROTECTIVE COATINGS solutions that cover your needs

PITT-CHAR

Protection from corrosion on a global scale

PSX 700 SigmaCover SigmaDur SigmaPrime SigmaGuard SigmaShield SigmaTherm SigmaZinc

Protective and Marine Coatings ANZ PPG Industries Australia Pty Limited, McNaughton Rd, Clayton Vic 3168 Australia Tel: +61 3 92636000 Tel: 1 300 659666 (Toll Free in Australia) Fax: + 611 300 659665 Email: pmcorders@ppg.com

October 2012 www.corrosion.com.au p.49

corrosion & prevention 2012 EXHIBITOR PROFILES

3M www.3M.com.au

Stand Number: 5 3M is a recognized leader in providing sustainable, economic solutions for maintaining and protecting critical infrastructure. By leveraging more than 50 years of pipe coating experience and unsurpassed research and development capabilities, 3M can help solve the challenges facing today’s and tomorrow’s infrastructure owners, engineers and contractors by delivering innovative and cost effective coating solutions for a diversity of operating environments.

The 3M Scotchkote brand family of products includes Fusion-Bonded (FBE), Liquid Epoxy and Liquid Urethane coatings, as well as low viscosity primer/sealers. They offer long term maintenance free coating protection and finishing of pipes, tanks, storage reservoirs and ancillary equipment such as pumps and valves, whether to help protect new assets or to rehabilitate aging infrastructure.

Based on the latest polymer technology, 3M Scotchkote Mechanical Repair Coatings provide solutions for shaft, pumps and valves with advanced metal and ceramic rebuilding technology, solutions for tyre and belt repair, with elastomeric polyurethane expertise, and solutions for metal loss due to abrasion using mechanical repair compounds, extending the life of equipment.

3M is the innovation company that never stops inventing.

With $27 billion in sales, 3M employs about 80,000 people worldwide and has operations in more than 65 countries.

3M and Scotchkote are trademarks of 3M Company.

For more information, call 136 136 or visit www.3M.com. au/waterinfrastructure

A & E Systems www.ae-sys.com

Stand Number: 34 The A&E Group is an international company with its headquarters, manufacturing and product development facilities in Malaysia and regional centres in the UK, Australia and the USA. The Company’s products have won wide recognition for innovation in the development

p.50 CORROSION & MATERIALS

and application of anti-corrosion coatings for use both above and below water. They are international leaders in a niche market estimated to be worth over US$4 billion, with Enviropeel as the only system of its kind in the world, developed by the Group’s own engineers.

The Group’s philosophy is to provide the best possible products for the worst possible conditions. Its Alocit products have been used and proven for three decades in very difficult areas: sweating pipes, steel and concrete piles, ‘green’ and oily concrete, in the splash zone and underwater. More recently, Enviropeel, a unique sprayablethermoplastic anti-corrosion system, has created new opportunities for the protection and preservation of industrial infrastructure, including offshore & onshore bolt-protection, mining conveyor protection, mothballing and standby equipment protection.

The environmentally-friendly characteristics of A&E Group products, their ease of use and durability in service are key factors in winning acceptance from the world’s most demanding specifiers.

Abrasive Blasting Service & Supplies www.abss.net.au

Stand Numbers: 49 & 50 Abrasive Blasting Service & Supplies Pty Ltd (ABSS) was founded in 1989 after the Directors at the time recognised that there was an opportunity to manufacture Abrasive Blast Cleaning and Shot Peening Equipment here in Australia.

We are now considered an industry leader in the surface finishing sector throughout Australia and New Zealand. Our offices and distributors are located across Australia and New Zealand so we can easily service all requirements.

At ABSS, our range of Australian Made equipment includes Abrasive Blast Cleaning Rooms, Airless Blast Turbine Wheel Machines, Abrasive Recovery Systems, Blasting Cabinets, Blast Pots, Mega Blast Vessels, Dustech Reverse Pulse Dust Collectors, Bucket Elevators, Screw Conveyors and Compressed Air Pre-Filter Systems.

Working closely with our Global Partner Network, we complement our Australian Made products with a range of Growell Turbine Airless Blast Systems, Camfil Gold Series Dust Collectors, Mobile Dust Collectors and the latest innovative range of EcoQuip Vapor Abrasive Blasting Systems.

corrosion & prevention 2012 EXHIBITOR PROFILES

We carry an extensive range of Blast ancillary equipment and Blasting Media including Garnet, Glass Bead, Plastic, Ceramic Bead, Steel Grit and Steel Shot.

Altex Coatings www.altexcoatings.com

ABSS is ready to give our customers the best solution and the best attention by listening to them and understanding their exact requirements.

Absafe www.absafe.com.au

Stand Number: 41 Absafe Pty Ltd is a specialist contractor that provides inspection, remedial and maintenance services to all forms of façade and structures as well as Height Safety services.

We specialise in working at height, confined spaces and other difficult access situations such as remote or rugged terrain.

We are members of the Industrial Rope Access Association, Australian Concrete Repair Association and Civil Contractors Federation as well as the Australasian Corrosion Association.

Our range of services is:

Inspections - coatings, corrosions, façades Height Safety -consulting, engineering, installation Remedial Engineering and Maintenance - façade refurbishment, concrete repairs, stabilisation

Protective coatings - abrasive blasting, industrial coatings, waterproof membranes Specialist Access - Industrial abseiling, confined space, rigging.

We provide in-house engineering design services for all height related issues and are licensed installers of most major brands of height safety systems.

Absafe’s core expertise lies in its ability to access difficult work spaces and carry out works proficiently and safely.

Our rope access skills and sound rigging expertise combined with a vast array of modern tools and equipment means we can cater for most emergencies.

CONTACT DETAILS: Absafe Pty Ltd Building 1, 433 Smith Street Fitzroy VIC 3065 Ph +613 9486 3777 Fax +613 9486 6111 info@absafe.com.au

Stand Numbers: 22 & 23 Altex Coatings, ISO 14001 accredited and over 55 years experience in the manufacture of heavy duty protective coatings, is one of 19 Carboline global partners supplying a wide range of high performance protective coatings and systems for almost every major industry sector.

Carboline, a globally trusted name, is often recognised as the benchmark in the protective coatings industry and is dedicated to being the technology and market leader.

Carboline specialises in high performance coatings, linings and fireproofing products for the protection of steel and concrete substrates from both corrosion and fire damage.

With operations in over 90 countries, and extensive case histories and established network of associates and certified professionals, Carboline provides an extensive global service with products that have earned the reputation for proven performance at every level.

Altex Coatings services include a full “ Custom Specification Service”, Corrosion Audits relating to protective coatings, a “Service to First Maintenance Prediction Analysis”, and Quality Assurance Training. We supply Carboline systems to provide cost effective low risk solutions for high risk environments, engineered solutions that are proven and reliable.

AMAC Corrosion www.amacgroup.com.au

Stand Number: 12 Still Manufacturing in Australia!

AMAC Corrosion is a family owned company and have been manufacturing cathodic protection systems right here in Melbourne since 1974. Our factories include casting areas for producing Aluminium, Magnesium and Zinc sacrificial anodes along with areas for manufacturing & assembling impressed current anodes and cathodic protection materials and equipment.

October 2012 www.corrosion.com.au p.51

corrosion & prevention 2012 EXHIBITOR PROFILES

We design and manufacture products to suit every application and industry. With over 38 years experience, we offer the most cost effective products, designed to minimise installation time.

We have been ISO9001 accredited since 1997. We are proud to be the first Australian Anode Manufacturer to achieve and maintain this accreditation.

Our laboratory is set up to analyse the chemical composition of anodes to ensure they meet recognised standards and specifications. This is achieved through spectrometer analysis, electro-chemical testing as well as a range of other tests to ensure high quality product and consistency.

Our dedicated team have been involved in the manufacturing of anodes for a collective total of over 120 years, and are more than happy to chat with you at booth 12.

MIJ’s and Flange Isolation Casing Isolators Coating Repair Systems Pile Protection and Marine Anti-Fouling Nut and Bolt Protection Remote Satellite CP Monitoring Systems Swain Meters and Equipment Thermoelectric Generators (TEGs) Vapour Phase Corrosion Inhibitors Come and see us at Booth 57 in Melbourne Toll free 1800 446 400 www.anodeengineering.com sales@anodeengineering.com

Anti Corrosion Technology www.anticorrosiontechnology.com

If you require any information, please contact Mark Rigg on 03 9729 8888 or email markrigg@amacgroup.com.au

Anode Engineering www.anodeengineering.com

Stand Number: 57 Anode Engineering Pty Ltd is a specialist supplier and technical service provider to the corrosion prevention industry in Australia, New Zealand and South-East Asia.

We pride ourselves on being able to provide complete corrosion management solutions for our clients. Our long standing association with the industry has allowed us to become a market leader in providing cutting edge products and services technology for corrosion management and/or prevention needs. Our engineering group leads the industry in design, installation, commissioning and management of corrosion prevention systems. We provide quality services to the region in line with national and international standards.

We supply products under the following categories:

Anodes CP Power Systems, Instrumentation, Materials & Equipment, Cable, Services Coating Assessment and Survey Equipment Corrosion Probes and Monitoring Systems Earthing and Surge Equipment E xothermic Welding Earthing and Electrical Backfills Holiday Detectors

p.52 CORROSION & MATERIALS

Stand Number: 15 Anti Corrosion Technology (ACT) is an Australian-based engineering company that offers End Users in the oil & gas, water, mining and power generation industries full technical support on “everything corrosion” by senior specialists in materials engineering and corrosion control.

ACT is also the authorised sole distributor of STOPAQ systems in Australia offering unique and cost effective product & service solutions for external pipeline corrosion protection of field joints, flanges, HDD, steel pipe casing under road & rail crossings as well as external corrosion protection of tank bottoms and offshore/submerged structures such as pile-ons and jacket legs.

ACT’s first point of call is to offer asset owners, engineering firms and contractors alike remedial advice and qualifying the appropriate materials and application on every specific job, in light of the international standards and best practices.

Once a solution is proposed by ACT and accepted by the client, ACT will recommend and issue a full scope of work including a selected list of materials that make up the system as well as provide the Contractor with full training & certification for the applications. For critical projects, ACT also provides onsite supervision to ensure that the final product will meet the satisfaction of the asset owner to protect the asset against corrosion supported by an extensive product performance guarantee.

If you require any information on ACT services or STOPAQ products, please call Simon Ghobrial on (07) 3344 4434 or email the ACT team on info@anticorrosiontechnology.com

corrosion & prevention 2012 EXHIBITOR PROFILES

Aqua Environmental www.aquaenvironmental.com

Stand Number: 13 Aqua Environmental, a subsidiary of Pure Technologies, is a world leader in providing a systematic approach to pipeline condition assessment by identifying failure risks and assisting in prioritising repair and replacement efforts, thereby extending the useful life of assets through leak detection and condition assessment.

Utility asset managers are maximising their budgets by trusting our ‘Assess & Address’ program to identify pipeline risk and provide actionable information on selective rehabilitation.

Our specialised technologies provide water and wastewater operators state-of-the-art solutions to solve many types of challenges and help manage the life cycle of their pipelines.

– Corrosion detection is one of ATTAR’s highly developed fields, as is mitigation of corrosion and erosion on structures and vessels

NDT Level 3 Consulting and Auditing Services – Selection and optimisation of NDT methods and procedures – Personnel hold AINDT (AS 3998), BINDT (PCN to ISO 9712 & EN 473) & ASNT certifications NDT Training – Australia’s largest NDT training supplier – Wide range of methods – Pathway to certification (AS/ISO/PCN); RTO E xpert Witness Services – Accident and incident investigations Floor Consulting – Comprehensive Risk Assessments & Slip Resistance testing – Fitness for Application, new material specifications, installation advice, durability, accelerated wear testing, maintenance schemes, surface treatments, remediation advice.

The Bottom Line:

Understanding the condition of a pipeline permits cost effective, safe operation and management.

The Australasian Corrosion Association Inc. www.corrosion.com.au

Averting catastrophic pipeline failure can save a utility significant cost while improving public perception.

Proactively managing a main through inspection and

repairing only the locations of damage can result in millions of capital savings over replacement or sliplining.

ATTAR www.attar.com.au

Stand Number: 11 ATTAR is an Engineering, Consulting and Training organisation specialising in:

Materials selection, analysis and characterisation – Turnkey solutions in respect of all types of materials (Metallic, Polymeric, Ceramic, Composite) – Mechanical Consulting F orensic Engineering and Failure Analysis – Root Cause Identification ; Failure Modes – Evaluation of Substitute Components N on-Destructive Testing (NDT), Condition Monitoring and Specialised Detection Methods – Pressure vessels, pipelines, overhead line corrosion detection, transformers, EWP inspections, gas testing stations

Stand Number: 56 The Australasian Corrosion Association Inc (ACA) was established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals working against corrosion.

A membership-based, not-for-profit industry association, the ACA promotes the co-operation of academic, industrial, commercial and governmental organisations that are involved with corrosion, and it works to disseminate information on all aspects of corrosion and its prevention by promoting lectures, technical meetings, symposia and other activities related to the industry.

When members join the ACA they choose up to five Technical Groups which provide a structure for technical activities within a segment of industry or technical expertise. The eight Technical Groups created from and formed for the benefit of members and Industry are:

Concrete Structures & Buildings Cathodic Protection Coatings Mining Industry Petroleum & Chemical Processing Industry

October 2012 www.corrosion.com.au p.53

corrosion & prevention 2012 EXHIBITOR PROFILES

Research Water and Water Treatment Welding, Joining & Corrosion

Bureau Veritas www.bureauveritas.com.au

Membership of the ACA is available to anyone with an interest in corrosion and its control. There are four categories of membership: Corporate, Individual, Student and Retired.

For further information on the ACA, please contact +61 3 9890 4833 or aca@corrosion.com.au

Blygold www.blygold.com.au

Stand Number: 59 Blygold stops corrosion in air cooled Air Conditioning systems from occurring by cleaning and coating both new and existing heat exchangers with our unique anticorrosion products. As a result substantially savings are realized on energy expenses and capital costs. Blygold also specializes in treating AHU’s and casings of chillers with the Blygold anti-corrosion treatment.

Our great value proposition: Everyone knows Air-conditioning systems are huge energy consumers (40 - 70% of energy use in most buildings). Therefore, it is very important for each unit to operate at optimal levels with the highest efficiency possible. When corrosion occurs and pollution adheres the performance will decrease dramatically and energy consumption will increase.

The Blygold corrosion protection will avoid this from happening and stop an increase of energy consumption.

The current generation of anti-corrosion treatments from Blygold has been tested successfully at 4000 Hours + against salt and acid spray.

Benefits Blygold treatment:

 s ave up to 20% on energy use d ouble the lifespan of the heat exchangers e nsure the highest level of performance

Stand Number: 52 Bureau Veritas has over 50 offices across Australia and New Zealand. It is a French-based, ISO9001 accredited company operating throughout 140 countries with over 34,000 experienced professionals servicing over 300,000 clients across the world. Bureau Veritas provides services via 8 dedicated business lines including Health Safety & Environment, Industry, Marine, International Trade, Certification, Consumer Products, Inspection & In-Service Verification, and Construction.

Bureau Veritas Asset Integrity and Reliability Services (AIRS) in Australia is a part of the Industry business line, and provides a full suite of asset reliability management services including condition monitoring, non destructive testing, structural integrity, metallurgical services, root cause analysis, risk based analysis, risk based inspection, and finite element analysis. The Materials Science and Engineering group is comprised of over 30 metallurgical consultants and technicians spread across Australia. The services provided include:

Root cause failure analysis of plant and equipment Identification of corrosion failure mode NATA accredited chemical analysis (atomic emission

spectroscopy) and mechanical testing Preparation of material specification and Inspection and Test Plan In-situ metallurgical testing: metallographic replication, hardness testing, and positive material identification Wear debris analysis Scanning electron microscopy and energy dispersive spectroscopy analyses for high resolution imaging and elemental analysis.

Cathodic Diecasting www.cathodicdiecasting.com.au

of heat exchangers

 increase reliability of the climate control system p rovide cleaner air to staff, visitors and other users

Stand Number: 60

o ur services generally earn themselves back within

The cost of fighting corrosion in Australia has been estimated at a staggering $30 billion per year, which represents 3% of Australia’s GDP. We are proud to be part of the industry that is helping to fight corrosion.

We manufacture Galvanic Anodes. High quality

12 months

Blygold can increase the lifespan of these systems as well as greatly reduce the amount of energy they use over their lifetime.

p.54 CORROSION & MATERIALS

corrosion & prevention 2012 EXHIBITOR PROFILES

(ISO 9001 accredited by LRQA), fast turn around and competitively priced.

Our anodes protect billions of dollars worth of infrastructure around Australia, the South Pacific and South East Asia including industrial anodes for offshore oil rigs, floating FPSOs, mining, construction and pipelines as well as for the protection of infrastructure such as ports, wharves, sheet pile walls and desalination plants. Our anodes also protect ships, yachts, marine motors, tanks and hot water systems.

Since commencing manufacturing in 1984, we have established ourselves as Australia’s largest galvanic anode manufacturer. Our foundry is designed based on Lean Manufacturing principles, where work flow efficiency gains and minimal down time has lead to significantly shorter lead times and reduced energy use.

Our services include: Application Equipment sales, servicing and support Application Equipment replacement parts sales Safety Supplies Cartridge filters sales and support Training and consulting services Testing Equipment sales, servicing and calibration Coating jigs, hooks and masking supplies Deepwater Corrosion Services

Deepwater Corrosion Services www.stoprust.com

An integral part of our commitment to providing high quality anodes is our laboratories which include an Optical Emission Spectrometer for chemical analysis, electrochemical test baths, anode-to-core resistance testing and more.

Stand Number: 58

We look forward to seeing you at the ACA conference.

Founded in 1986, Deepwater is a full-service offshore corrosion-control company providing the oil and gas industry with expertise in cathodic protection and assetintegrity management. Using our own proprietary product designs, we have focused on developing innovative methods and new products to improve upon lagging industry standards, resulting in a much more reliable and cost-effective approach to offshore corrosion prevention.

From corrosion inspection services to engineering and turnkey project management, Deepwater provides design, manufacturing, consulting, logistics and installation supervision in all of the world’s main market areas.

Coating Supplies Australasia Pty Ltd www.coatingsupplies.com

Stand Number: 6 Coating Supplies Australasia Pty Ltd is a privately held and independently operated Australian company that specialises in the distribution, supply and servicing of high quality coatings application equipment, testing and inspection instrumentation and associated supplies for powder and industrial coatings applicators as well as associated industry service providers.

With a depth of experience in both Powder and Liquid coatings we offer our customers the highest level of technical support and expertise. Our parts, supplies and services will keep you running efficiently and save you time and resources by providing a one stop sourcing solution.

Coating Supplies Australasia Pty Ltd is proud to be the distributors in Australia and New Zealand of TQC Vision on Quality Testing Instruments, QNix™ Coating Thickness Gauges and Elmed Isotest© Holiday Detectors. We also are proud to be authorised distributors of Graco and Gema™ powder coating equipment. Other brands in our stable include 3M, Sundstrom and Frontier Safety equipment.

Deepwater designs and manufactures cathodic protection systems for offshore and marine assets, specializing in the development of innovative retrofit technology for aging assets in need of life extension.

Over the last 25 years, our cathodic protection designers and corrosion engineers have been at the forefront of the offshore industry, writing inspection procedures, developing standards and helping operators protect their infrastructure by inventing new systems that combat corrosion in almost every environment. The Deepwater team has brought the science of cathodic protection up to speed with today’s cutting-edge energy market.

Our approach has constantly evolved to provide more efficient and affordable alternatives to traditional cathodic protection design, which relies heavily on simple sacrificial-anode systems.

Deepwater Corrosion Services corporate headquarters are in Houston, USA . Email us directly for enquiries about anodes, cathodic protection systems, engineering or inspection: enquiries@stoprust.com

The team at Coating Supplies Australasia understands the needs and daily operations of coating applicators.

WE ARE COMMITTED TO YOUR BUSINESS SUCCESS!

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corrosion & prevention 2012 EXHIBITOR PROFILES

Dehumidification Technologies www.rentdh.com

Stand Number: 21 Dehumidification Technologies, Inc. (DH Tech) is a provider of temporary dehumidification, heating and cooling equipment. Industries served include industrial painting, commercial building construction, water damage restoration and a variety of industrial, food processing and manufacturing processes where precise humidity and temperature control are critical. The company was founded in 1993 in Houston, Texas where the business flourished in the heart of the petro-chemical industry.

The firm operates from nine offices in the USA and two in Australia. These are Philadelphia, Chicago, Los Angeles, San Francisco, New Orleans, Delaware, Corpus Christi, Houston, Miami, Melbourne and Sydney. A new office has also been established in Thailand.

DH Tech maintains an extensive fleet of mobile climate control equipment in the US and Australia with a focus on desiccant dehumidification. The desiccant dehumidifiers exhibit the latest technology in desiccant rotor technology and electronic controls. They are manufactured in the Houston, Texas factory. Over its 19 year history, DH Tech has been a leader in combining cooling and desiccant technologies to deliver efficient and exact humidity control in hot or humid environments.

Responsible for the success and growth in the company, is a dedication to responsiveness and a deep understanding of customer needs. This is reflected in the design of the equipment, the internal processes employed and the choice of field personnel. In Australia, the company is represented by David Dawson, Dean Clarke & James Smith.

Denso Australia www.densoaustralia.com.au

DENSO NORTH AMERICA INC.

Stand Number: 27

Denso (Australia) Pty Ltd are principal manufacturers of long life anti-corrosion products and sealing systems, which service a multitude of industry groups. Denso services, as it’s core markets, Oil & Gas, Marine, Mining, Minerals Processing and Water Industries, throughout Australia and New Zealand and Pacific Islands.

Denso (Australia) Pty Ltd adapts and refocusses on a continuing basis, making certain that as the industries we serve change, Denso, and our products and services

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remain as not only the internationally recognised standard, but the supplier of preference.

The Denso range comprises a variety of specialist pipe & structural coatings, marine protection systems, concrete and tank coatings, including tapes, brush and spray applied liquid coatings, mastics, primers and sealants based on materials such as petrolatum, butyl rubber, bitumen, plastics, heat shrink sleeves and epoxy resins.

Systems are tailor made for individual anti-corrosion and sealing problems developed with the realities of an onsite application in mind. Denso’s extensive product range is suitable for use in a wide range of highly corrosive environments with operating temperatures from sub-zero to 250°C. Brand names include Seashield, Archco-Rigidon, Protal, Rigspray, Denso, Densopol, Ultraflex, Densoramic and Polybron.

Associated group companies include Winn & Coales (Denso) Ltd, Archco Rigidon, Premier Coating Ltd, Seashield International, Denso (New Zealand) Ltd, Denso North America Inc and Denso South Africa (Pty) Ltd.

Dulux Protective Coatings www.duluxprotectivecoatings.com.au

Stand Numbers: 37, 45 & 46 Dulux® is Australian owned and committed to the supply of high performance protective coatings to the AustraliaPacific region for over 75 years. Dulux® Protective Coatings manufacturers a comprehensive and diverse range of protective coatings for heavy duty applications in the oil and gas industries, mining, infrastructure, chemical manufacture, purification and processing plants and coastal and off-shore construction.

Long term corrosion control has been effectively achieved by the use of Dulux zinc rich epoxy primers, inorganic zinc silicates, high build epoxy intermediates, chlorinated rubber, acrylic and polyurethane topcoats; micaceous iron oxide coatings and specialist high performance systems such as pure polyurea elastomers and heat resisting product lines.

With our world-class Research and Technology Centre and new manufacturing plant in Dandenong, and customerfocused technical consultants, we provide rapid, tailor made corrosion solutions for just about every aspect of heavy industry. Information on everything from substrate preparation, detailed coating system specifications, application methods and maintenance scheduling.

Dulux Protective Coatings also has the most extensive distribution network in the industry with a comprehensive

corrosion & prevention 2012 EXHIBITOR PROFILES

supply chain network of over 230 trade distribution outlets nationally. This ensures rapid, reliable service right across the country.

Call Dulux today on 13 23 77 or visit www.duluxprotectivecoatings.com.au.

Worth doing, worth Dulux®.

Hempel www.hempel.com

Stand Number: 42

independent and authoritative consultancy in the fields of Corrosion Engineering and Asset Management.

Our independence is vital, allowing us to offer our clients totally unbiased optimum advice, without commercial constraints in the following specialised areas:

A sset Integrity Management Surveys – Guardian® Cathodic Protection Coating Selection and Specification Development 3rd Party Independent Coating Inspections and Certification Failure Analysis Metallurgy & Materials Consulting Welding Inspection, Specification Development and Certification Concrete Condition Surveys Workforce Training and Competency Certification

Hempel is a world-leading supplier of protective coatings for the marine, protective, container, yacht and decorative segments. From windmills and bridges to hospitals and ships, their coatings protect man-made structures from the corrosive forces of nature.

With offices throughout Australia and in key locations in Singapore, Kuala Lumpur and Hong Kong, Incospec continues to expand its presence and delivery of high value technical corrosion engineering consultancy, research, training and field services to key global clients.

Hempel’s goal is to increase the long-term value of their customers’ assets by providing them with coatings that help extend product lifetimes and reduce maintenance costs. Their R&D teams around the world are constantly working to develop new and innovative products and solutions that improve performance and lower application costs for their customers. Hempel believe that the coatings industry can and should contribute to a better environment, so they invest in advanced products and innovative ideas to create environmentally friendly solutions that help customers cut fuel consumption and reduce emissions from their operations.

Our continued strategic focus of providing high value asset integrity maintenance management systems through Guardian® directly to key asset owners continues to support our primary Corporate mission – ‘To Assist Clients Protect Their Assets’

Represented in more than 80 countries, Hempel have 21 factories, 47 sales offices and more than 150 stock points strategically located around the world. Hempel also have three main R&D Centres in China, Denmark and Spain, and regional R&D Centres in Bahrain, Germany, Korea, Singapore and the US. www.hempel.com 1800 HEMPEL

Incospec recently announced a key commitment to the continued development of the Northern Australia resource sector with its partnership with Charles Darwin University and the North Australian Centre for Oil and Gas. Proudly In Partnership With

Infracorr www.infracorr.com

Incospec & Associates Australia www.incospec.com.au Stand Number: 24 Stand Numbers: 28 & 29 Corrosion Engineers & Consultants – Independent Advice Established in 1981, Incospec & Associates Australia has grown to be one of the largest Corrosion Engineering Consultancies in Australasia. We provide both

Infracorr Consulting Pty Ltd is an innovative specialist engineering consultancy offering unbiased advice on rehabilitation solutions for infrastructure damage caused to your assets by corrosion and deterioration of materials.

With over 25 years’ experience in the investigation, repair and protection of all types of structural assets and with specialist materials knowledge, we aim to provide you

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corrosion & prevention 2012 EXHIBITOR PROFILES

with optimal corrosion mitigation solutions to preserve and extend the lifespan of your infrastructure.

and remediation and you have the solutions for all your coating needs.

Our team of engineers along with technical support staff have extensive skills and knowledge from backgrounds in both civil and materials engineering. We provide specialist materials knowledge, detailed corrosion surveys and through investigations to determine the cause and extent of the deterioration and provide appropriate repair and protection options for the long term.

International is exhibiting at the ACA Corrosion & Prevention Conference being held 11th -14th November 2012 at the Crown Conference Centre, Melbourne. We are located at stands 7 and 8.

Infracorr is the leader in the fields of Cathodic Protection and Hybrid systems, as well as conventional repair options.

We provide exceptional technical knowledge and expertise in the implementation of lowest cost solutions with minimal disruption, to solve durability problems in Infrastructure.

Operating in such diverse sectors as: Mining and Resources Buildings Marine Civil & Water/Waste Water Power and Industrial

International Paint www.international-pc.com

Stand Numbers: 7 & 8 Akzo Nobel, is a market driven, technology based company specialising in coatings and chemicals and serves the Marine and Protective Coatings markets, under the brand ‘International®’.

International’s Protective Coatings division supplies market focussed, innovative coatings to the Mining, Oil & Gas, Water & Waste, Infrastructure, and Power Generation markets. With tailor made, high performance coating solutions for new construction and maintenance of both steel and concrete substrates International can provide for all your project needs.

Our global presence means that International’s project management and technical service experts can assist with all your project’s coating needs. From specification advice during FEED, to spec optimisation at detailed design, to on site tech service during application (available worldwide), and finally to our Interplan® maintenance planning survey programme at commissioning and operation, International is there to support you every step of the way.

Toll free Australia: 131 474 Toll free New Zealand: 0800 808 807 Email: pc-australasia@akzonobel.com

Jacobsen Colourplus Limited www.colourplus.co.nz

Stand Number: 44 Jacobsen Colourplus Ltd is a privately owned company located in Auckland, New Zealand, manufacturing paint and industrial coatings for the past 27 years from its well appointed ISO 9001 acredited manufacturing plant. The facility incorporates a fully accredited laboratory to ISO 17025 , together with excellent distribution facilities guarantees the best quality coatings are produced to the most stringent quality quantrol standards and dispatched efficiently world wide.

Jacobsen Colourplus Ltd is the Australia, New Zealand and Pacific region distributer for ZRC Worldwide, the leading manufacturer of high quality zinc rich anti corrosive coatings for the long term protection of iron and steel against corrosion. Over the last 50 years ZRC products have been included by architects and specifiers for thousands of projects throughout the world. These include transmission towers and antennas, steel decking and bridges, power plants and waste and water facilities. It is commonly used by OEMs as an in-plant substitute for hotdip galvanizing.

Jacobsen Colourplus Ltd is also the manufacturer/ distributer of the Camrex Camovin range of industrial coatings. These include vinyl top coats and zinc rich anti corrosive primers used extensively in the power industry in Australia and New Zealand for the last 20 years.

Jotun www.jotun.com.au

Standard

International is home to some of the best known product names in high performance coatings such as: Interline, Enviroline, Ceilcote and Polibrid for severe chemical environments; Intertherm for high temperature, cryogenic and CUI applications; and Interchar and Chartek for high performance passive fire protection. Add these to the recently released Intercrete™ range for concrete repair

Stand Numbers: 17 & 26

Jotun blue

Jotun is one of the world’s leading manufacturers of paints, coatings and powder coatings. The group has 74 companies and 39 production facilities on all continents. In addition,

Black and white

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corrosion & prevention 2012 EXHIBITOR PROFILES

Jotun has agents, branch offices and distributors in more than 80 countries. The Jotun Group has four divisions employing more than 8,500 employees globally, and its head office is located in Sandefjord, Norway.

Jotun Australia Pty Ltd is a wholly owned subsidiary of the Jotun Group and supplies Protective Coatings, Marine Coatings and Powder Coatings for corrosion control and other specialised applications.

In 1990 Jotun purchased the Dimet business linking the best of European technology with an Australian business that brought innovative products to the world.

Our local manufacturing unit accredited to ISO 9001 is situated in Brooklyn, Victoria, where we maintain a NATA (National Association of Testing Authorities) registered laboratory and a manufacturing facility recognised by Australian Paint Approvals Scheme. In addition the Brooklyn site holds accreditation to ISO 14001 (Environmental) and OHSAS 18001 (Safety) management systems.

At Jotun, we are able to draw on our vast worldwide experience to provide technical assistance and coating recommendations in Mining, Smelting, Chemical, Petrochemical, Offshore, Water, Sewerage and many other industries where corrosion problems are found.

Jotun Australia has activities in all states and is able to provide a high level of local service supported by the global strength of Jotun’s worldwide activities.

Jotun Australia’s head office and manufacturing can be contacted on +61 3 9314 0722.

M Brodribb www.brodribb.com.au

Stand Number: 4 Founded in 1949, M. Brodribb Pty Ltd gained a sound reputation for excellence in designing, manufacturing and supplying power conversion equipment and systems that underpin many of Australia’s major public and private infrastructure projects. Commencing as a manufacturer of small power and audio transformers for the local industry, it progressed to larger and more sophisticated production of power conversion equipment.

The Company’s client list is testimony to its ability to satisfy the technical and commercial requirements of its clients. The client base includes Power Commissions, Major Electrical Contractors, Local, State and National Government Authorities, Defence Departments, Railways, OEM’s. Applications include Cathodic Protection, Battery Charging and major projects in the Mining, Primary and Extractive Industries.

M. Brodribb is an AS/NZS ISO9001:2008 qualified manufacturer. The quality management system accredits the “Design, manufacture and servicing of DC power systems for battery charging, cathodic protection, small power transformers and constant current regulators”.

M Brodribb manufactures electronic equipment and transformers to customised requirements and its flexible manufacturing systems can handle single items or short runs. The manufacturing and assembly facilities are in Glen Iris, Victoria. The Company enjoys continuing success in export fields with production directed offshore to our Asian and Pacific Rim neighbours including Indonesia, Singapore, PNG, Malaysia, Vietnam and Nepal.

Mears Integrity Solutions www.mears.net

Stand Number: 2 Mears Integrity Solutions are a world leading service provider specialising in corrosion control and asset integrity management. We offer superior engineering, technical and construction services to meet the challenges and demands of industry.

Founded in the USA in 1970, the company specialises in delivering customer specific solutions for all types of corrosion integrity problems, including turnkey inspection, remediation and repair services. Mears is a Quanta Services company with over 400 employees and more NACE certified technical staff than any other company in the world.

Mears have the experience and engineering expertise to provide our clients with optimum integrity solutions through corrosion evaluation, corrosion control, and remedial action. Our Senior Vice President of Special Projects is also the current President of NACE International.

Mears specialises in the pipeline and power industries and offers a safe, targeted, turnkey service to assist clients with their integrity management plans. The Mears Service Package includes the following Engineering, Technical, Construction and Field Services: Cathodic Protection In-Line MFL Pipeline Inspection & Tethered ILI Direct Assessment (ECDA, ICDA, SCCDA) Surveys (DCVG, ACVG, CIS, PCM) LFI - Induced AC current studies and mitigation Linear Anodes Excavation & NDT

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Pipeline coating removal, remediation and recoating H VAC Transmission tower corrosion assessment & remediation

Metz www.metz.net.au

Stand Number: 1 Metz areas of expertise are Acid Proofing for protection of concrete and steel against strong chemical attack and Industrial Flooring to provide hard wearing, chemical resistant and hygienic floors for all types of industries.

Industrial Applications For over 60 years Munters has engineered and manufactured equipment to solve humidity and climate control problems.

Surface Preparation & Coating Since the 1970’s, Munters desiccant dehumidifiers have been creating the ideal conditions for surface preparation and coating.

Construction Drying We recognize that delays in completing building projects will lead to financial penalties, a loss of reputation and ultimately a loss of business long term. That’s why our experienced technicians can be on-site within 24 hours of appointment to assess the requirements to cost effectively speed the drying process.

Metz materials are manufactured in Melbourne and we have three Australian branches. Metz is quality accredited to ISO9001:2008. Metz provides complete solutions based upon the most appropriate materials – whether traditional acid brick and tile or various coating and topping systems.

Neptune Asset Integrity Services Pty Ltd

Metz’s ability to supply and install our comprehensive range of specialist materials gives our clients single point of responsibility comfort. Our focus on the corrosive effect of harsh chemicals in industry and the protection of flooring in the most difficult physical and chemical environments gives us an expertise that is unmatched by other Australian companies.

Stand Number: 14

Metz has distributors in most Asian countries as well as in the Middle East.

Munters www.munters.com.au

Stand Number: 3 Munters is a global leader in energy efficient air treatment solutions based on expertise in humidity and climate control technologies. With a network of depots throughout Australia, Munters can deliver state of the art dehumidification equipment for short-term or long-term climate control to any location.

Our technical expertise gives you the added advantage of knowing that our specialist team will advise you on your requirements and timeframes ensuring you only rent the equipment you need for as long as you need it. Our technicians will also install, set and monitor the equipment throughout the duration of the project giving you the reassurance you need to know that the job will be completed efficiently and cost-effectively.

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www.neptunems.com

Neptune Asset Integrity Services provides a range of NDT, Inspection, engineered specialist access solutions and trade services.

Our multidisciplined teams are selected based on their accreditations, qualifications, track records and demonstrated competency.

With applications on and offshore, rope access techniques provide numerous advantages including cost and time savings, flexibility, minimal or no disruption to in-service equipment, and above all else, safe operation.

Complementing the rope access services are our specialist access solutions, including our patented modular platform, tensioned netting and suspended decking systems providing versatile solutions which are efficient and cost effective for challenging offshore structures in adverse weather conditions.

Bespoke access solutions are also available utilising our in-house Neptune Engineering design service.

Neptune conducts IRATA accredited rope access training in the application of all techniques at purpose designed facilities in both Melbourne and Perth, simulating the scenarios a rope access technician will encounter in the field.

Services Available:

Standard & Advanced Non-Destructive Testing Services, including Ultrasonic Thickness Testing, EddyCrrent, ACFM, Phased Array, Close Visual Inspection.

corrosion & prevention 2012 EXHIBITOR PROFILES

C lass Surveys to Lloyds Standards Tanks inspection P ressure Vessel and Piping Inspection (API 510 & 570; NATA ISO17020 & 17025) Lifting Equipment Inspections (LEEA) SPS & UWILD Corrosion Under Insulation Mechanical repair and maintenance

Newspec Pty Ltd www.newspec.com.au

Stand Number: 36 NewSpec specialises in the sales and service of high-end scientific research equipment manufactured by leading international companies including:

Bruker Nano Surfaces (former Veeco

metrology products) Hitachi High-Tech CETR Newport Corporation Spectra-Physics Lasers NewSpec’s comprehensive product portfolio includes: Tribology & Mechanical Testing Equipment Corrosion Analysis Equipment Scanning Probe & Atomic Force Microscopes (SPM, AFM) Optical and Stylus Surface Profilers (Wyko, Dektak) Micro & Nano Indentation Systems Electron Microscopes & Accessories (TEM, SEM) Lasers, Solar Simulators & Light Sources Optical Tables & Vibration Isolation Systems S pectroscopy, Radiometers & Optical Measurement Systems Optics & Mechanics Motorised & Manual Positioning Systems

industry. The Centre is a hub for training and education programs together with consultancy and research capabilities targeted at the specific needs of oil and gas operations and developments in the region.

Services for the Oil and Gas Industry Corrosion Engineering The Centre has a focus on research into corrosion prevention and control in tropical environments. A range of corrosion assessment and materials testing services are available.

Multiphase Flow and Phase Behaviour Another core research and consultancy focus for the Centre is process stream analysis and flow assurance aimed at optimising production of petroleum products.

VET CDU offers an extensive vocational education and training (VET) programs covering electrical, construction, metal trades, transport and logistics, process plant operations and other trades training relevant to the petroleum and mining sectors.

Process Engineering The Associate Degree in Process Engineering provides the necessary academic background and practical training for mid-level engineering employment, such as engineering technical officer or site supervisor.

Chemical Engineering A new specialisation of Chemical Engineering will be offered from 2013 in the Bachelor of Engineering and Master of Engineering degrees at CDU by on-campus mode as well as by distance learning mode. This will be the first time Chemical Engineering will be available by distance mode study in Australia.

Research Research degree opportunities are available in multiphase flow analysis of hydrocarbons and corrosion engineering.

For further information please contact Asma Rehman Khan: T. 08 8946 6828 E. oilandgas@cdu.edu.au

North Australian Centre for Oil & Gas

NMT Electrodes (Australia) Pty Ltd

www.cdu.edu.au/engit

www.nmtelectrodes.com

Stand Number: 55

Stand Numbers: 53 & 54

Charles Darwin University (CDU) has established the North Australian Centre for Oil and Gas with support from the Northern Territory Government and the oil and gas

For many years NMT® Electrodes companies have been offering industry a cleaner solution to many of its problems via the application of Electrochemistry.

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corrosion & prevention 2012 EXHIBITOR PROFILES

Applications such as the production of chlorine, hypochlorite and sodium chlorate; inorganic and organic chemical manufacture; waste water treatment and metal winning are but a few areas where NMT® Electrodes’ products and technology has been utilised.

NMT® Electrodes is now a well-established name in providing cost effective solutions and products in the Cathodic Protection field. NMT’s MMO and Platinised titanium Anodes are products of choice and are used and specified worldwide for use in concrete, underground storage tanks, pipelines, offshore and marine installations to name but a few.

NMT’s full range of tubular, wire, ribbon, rod, mesh and plate anodes are available from its Australian, South African and now European facilities.

Address (Australian): Unit 2, 26 Baile Road, Canningvale, WA 6155. Phone: +61 (0)8 9256 4499; Fax: +61 (0)8 9256 4599; Mobile: +61 408 931 072

Pan Abrasives www.pan-abrasives.com

Stand Number: 20 With a history dating back to 1954, the Pan Abrasives Group has played a leading role in the surface preparation and finishing industry worldwide over an extended period of time.

Using this extensive industry experience to design and develop new product lines, Pan Abrasives now manufactures a complete and extensive range of surface preparation products, marketed under the Trademark name of “PanBlastTM”.

In addition to our Singapore head office, Pan Abrasives has subsidiary companies located in Australia, China and Malaysia. Visit our website for more details, www.pan-abrasives.com For sales enquiries, please email to: paa_sales@pan-abrasives.com

Parchem Construction Supplies www.parchem.com.au

Stand Number: 48 Customer Service 1800 801 108 Parchem Construction Supplies offers over 50 years experience servicing the construction, civil and concrete industries. Specialising in the supply and manufacture of construction and decorative concrete products, equipment and tools, Parchem brings together industry leading brands with a strong commitment to service and technical support.

With trusted brands such as Fosroc, Vector and Max Frank, Parchem has a solution for all civil, commercial and industrial projects. With a specific focus on the durability of concrete infrastructure our construction products range include: Concrete repair materials – Renderoc Range of products

Corrosion protection solutions – Galvashield range of

galvanic anodes Protective Concrete Coatings – Silanes, anti carbonation and epoxy coatings Concrete fibre spacers with known durability performance properties Controlled permeability formwork liners (CPF) - Zemdrain Calcium aluminate mortars for sewer rehabilitation SewperCoat

The range of PanBlastTM products for the abrasive blasting industry include pressure blast pots, all associated spares and ancillary accessories, suction and pressure blast cabinets, airless painting systems, right through to airless wheel blast parts to suit most popular brands.

PCTE

Pan Abrasives also supplies a complete range of abrasive blasting media, including EnviroGritTM Garnet, QuickCutTM Aluminium Oxide, PanaShotTM Steel Shot, PanaGritTM Steel Grit and BrightBlastTM Glass Beads.

Stand Number: 40

Our head office, located in Singapore, includes our central distribution warehouse and our final assembly, inspection and packing facility. Singapore’s logistically central location allows us to distribute efficiently and globally via both our own branch network, as well as our extensive distribution network partners.

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www.pcte.com.au

Papworth Construction Testing Equipment trading as PCTE has been in business since 2004, as an expert supply company focusing on Non-Destructive testing equipment for construction materials. Originally started in Western Australia by Frank Papworth, PCTE has expanded to Service both the east and west coasts with offices in Victoria, New South Wales and Western Australia. Plus a new office planned in Brisbane by year end.

corrosion & prevention 2012 EXHIBITOR PROFILES

The equipment they supply can be used to assess the Quality and Strength of new structures and old, to examine the geometry of structures that lack records, for concrete defect location, and to find corrosion before its effects are visible or to monitor at risk structures.

From the beginning PCTE has endeavoured to not only just import equipment but to develop professional expertise in the equipment they sell. The team is made up of engineers managing the company and acting as sales staff. So they really understand the capabilities of the products they offer, and are always working to expand the body of technical knowledge on their equipment.

Reuben Barnes is the Managing Director and head of the sales team operating out of Victoria. He has extensive experience in NDT and has trained internationally in such areas as Ground Penetrating Radar and Impact Echo testing. Please feel free to visit our website www.pcte.com.au or by phone 03 9938 3830.

Peerless Industrial Systems www.peerlessindustrialsystems.com

Stand Number: 30 Perth, Melbourne, Brisbane, Singapore, Hongkong Epigen lining & repair composite polymers dominate in water storage & treatment, grouting & backing, linings for aggressive chemical resistance, process tanks, nonskid flooring, pump repair/rebuilding, turbine & motor chocking, joints, adhesives, and metal repair.

Peerless – Celebrating 65 years in 2012 Epigen – Celebrating 40 years in 2010 Chemproof – Celebrating 21 years in 2010 KIS – New Patented Elastomeric, high elongation – “Keep It Stretchy” Tel. +61 (0)8 9477 3788 Fax +61 (0)8 9477 3766 Email nick@epigen.com.au www.peerlessindustrialsystems.com

Phillro Industries Pty Ltd www.phillro.com.au

Stand Numbers: 32 & 38 Founded in 1971, Phillro Industries have grown to be a respected specialised supplier of high quality products and equipment including:

NDT (Ultrasonic Non Destructive Testing) Enterprise training Coatings fluid transfer pumps Spraying and Finishing Guns, Hoses and Systems Spray Booth Filtration A ssociated Safety products Solvent Recovery Food and Pharmaceutical Fluid Transfer Coatings Inspection Concrete Inspection Metal Detection

Sectors include power, water industry, mining, mineral processing, petroleum, refining, and materials handling with past projects including linings for the Merrimac (Gold Coast), Rosedale (NZ), WA21 in Perth, and lining materials for the Mackay WWTP. Water products are approved to AS4020 successfully date back to the 1970’s. Significant applications include internal linings in FGD and Stacks in Power Stations around Asia working closely with Institutes in China, ground breaking over recent years.

They are also trained and authorised service and repairers of Major Brands such as Graco & Ciemme. As the Principal Australasian/Oceania Importer Distributor for Elcometer Ltd, Phillro are the only Elcometer authorised Service centre in the region.

The Epigen Chemproof 4000 range of novalac products; lead the field for aggressive chemical resistance; installed at major sites throughout Australia including Nickel West Acid Facility, Murrin Murrin, Tiwest, CSBP, BHP Billiton, for protecting concrete and steel.

PPG Industries

Peerless enjoys an excellent reputation in liaising with contract applicators, consultant design engineers and asset owners to qualify protective systems for their particular operating environments. Working with all ensures that the principle receives a system that achieves the maximum service life possible.

Phillro’s activities include Focussed Product Training, Sales, Service and Hire of Equipment manufactured by the world’s most respected Brands.

www.ppgpmc.com.au

Stand Numbers: 35 & 43 PPG Industries’ vision is to continue to be the world’s leading Coatings and Specialty Products Company.

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corrosion & prevention 2012 EXHIBITOR PROFILES

Through leadership in innovation, sustainability and colour, PPG helps customers in industrial, transportation, consumer products, and construction markets and aftermarkets to enhance more surfaces in more ways than does any other company.

Founded in 1883, PPG operates in more than 60 countries around the world. Sales in 2011 were $14.9 billion.

PPG Protective & Marine Coatings, part of PPG’s Performance Coatings’ business segment, is uniquely placed to offer the highest-quality coatings for the protective and marine coatings industries. Whatever your requirement, our proven products and technologies can safeguard a wide variety of assets in the markets we serve.

The knowledge we have gained throughout the world has given us an unrivalled heritage and level of technical expertise: experience that guarantees exceptional products, performance and service.

No matter what the size of your organisation, PPG has the scale and resources to deliver outstanding support, with well-established operations in over 60 countries.

Our aim is to become the world’s leading protective and marine coatings company: unrivalled in performance and protection among asset owners, contractors, fabricators and applicators across the globe.

ProDigital www.prodigital.com.au

Stand Number: 47 ProDigital Pty Ltd are the representatives in Australia and New Zealand for two global leaders in the manufacture of electrochemical instrumentation, including potentiostats and galvanostats for research electrochemistry, applied corrosion, battery and fuel cell research, biomedical research, plating and sensor applications.

Princeton Applied Research and The Solartron Group offer world class instrumentation and software for the characterisation and analysis of materials, employing spectroscopy techniques in a wide range of applications including electrochemistry, materials testing and metals analysis.

Both being of a high standing in the industry bring together more than 70 years combined experience under Ametek Corporation.

ProDigital Pty Ltd, now in its 15th year, offers local expertise, service and support for all the product range it offers.

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Pumpline www.pumpline.com.au

Stand Number: 51 Established in 2002 Pumpline is the first WA owned and operated authorised Graco Distributor, they opened their Melbourne branch in 2007. Our mission is to provide innovative and best quality solutions to the spray and pump industry. With a vision to assist our people, our customers and their communities to achieve their goals and make their daily tasks easier.

The Pumpline sales and service team have many years of experience with the Graco range specialising in pumping and spraying products to suit all your requirements including turnkey solutions. Pumpline also offer a wide range of products and services for all your powder coating, blasting and specialty applications and a wide range of parts and accessories.

Graco is the world leader in fluid handling systems and components and their products move, measure, control and disperse a range of fluids and viscous materials in commercial and industrial settings.

As well as Graco Pumpline also distributes and services equipment for ABSS blasting, Anest Iwata, Gema powder coating, Glascraft Fibreglassing and Finishing Brands Australia which includes Devilbiss, Binks and Ransburg.

Rezitech Services www.rezitech.com.au

Stand Number: 39 Rezitech Services Pty Ltd is a 100% Australian owned and operated company that commenced trading in 1968 with offices in Melbourne, Perth, Sydney, Brisbane and Townville.

Supporting distributors can also be found in South Australia.

Over many years Rezitech Services has been involved with major plant upgrades and expansions projects for many major companies servicing the mining, petroleum, power, chemical, pulp and paper and water supply industries.

Through Rezitech Services extensive range of products and services they also support the food and beverage, plastics, marine and liquid waste truck industries.

Rezitech Services has the exclusive Australian distributorship for the Belzona range of wear and chemical resistant metal, rubber and concrete compounds from

corrosion & prevention 2012 EXHIBITOR PROFILES

Belzona Polymerics. The Belzona range of products has many uses in virtually all process industries including cold curing, hand applied wear resistant coatings that provide similar wear rate to basalt tiles; ceramic coatings for pump internals and cold curing rubber for conveyor belt and dredge hose repairs; and rebuilding and coating materials for chemically or mechanically damaged concrete.

In addition to the Rezitech portfolio is Sponge-Jet, a low dust alternative to abrasive blasting. “Sponge Jet” are leaders in clean, dry, low dust, reusable media for surface preparation. Sponge Jet protects your environment and bottom line. Further benefits of Sponge-Jet are its ability to allow other trades people to work in close proximity to the blasting area reducing costly production down time. The dramatic reduction in air borne particles also significantly reduces the risk of eye injuries and respiratory problems.

Russell Fraser Sales www.rfsales.com.au

Stand Number: 18 Visit the “Toy Shop” on Stand 18 Russell Fraser Sales Pty Ltd (RFS) has been serving Australia and New Zealand’s Non-Destructive Testing and Inspection community since 1993. Today, stronger than ever, the business has grown, along with its team of 12 staff who are committed to ensuring best customer services practices at all times.

RFS supplies quality NDT equipment to the Corrosion, Engineering, Mining, Aerospace, Diving and Construction industries. We know how important it is to provide solutions to inspection problems in a timely fashion so our aim is to keep most items in stock and available for immediate dispatch.

Specifically for the Corrosion industry RFS supplies Ultrasonic Thickness Gauges, 3D Laser Scanners, Holiday Detectors, Thermal Imagers, Field Microscopes, Surface Replication products and much more.

Come along to the “Toy Shop” to play with the gear we have on display at stand #18.

Russell Fraser Sales Pty Ltd Unit 7/38 Waratah Street, Kirrawee NSW 2232 T: (02) 9545 4433 F: (02) 9545 4218 E: rfs@rfsales.com.au W: www.rfsales.com.au

Sika Australia Pty Ltd www.sika.com.au

Stand Number: 31 Sika Australia was founded in 1976 as a member of the Sika Group of companies. Initially, Sika Australia was mainly a trading company sourcing finished products from sister companies overseas and marketing them throughout Australia. In the early days, a few products were already manufactured in Australia, such as Rugasol, as well as some concrete and mortar additives.

As a specialty chemical supplier and manufacturer for the building and construction industry, Sika Australia prides itself on being technically driven and project motivated.

The business is typically balanced between contractors, architects, engineers and other specifiers and distribution marketing through retail hardware.

Sika Australia has cultivated a stand-out team of more than a hundred staff nationally including onsite product engineers, well trained customer service, other technical services team, as well as well-equipped and knowlegeable sales force. The company has access to overall a thousand products available throughout Australia in all major capital cities.

Specialist Repair and Construction Products (SRCP) Pty Ltd www.srcp.com.au

Stand Number: 9 SRCP’s current focus is supplying impressed current and sacrificial anode cathodic protection systems for corrosion control of concrete structures. ICCP systems are ideal where a fully monitored and controlled system is required for critical elements or where a long design life is necessary. SACP systems are perfect where a quick, low cost repair or holding repair with 15-25 year design life is required.

SRCP was founded by Frank Papworth, a well known consultant in the area of concrete durability, in order to bring to Australia some innovative materials and equipment he considered valuable to the industry.

Products to date include: Metalnastri’s 80 micron ZincTape with conductive adhesive for active corrosion protection of pipes, tanks and steelwork. A unique product with 30 yrs proven performance

October 2012 www.corrosion.com.au p.65

corrosion & prevention 2012 EXHIBITOR PROFILES

c orrPRE’s galvanic anodes for concrete including Zinc Layer Anode, the world’s simplest, proven and replaceable galvanic anode P rotector’s Zebra conductive paint for ICCP of concrete building elements including facades, beams and industrial floors P rotectors Cassette, a surface mounted ribbon anode for ICCP of concrete in wet/splash exposures P rotector’s Camur II remote monitoring (web interface) and corrosion control system for CP systems.

SRCP are seeking a national manager to develop the business. Opportunity for ownership participation.

Contact Details: Frank Papworth Tel 0411 018 702 f.papworth@srcp.com.au

Svenic Australia Pty Ltd www.svenic.com.au

Titanium Anode Corporation Stand Number: 25 Titanium ANODE CORPORATION PTY LTD

Titanium Anode Corporation Pty Ltd (TICOR) has been licensed by Titanium Electrode Products Inc of the USA to produce in Queensland its worldwide recognised and specified range of MMO and Pt/Ti anodes for use in Cathodic Protection. TICOR brings to Australia anodes with MMO coatings for use in the onshore, offshore, marine, industrial and civil industries which have been independently tested to NACE TM108-2008 at Manchester University, England. TICOR offers clients in Australia full anode design support by qualified and experienced Cathodic Protection engineers, allowing clients to produce optimised technical solutions in the most cost effective way.

Contact Details: PO Box 280 Sunnybank, QLD, 4109 e-mail: biagioli@btconnect.com

Wattyl Industrial Coatings Stand Number: 33

www.wattyl.com.au

Svenic will display its UNIQUE two Component Coating and Foam (CAF) Spray System.

The unique Svenic CAF (Coating and Foam) Spray System uses disposable two part cartridges and static mixers to spray paints, epoxies, polyurethanes, acrylics, polyureas, foams through a lightweight portable or hand held dispenser. Each component of the material is packed into separate, two component cartridges. Mixing only occurs when the two components enter the static mixer.

Atomized spraying is then controlled from the static mixer. The system is low cost, easy to use, significantly improves OH&S and reduces material wastage. Clean up, maintenance and training is minimal. CAF is ideal for spraying pipes, decks, equipment, floors, repairs and maintenance, small jobs and hard to get at areas.

Also on display: 1. Manual, air and battery operated applicators for dispensing sealants, adhesives and coatings packed in single and two component cartridges, sausages and pails.

2. S yringes, cartridges and static mixers, suitable for metering and mixing sealants, adhesives and coatings, such as epoxies, polyurethanes, acrylics, polyesters.

3. Crack Injection 4. Spray Polyurethanes and Foams Svenic’s services include: a ) C ontract filling of sealants, adhesives, coatings and foams b) P roviding specialist materials in our two part cartridge system under your own company’s brand

p.66 CORROSION & MATERIALS

Stand Numbers: 10 & 19 Wattyl Industrial Coatings, a division of Valspar Paint Australia, specialises in high performance coating systems for use across a vast range of market segments. Wattyl industrial coatings have been used a full spectrum of exposure environments including off shore, buried, coastal and tropical. Our extensive project history is a testament to the enduring performance of our products. Wattyl Industrial Coatings specialists are technical experts in their field and available nationwide to assist in product and system selection for almost any exposure environment.

Valspar acquired the Wattyl Group in 2010, further strengthening the Wattyl brand by bringing expertise and experience from one of the largest global coatings companies.

Wattyl Industrial products are stocked in numerous locations across Australia and New Zealand ensuring product is available in your location when required.

The Wattyl Industrial sales team is backed by a highly experienced technical department. The technical facilities have NATA certification and many products developed by the technical team are both APAS approved and conform to the relevant Australian Standards.

Regardless of your project size, Wattyl Industrial Coatings can supply a coating system solution for you.

COATINGS GROUP MEMBER PROFILE

Thomas Contracting Pty. Ltd. Q: In what year was your company established?

gas, marine, chemical process, general fabrication, tank lining, offshore etc.

A: 1997

A: We work with state and federal governments, statutory authorities, local shire councils and private industry in areas of:

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

A: 3 Q: How many do you currently employ?

A: 28 Q: Do you operate from a number of locations in Australia?

A: Our Head Office is in Adelaide and we have a Warehouse in Melbourne.

We do work throughout South Australia and all eastern states. Our significant flexibility enables us to promptly mobilise, establish and maintain site office’s at remote locations wherever projects are taking place.

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

A: Our core business consists of: c orrosion control and protective coatings hazardous paint removal (including lead based paints) abrasive blasting & cleaning rigging and specialised access & containment systems steel repairs and steel fabrication concrete and timber repairs Q: What markets do you cover with your products or services? eg: oil & Sadliers Crossing Rail Bridge

ridges (covering rail, river and road) b marine & shipping services power stations antennaes tanks walkways boats grain silos statues heritage structures Q: Is the business yard based, site based or both?

A: Only site based. Our significant flexibility enables us to promptly mobilise, establish and maintain site office’s at remote locations wherever projects are taking place.

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

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

A: We specialise in high access work and providing clients with business solutions to complex and difficult projects.

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

A: The most satisfying project would be the refurbishment of the Ipswich Electrified Rail Bridge which included the removal of the lead based paint. We were able to provide a business solution for the client to enable one of the two rail lines to remain in service at all times during the complete refurbishment, providing the client with significant savings. The project completed well within the contract period.

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

A: There must be a total commitment from all concerned parties, along with regular partnering meetings to maintain the schedule and progress.

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

A: We are extremely safety conscious and through years of experience know what is the safest and best way of doing the work and as such provide our own internal training in areas that utilises our specialised skills. External training is provided for the more general areas (ie EWP tickets, Welding etc).

Thomas Contracting 26 Audley Street Woodville North SA 5012 T: (08) 8268 5538 F: (08) 8268 3550 www.thomascontracting.com.au

Birkenhead Bridge

October 2012 www.corrosion.com.au p.67

TECHNICAL INTRODUCTION

Designing with Steel for Corrosion Protection – Common Issues Introduction The corrosion protection of steel structures is usually focussed on the selection of the corrosion protection system. However, the correct design and detailing of steelwork in the initial instance can greatly improve the performance of a corrosion protection system. All too often, energy and resources are devoted to the question of “What is the best corrosion protection system for steel in this environment?” when an equal or even greater effort should be directed to adopting the correct steel design principles in the first place.

This discussion will focus primarily on mild steel in atmospheric environments as this is both the largest application of metal in engineering and construction and also the largest area of the cost and impact of corrosion.

What Is Good Design?

The good design of steelwork can be thought of as the foundation on which an effective corrosion protection system can be built. If the design of a steel structure is poor, then the corrosion protection system will not be able to protect it properly, no matter how sophisticated and/or well applied it is. For example, there is no point designing for a thirty metre galvanized steel beam if there is no way of actually galvanizing such a beam in the first place. Likewise, to use another example, there are many potential problems if steel is designed with sharp edges, lap welds and inaccessible areas if the structure or item is to ultimately be painted with a protective coating.

Good design of steelwork, including the consideration of the ultimate corrosion protection system, should be done at the beginning of the design process, not as an afterthought, otherwise expensive detailing or re-design may then be necessary.

Careful design will remove many of the corrosion hazards or “hotspots” that commonly affect steel structures and that are often independent of the actual corrosion protection system being considered.

p.68 CORROSION & MATERIALS

Section 3 of AS/NZS 2312 provides some useful guidance that designers can apply when designing steel sections and it is highly recommended that this document be referenced.

The list below is by no means exhaustive, but it provides a checklist of “common” issues and some of these will be explored below and in a following part of this discussion: Dissimilar metals Ponding Crevices Flat surfaces in contact J oints and connections (bolting and welds) Sharp edges and corners Sheltering Detailing of welds Inappropriate material selection Dissimilar Metals Contact between different metals introduces the possibility of galvanic corrosion. Galvanic corrosion occurs because metals have a potential difference between them. This potential difference causes a current flow which then results in galvanic corrosion. There are many metals that can corrode or cause corrosion of the steel when they are in electrical contact.

In special situations, the contact does not have to be physical: two metals in close proximity to each other can be bridged when they are in the presence of a suitable electrolyte, for example seawater. This may occur in situations where the metals are submerged and also in areas of high moisture and significant time of wetness, for example coastal locations and some industrial environments.

The electrolyte allows for the transfer of ions between the two metals which then sets up an electrical circuit

when they are in physical contact.

One metal will become anodic and the other will become cathodic.

The anodic metal will corrode more quickly and the cathodic metal will be protected or corrode more slowly.

The concept of galvanic corrosion can be used to the advantage of corrosion protection designers, such as the case with zinc anodes and impressed current, but unintentional galvanic corrosion can result in costly damage and premature failure of steel structures.

One of the major areas where galvanic corrosion can be a problem is with fasteners. Fasteners can be made of various materials and this causes issues if a suitable material is not selected for a certain application. Corrosion in fasteners can be more dramatic because the severity of the galvanic corrosion is related to the ratio of the area between the cathodic and anodic metals. Because fasteners are relatively small, the ratio of their surface area compared to that of the overall structure will be quite small. For example, zinc coated fasteners used with stainless steel can corrode quite quickly in corrosive environments due to the fact that zinc is anodic to stainless steel. Zinc coated fasteners or screws have only have a relatively small mass of zinc on them, resulting in rapid corrosion and possible failure when they are corroding sacrificially.

On the other hand, even though zinc is anodic to stainless steel, the use of stainless steel fasteners in galvanized steel structures is common. This is due to the fact that the structure has a much larger surface area than the stainless steel fasteners, resulting in minimal corrosion of the structure. In corrosive environments, however, such as in coastal applications, there still may be some cosmetic corrosion of the zinc around the fastener, so it may well be advisable to use galvanized fasteners in such applications to avoid the unappealing staining that results. It is always best practice to attempt using a fastener made either of the same metal as the structure or one that is cathodic to the metal in the structure.

TECHNICAL INTRODUCTION

Ponding (or drainage) The collection of moisture on the surface of a steel structure or in contact around it for prolonged periods should be avoided. Good design will ensure that the steelwork has good drainage and does not have areas where the moisture can build and pond. An example of this is the correct orientation and design to avoid the entrapment of moisture. Drainage holes and drip points should be designed into the structure to minimise any areas where moisture and/or other detritus can sit. The collection of other matter with the moisture further compounds the issue since some materials combined with moisture can cause significant corrosion, for example rotting vegetation.

Ponding is not only restricted to areas where there are obvious pools of moisture. In corrosive environments such as coastal and industrial areas, even droplets of moisture allowed to sit on the surface of steel too long will accelerate corrosion. As they dry out, they can set up a small galvanic cell and cause localised corrosion if they do not evaporate quickly. This is why in coastal areas, peaked roofs work much better than flat roofs in resisting corrosion. The steeper the drainage, the more resistant to corrosion is the structural element as it minimises the settling of moisture in a particular area for prolonged periods.

One of the most common examples of ponding is at the foot of structural members. Due to the combined effect of drainage (or runoff) from the structure and also the settling of moisture on the ground, the area at which a steel structure is supported in the ground can be a problem. Inserting the member directly into the ground without the correct detailing can cause serious issues. One of the easiest ways to avoid this is to ensure that the moisture cannot sit around the base of the steelwork. Another common method is to attach a baseplate to the steelwork and then have this elevated from being in direct contact with the ground.

Crevices Crevices can be thought of as small areas where moisture and dirt can accumulate. Crevices can sometimes be naturally occurring due to surface imperfections or damage from poor manual handling. More commonly, crevices are introduced as part of the fabrication and assembly of a structure.

Joints, using either fasteners or welds, and overlapping surfaces are the major causes of introduced crevices.

Figure 1: The bolted sections of a hot dip galvanized bridge rail using galvanized steel bolts performing well in a coastal environment

Figure 2: Ponding at the base of a galvanized light post on a tennis court. Note the application of zinc rich paint as an afterthought.

Figure 3: Same tennis court, different light pole. The base corroded straight through causing the light pole to fail.

October 2012  www.corrosion.com.au  p.69

TECHNICAL INTRODUCTION

(a) Backs of double angles cannot be easily painted and maintained

Crevice Bad (narrow crevice, difficult to protect) Figure 5: Flat surfaces in contact are not recommended (AS/NZS 2312)

Figure 4: Better detailing at the base of another galvanized light pole in a coastal environment.

Crevices encourage corrosion because the conditions across the crevice vary, resulting in a different potential even if the “components” of the crevice are all made of the same material. The areas within the crevice will have less access to oxygen than those exposed to the environment, setting up different corrosion potentials. This internal area may then become anodic to the external area and sacrificially corrode. The fact that the corrosion may be hidden means that it may proceed for some time before it is noticed, causing a risk of a previously unidentified failure.

One way of preventing crevice corrosion around fasteners is to employ a non-conductive gasket or sealant. The best option is to design out crevices by using proper welding techniques and avoiding lap joints.

Flat Surfaces in Contact Besides the problems that can be introduced by crevices, flat surfaces in contact can lead to moisture being drawn between them by capillary action. This is especially the case where the surfaces are only in loose contact, as can be the case with steel sheet roofing and cladding. The moisture does not necessarily have to be deposited by the obvious method of rain or spillage.

In areas of high humidity or great temperature variation between day and night, condensation can cause sufficient moisture to be drawn into the space between the two surfaces. The moisture will then take longer to evaporate than if it was fully exposed, increasing the time of wetness.

Flat surfaces in contact should either be sealed in such a way to prevent the moisture being drawn in or the

configuration can be designed out altogether. For example, this can be achieved through the use of solid sections to remove the need for contacting sections.

Design as single angle truss, or use T-section Continuous Welds

Closed Crevice Better

Best (single solid component) Figure 6: Suggested remedies to achieve the structural profile required (AS/NZS 2312) There will be further discussion of designing for corrosion protection in a following article.

Emmanuel Pimentel

Join The Australasian Corrosion Association LinkedIn Group The ACA is delighted to launch the official ACA LinkedIn Group.

The Australasian Corrosion Association LinkedIn Group is open to both members and non-members of the ACA and is limited to the Australasian, Oceania and South East Asian regions.

Young Corrosion Group on Facebook

This Group has been established for the purpose of: etworking and connecting with professionals and practitioners N throughout Australasia Staying up to date with ACA’s activities Starting and contributing to discussions on Corrosion related issues Sharing industry news, ideas and insights

p.70 CORROSION & MATERIALS

To get the latest updates on YCG events, scholarships or to see photos from the New Zealand event, like YCG on Facebook.

UNIVERSITY PROFILE

James Cook University Dr. Bobby Mathan, currently the Head of Chemical Engineering and a Senior Lecturer at James Cook University (JCU), established a research group at the university in 2010 entitled “Biomaterials and Engineering Materials (BEM) Lab” with the aim of studying corrosion in biomaterials and engineering materials. JCU’s geographical location in tropical Northern Australia provides the research group with opportunities to understand and mitigate corrosion in the tropics.

The group has received a number of contracts from local minerals processing industries to solve corrosion-related problems in their plants.

The BEM group’s main areas of research focus are: (i) Biomaterials Corrosion There is a growing interest in the development of biodegradable implants for bone fracture repair and a potential candidate for such implants is magnesium-based alloys. Magnesium has many benefits as an implant material, being both biodegradable and biocompatible, as well as having mechanical properties well matched to natural bone. Unfortunately, magnesium corrodes too quickly under physiological conditions. Bobby and his team have been developing and characterizing new coatings to tailor the corrosion rate of magnesium and its alloys for potential biodegradable implant applications. The BEM research group has conducted extensive research on magnesiumbased biodegradable biomaterials and has received international recognition for this work including citations and invitations to deliver lectures both nationally and internationally.

The research group enjoys a highly beneficial collaboration with the BioMedical Sciences and Applications (BMSA) group in the School of Medicine and Dentistry at JCU. (ii) Environment-assisted Cracking Aluminium alloys and magnesium alloys are widely used in the automobile industry due to their high strength-to-weight ratio.

However, these high strength light alloys are prone to environmentassisted cracking (EAC) in chloridecontaining environments. Bobby has carried out extensive research on the EAC behaviour of high strength aluminium alloys and magnesium alloys. Currently, his team is focussing

on the EAC behaviour of ultra high strength steels. Slow strain rate testing is generally carried out to understand and evaluate the EAC of various engineering materials. (iii) Polymer Coatings The BEM group is also investigating conducting polymers and biodegradable polymers for corrosion mitigation/ tailoring of metals for different applications. Electrochemical impedance spectroscopy is carried out to evaluate the performance of the coatings.

Research Facilities The BEM lab has a comprehensive range of equipment to carry out the biomaterials and engineering materials corrosion research including electrochemical systems, a slow strain rate testing machine, a spin coater, a coating adhesion tester and an optical microscope. The BEM group has access to characterization instruments such as SEM/EDX, XRD, ATR-FTIR, XRF and AFM at JCU’s Advanced Analytical Centre. The research group has also established international collaborations with overseas universities and institutes including Chosun University in South Korea and the Helmholtz Research Centre in Germany.

Dr. Bobby Mathan’s Profile Bobby Mathan completed his PhD in 2005 at the Indian Institute of Technology Bombay in India. He received a DAAD scholarship to carry out part of his PhD work at the University of Erlangen in Germany. His PhD dissertation was on developing a phenomenological model for the stress corrosion cracking mechanism in high strength aluminium alloys.

He won the Best PhD Thesis Award from the National Association of Corrosion Engineers (NACE), India Section. After completing his PhD, he worked as a post-doctoral fellow at the Helmholtz Research Centre in Germany. His research focus was on understanding the localized corrosion mechanisms of advanced magnesium alloys. In November 2006 he joined Monash University as a post-doctoral fellow where he initiated his work on magnesium-based biodegradable biomaterials. In February 2009 he joined JCU as a Lecturer of Chemical Engineering. He is currently a Senior Lecturer and the Head of Chemical Engineering in the School of Engineering and Physical Sciences.

His research interests include biomaterials corrosion, environmentassisted cracking, hydrogen permeation, localized corrosion, polymer coatings and failure analysis.

He is currently supervising four postgraduate students who are working on different aspects of corrosion in biomaterials and engineering materials. He has over 50 publications in journals and peer-reviewed conference proceedings. He has written four book chapters (three chapters for ‘Stress corrosion cracking: Theory and Practice’ Eds. V. S Raja and T. Shoji and one for ‘Corrosion Protection and Control using Nanomaterials’ Eds. V. S. Saji and R. Cook) and also holds a patent on the mitigation of magnesium alloy corrosion using polymer coating (German patent no: DE 10 2007 007 879.1).

He has received numerous awards including the Dean’s Research Excellence Award (2011), ACA Best Poster Award (2006) and NIIS Best PhD Thesis Award (2005). His fellowships/ scholarships include the Helmholtz Post-doctoral fellowship (2005), the DAAD fellowship (2003) and the Australian-Korean Foundation scholarship (2011). He has been invited to give talks at various international conferences and recently spoke at the 2012 Aqueous Corrosion Gordon Research Conference in the USA and the 2011 THERMEC Conference in Canada. He is a serving member of the editorial board for Journal of Material Science & Engineering and a reviewer for a number of international journals.

Contact Details Dr. Bobby Kannan Mathan Senior Lecturer & Head of Chemical Engineering School of Engineering and Physical Sciences James Cook University, Townsville 4811, Australia Ph: +61 (0) 7 4781 5080 Fax: +61 (0) 7 4781 6788 Email: bobby.mathan@jcu.edu.au Webpage: www.jcu.edu.au/eps

Biomaterials and Engineering Materials (BEM) Group

October 2012 www.corrosion.com.au p.71

PROJECT PROFILE

Rio Tinto Dampier Salt Operations Mistaken Island Mooring Dolphin Repair Project Introduction The Rio Tinto Dampier Salt Limited mooring dolphins were constructed in 1971 in conjunction with the load out wharf and ship-loader platform at Mistaken Island in the Burrup Peninsular Archipelago, 1250km north east of Perth and 21km northwest of Karratha in Western Australia.

The dolphins or ship berthing stations are used for the shipping of up to 4.2 million tonnes of salt per annum. The dolphins comprise seven reinforced concrete platforms 7.5m

long x 4.57m wide by 1.55m to 2.15m deep supported by ten steel encased reinforced concrete driven piles.

Situated in a severe marine environment, the reinforced concrete dolphins have been subject to 40 years of chloride attack associated with saltwater windblown spray and splash.

Some of the dolphins had previously been conventionally patched repaired in 1984 and 2009, but it was recognised in 2010 that dolphins 3, 4 & 5 were in need of further

remediation using cathodic protection (CP). Invitations to tender were called in March 2011 and following a detailed review of submissions, Duratec Australia was awarded the works in May 2011 on the basis of its alternative proposal which included design and installation of a Hybrid CP system, (the first in Western Australia), which satisfied the need for a simple, cost effective, robust, long-term reinforced concrete protection system in this environment.

Dolphins on a moonlight nightshift.

Original dolphin condition.

p.72  CORROSION & MATERIALS

Original soffit condition.

Original fender hook condition.

PROJECT PROFILE

Hybrid CP – Background Many reinforced concrete structures suffer attack from ingress of water soluble salts into the concrete and or carbonation of concrete due to atmospheric exposure leading to loss of passive alkaline conditions surrounding the embedded reinforcing steel. The associated corrosion of the reinforcing steel is an electrochemical process and the most effective means of arresting this process is to apply electrochemical treatments. One recently developed preventative treatment is called Hybrid Cathodic Protection. This technology is a combination of electrochemical treatments using both an impressed current and a galvanic anode cathodic protection phase. An impressed current is applied to the reinforced concrete for a short period, (7-10 days), during which propagating acid corrosion sites are neutralised to re-passivate the reinforcing steel. The system then reverts to a galvanic anode system providing a relatively low current to maintain the passive condition of the reinforcing steel and prevent long term further corrosion. This simple cost effective corrosion control process is robust, rapidly inhibits corrosion, can be applied in shutdown conditions,

requires no long term power supply, requires no long term maintenance and can easily be monitored. For these reasons the client chose to adopt this treatment for the Dampier Salt mooring dolphins.

The Contract The initial contract works included the following on mooring dolphins 3, 4 and 5: emediation of the reinforced R concrete including design supply, installation and commissioning of Hybrid CP; Hawser rail replacement; and emoval of existing fenders and R the assembly and installation of replacement fenders.

In addition, the contract required the following works on all seven mooring dolphins: xisting mooring hook removal and E replacement; and I nstallation of access bridge mounting plates.

A further contract was also awarded which involved the following refurbishment works on dolphins 3, 4 and 5: emoval of ancillary steelwork and R marine growth from all ten piles of each dolphin; and S urface preparation and installation of a heavy duty marine pile protection system to the steel piles for 5.8m below the soffit.

Details of the Works Concrete Remediation and Hybrid CP Installation The works commenced in June 2011 with the shutdown of all ship loading for a period of eight weeks. Work was performed around the clock commencing with removal of existing fenders using a barge mounted crane and installation of fully encapsulated scaffold access platforms on dolphins 3, 4 and 5. Delaminated cover concrete removal was performed using the hydro-demolition technique employing the use of a filter-cloth debris capturing system and waste water quality monitoring throughout to satisfy environmental requirements.

Low tide access condition.

Concrete and steel condition after cover concrete was removed by hydro-demolition.

Reinstated cover concrete.

Old fender removal by barge.

October 2012  www.corrosion.com.au  p.73

PROJECT PROFILE

The exposed reinforcing steel was replaced or augmented where greater than 20% loss of section occurred.

All reinforcement was checked for electrical continuity, with isolated areas requiring welding in place of 6mm bar to make good. While the reinforcement was exposed, negative cable connections were made along with the installation of permanent reference cells. This was closely followed by dry spray gunite application of cover concrete to restore the original surface profile and when sufficiently cured, core drilling and installation of 20mm studs for fender cone and chain anchor points. Mooring hook removal and replacement works were performed concurrently during these works.

Progressive installation of the design approved Hybrid CP system followed involving the following procedures: rilling and initial soaking for 24hours D of anode holes 30mm dia. x 150mm deep in vertical faces and soffit;

I nstallation of anodes in alkaline paste backfill; rogressive powering of each P zone using a temporary TR at 12 volts for 10-12 days with current recorded daily; assage of a minimum charge of P 50KCoulombs/m2 rebar area in each zone with the aim of re-passivating the reinforcement; nce the applied charge criteria had O been met, the system was converted to galvanic mode with the rebar negative connection connected to the titanium wire connection in the junction box. The galvanic current achieved was between 2 and 3mA/m2 of reinforcement; and ackfilling of titanium wire slots with B cementitious repair mortar.

Evaluation of the system performance was assessed against a corrosion rate criterion based on the Stearn Geary

Equation with a targeted corrosion rate of less than 2mA/m2 of steel which is equivalent to a corrosion rate of 2mm section loss in 1000 years. This criterion has been recently adopted by the latest European Standard BSI EN ISO 12696:2012 Cathodic Protection of Steel in Concrete. This was measured by recording the galvanic current of each subzone and completing an instant-off and depolarisation test, (similar to ICCP), utilising these figures to calculate actual corrosion rates.

Corrosion rates so obtained were all below the 2.0mA/m2 target.

Pile Protection Application Pile surface preparation and wrapping was undertaken using a specialist diving contractor and installation of the Denso Seashield Series 200FD heavy duty marine system. This was complemented by a conventional abrasive blast surface preparation and the application of Interzone 954 high-build epoxy protective coating system applied in the complex geometry zones.

Hybrid CP installation on vertical face.

Hybrid CP installation on dolphin soffit.

Some piles were coated and partially wrapped where the geometry did not allow full wrapping.

Piles wrapped in the Denso Seashield system.

p.74  CORROSION & MATERIALS

PROJECT PROFILE

New Fender Installation On completion of these works installation of the new pre-assembled fender units was performed using a 35m barge with 20 tonne lifting capacity to place the 10.5 tonne units comprising:

New mooring hooks were installed. a team environment. There were many challenges which the project team had to face. These included: ajor logistics working on multiple M dolphins separated by water;

Front fender panel; Fender rubber cone; Fender cone flange plate; and Support and link chains.

New fender at work on dolphin 3.

Access restrictions; orking 12 hour shifts 24/7 for W 8 weeks;

Working over water;

o-ordinating multiple tasks in C limited space and access only by boat with a large workforce;

ifficult weather conditions including D wind and high temperatures;

recision works on concrete P structures; and

High tidal range;

perating in a sensitive marine O environment.

Underwater works;

Project Summary A project like this can only be delivered by sound project management and the commitment of the entire workforce including specialist subcontractors to working collaboratively and harmoniously in

It was with a strong team approach that despite these challenges all of the works were completed safely, on time and within the eight week shutdown and without incident.

Acknowledgements Our thanks go to the project management team at Rio Tinto DSL, Infracorr Consulting, and Bhagwan Marine, Seaforce, the Duratec Project Management team and work crew and subcontractors who all contributed to the successful delivery of this remediation project.

Completed Dolphin 5.

October 2012  www.corrosion.com.au  p.75

PROJECT PROFILE

Thinking Laterally (and vertically) for Woodside Engineers love solving problems. They get a buzz out of combining their technical knowledge with lateral thinking to overcome challenges. The challenge facing Woodside at their North Rankin A platform in 2009 was to prevent the potential for corrosion of the LP flare stack – which required some lateral thinking from the anti-corrosion specialists at Corrocoat.

In order to extend the original flare stack design life, additional maintenance was required to preserve its integrity.

Woodside North Rankin A platform (image supplied by Woodside).

The project Over the years, wet carbon dioxide inside the stack had formed a corrosive atmosphere. The resulting condensation on the inside of the stack has the potential to cause corrosion and material loss including around the weld areas within the flue.

There was concern that the corroded walls could ultimately affect the stack’s structural integrity if left untreated.

A tall order in a short timeframe To replace the stack would cost millions of dollars and require the platform to be shut down for an extended period of time, resulting in lost production and

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revenue. The ideal scenario then, was to refurbish the stack in situ and ensure it would be protected for the rest of its operational life.

But how do you tackle such a complex challenge?

To put the size and difficulty of the task in context, we’re talking about blasting and then applying a protective anticorrosion treatment inside a 38-metrehigh flare stack 400mm in diameter, on a major offshore hydrocarbon production facility, perched on a 1-metre-wide gangway, 100 metres from the main platform, in the middle of the ocean. All with minimal downtime.

Woodside turned to Corrocoat to investigate if there was any way the flare stack could be internally coated, in situ, with one of their high performance industrial coatings.

An ingenious solution Along with their range of industrial anti-corrosion coatings, Corrocoat’s engineering expertise is widely respected. They have developed an array of patented internal pipe blasting and spray equipment. However, in its current form the equipment was not suitable for this unusual challenge.

This was going to require a completely new solution.

PROJECT PROFILE

Not a company to shy away from a challenge, they enlisted assistance from experts in offshore subsea service and maintenance to jointly design and build a remote controlled, selfpropelled robotic buggy – which would come to be known affectionately as ‘Corrobot’ – to conduct the blasting and coating on North Rankin A. The small robot with a big job to do The bespoke solution was engineered specifically for the unique conditions.

It was small enough to navigate the pipe diameter. Yet it was also robust enough to propel the pipe blast head, pipe spray head and spark testing equipment, as well as all the necessary hoses and cameras, vertically up the flue at a constant speed to ensure a smooth coating.

Robotic Head

That’s 200kg of equipment for gritblasting and then treating the vertical interior walls of the stack with a protective anti-corrosion coating – in this case a Vinyl Ester coating with ECR glass flake.

Tight on space and time According to the project’s design and development team, it was the lack of space at the base of the stack that posed a bigger challenge than the height of the flare stack itself.

A testing time Before commencing work on-site, the design and development team tested the robotic system extensively, on dry land.

Despite the robotic nature of ‘Corrobot’, the restricted space meant there was a serious physical challenge for the human contingent. The plan involved man-handling the blasting garnet and coating materials down the gangway. What’s more, the compressor would have to be located on the main platform, 250 metres away from the blast head.

A series of R&D tests were performed in Perth. Even a dummy stack was built and the entire blasting, coating and testing process was duplicated to ensure ‘Corrobot’ was up to the job. In one test, a section of flue was hoisted 45 metres above the ground, such was the need to prove the robot’s credentials.

Only once everyone in the development group was satisfied were the robot and the specialist anti-corrosion team deployed on the platform.

As if the logistics of working in such a trying and confined space weren’t enough to deal with, there was one other critical restriction to consider – the timeframe. As an operational platform, North Rankin A has a minimal shutdown for regular maintenance.

The team had just 10 days to complete this world-first project.

Project completion No amount of testing can guarantee success, especially in such a unique situation with so many practical and technical challenges. Understandably, tensions were high as the platform ceased operations for the remedial work to be carried out.

The blasting and coating process was completed ahead of schedule, fulfilling all of the project’s requirements and specifications in just seven days.

Corrocoat and their partners had once again proved that with a little lateral thinking and a lot of expertise, even the most vertical of challenges can be overcome.

Dennis Berry Corrocoat Engineering (AUST) Pty Ltd

Robotic Head Section of Flue at 45 metres for testing (left and middle). Cross section of dummy stack cut into sections to verify coating thickness across several different welds (right).

October 2012 www.corrosion.com.au p.77

RESEARCH PAPER

This paper was originally presented as a Plenary Lecture at EuroCorr 2011 in Stockholm.

Acts of Secrecy: the DC-3 that Disappeared Christina H. Tengnér Metal Conservator The Army Museum, Stockholm

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Einar Jonsson Gruppchef

Bengt Book Operatör

Erik Carlsson Operatör

Börge Nilsson Operatör

Ivar Svensson Operatör

Figure 1: Crew members of the DC-3.

BY 31 LA

BY NDS 32 O NO RTS RR DJ BY KÖ 38 PIN KA GS RL DJ SÖ

0 50 100 150 200 250 300

BY 15 GO TL AN BY DS 20 DJ FA RÖ DJ

On the Bottom of the Baltic Sea The Baltic Sea has been an important waterway for centuries, known by the Romans and later used by the Viking ships on their journeys towards the East. Many sunken vessels rest in the waters, well preserved to this day. The Baltic Sea is an ideal site for the preservation of wood and other organic materials. The water is brackish with saline levels less than 3% and relatively cold. One of the major causes of degradation of wood, the ship worm, has only in recent years found its way into the southern parts of the Baltic Sea. Another factor that contributes to the preservation of most materials is that in many areas today the sea bed in the Baltic is oxygen free, or “dead” to use a less flattering term (Figure 2).

8 6 4

2003-01-142003-01-19

2

Syrgas (ml/l)

This particular aircraft had been rebuilt for a specific purpose.

It was bought by the Swedish military on the surplus market after the Second World War, where it had been in use for Allied troop transport in the Mediterranean area and later during D-Day. It was rebuilt in Sweden for radio surveillance, equipped with the latest US-manufactured radio equipment.

The main surveillance targets for the DC-3 at the time were the Soviet military bases across the Baltic Sea, more specifically the radar base in Liepaja on the south west coast of Lithuania.

The disappearance of a Swedish military aircraft equipped for “espionage” quickly turned into diplomatic difficulties that became even more complicated. In the days following the incident, the ocean was searched using both ships and aircraft.

During the search, one of the participants, a Catalina sea aircraft, was attacked by a Soviet MIG fighter and crashed into the sea. The crew managed to survive and was picked up by a passing ship. The drama of the search had made it quite clear that the DC-3 could have met a similar fate, or perhaps even been forced to land on Soviet territory. The Catalina came to be the third and last aircraft ever to be shot down by a Soviet fighter aircraft over the Baltic Sea. The Swedish military and government quickly decided to put the lid on the incidents and the situation was simply referred to as the Catalina Affair, to minimize the references to the surveillance DC-3. However, some of the missing crew members (See Figure 1) of the DC-3 were young men with wives and small children waiting at home, so behind the political drama of this affair lay the personal tragedies of those left to wonder about the fate of their husbands and fathers.

Herbert Mattson Färdmekaniker

BY 10

Had it been a civilian DC-3, at the time a common commercial transport aircraft, it would have been a tragedy in its own right. However in this case the missing aircraft would come to have political consequences beyond the personal. In 1952, the Cold War was still in its early years - the USA had just developed its first Hydrogen bomb and on the news were the reports of the Korean War. Tension was building between East and West. Sweden, with its location between NATO member Norway and the Soviet Union just on the other side of the Baltic Sea, remained neutral since the First World War.

Fanj Gösta Blad Navigator/Signalist

AN H KU OLT L E W LEN LA ND SK RO NA BY 1 BY 2A

BY RK 3 H ON

BY AMR A 4 A

BY CHR RNE 5 B IS SU OR TIA ND NH NS OL Ö MS DJ BC SI II10

Historical Background On Friday the 13th of June 1952, a Swedish military DC-3 along with its eight crew members disappeared during a flight somewhere over the Baltic Sea. It is of course by no means unique that an aircraft goes missing, but the context is far from usual. But in order to combine the history, preservation and exhibition of this very special object I need to start with the historical background and political situation surrounding this DC-3.

Fanj Alvar Älmeberg Pilot

Djup (m)

How do we preserve and present a modern aircraft wreck in a museum environment when it is a large scale archeological find? How can we make sure that aircraft aluminium immersed in saline sea water for 50 years it is stabilized and preserved for future generations? The main purpose of this article is to describe the preservation of certain modern marine archeological metals at the Air Force Museum in Linköping, Sweden. It is also a presentation of the most unique experience a metal conservator and museum professional could ever hope for.

H2S

Figure 2: Graphics presenting oxygen levels (Right vertical axis) in the Baltic Sea area in January 2003. BY20 is the point closest to the wreck site. Black areas show presence of H2S when all oxygen is consumed. Left side scale showing depth in meters.

Reproduced by permission of the Swedish Meteorological and Hydrological Institute).

In the 1980’s the Soviet Union admitted to causing the disappearance of the DC-3. A MIG pilot even signed a statement of how he had shot it down into the water in Soviet territory near the Lithuanian coast. 50 years after the Catalina Affair, in 2003 the DC-3 was located by Deep Sea Productions, a private funded search team scanning the sea bed with sonar equipment looking for sunken ships in general but the missing DC-3 in particular. It was resting 125 meters below the surface off the Swedish island of Gotland, in international waters. Since this DC-3 is a military aircraft, the military would also take responsibility for the salvage and forensic investigation. The many years of diplomatic difficulties following the disappearance and the speculation

RESEARCH PAPER

on the destiny of this, for its time high tech equipped, “espionage aircraft” could now come to a close.

The DC-3 wreck was found resting belly down buried partly in the mud on the sea bed (Figures 3 and 4). Mud had seeped into the structure. The left side of the cabin had been torn open, probably from the impact of the crash, and the wing on that side was torn off. This was the side where the radio equipment and the operators were seated. Around the site and also under the wreck was the debris of the parts broken off or torn out of the cabin by the impact. The cockpit was more or less destroyed but not torn off. Remains of four crew members were found in and around the wreck but still today the fate of the remaining four are unknown. The forensic investigation established that the time from attack to impact may have been several minutes, a time during which a trained crew could have evacuated the aircraft, or at least started to do so. Did four of them manage to make it out before impact or had they met the same fate as their fellow crewmembers?

The salvage of the aircraft wreck was done in 2004. It was then placed in a Navy facility on the coast south of Stockholm used for maintenance of ships and submarines. The forensic investigation was performed by the military (technical investigation of the wreck) in collaboration with the Swedish police (identification of the crew members through DNA).

Because of the important role of this aircraft during the Cold War in Sweden, once the forensic investigation was finished, it was to become a part of the Swedish Air Force Museum collection and to be preserved for the future.

Standard procedure after investigation would be to discard a wreck, so this is unusual, and was made possible through a political decision. This is where the corrosion engineers and the museum conservators were called in and the story of the preservation of a marine archeological aircraft begins.

The forensic investigation team worked on the wreck without any unnecessary altering of its state, an obvious part of their work process. This means that no major cleaning or any other measures were taken to remove the mud and salt from the sea. But as continuous corrosion could be observed from the minute it was exposed to the air the wreck was sprayed with a coating developed for industrial use to make it last for the duration of the investigation. The coating was unevenly distributed over the wreck consolidating a mix of corrosive agents onto the metal surface, of which chlorides from the sea water being the most potent. It probably prevented the most severe corrosion during the investigation but as it was going to be part of a museum collection, there was an acute need to act to remove this first coating to get the metal surface and cavities as clean as possible.

The Ethics of Conservation As a conservator at a national museum I am obliged to follow certain principles to ensure the wellbeing of the museum objects. The International Council of Museums’ (ICOM) code of ethics states that:

Figure 3: Graphic presentation of the damages on the DC-3 and the positioning of the parts on the sea bed.

Graphic: Patrik Winnfors.

2.23 Preventive Conservation Preventive conservation is an important element of museum policy and collections care. It is an essential responsibility of members of the museum profession to create and maintain

Figure 4: Panoramic view of wreck during forensic investigation at Muskö Marine Base. Photographer: Christer Magnusson

October 2012 www.corrosion.com.au p.79

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a protective environment for the collections in their care, whether in store, on display, or in transit.

2.24 Collection Conservation and Restoration The museum should carefully monitor the condition of collections to determine when an object or specimen may require conservation-restoration work and the services of a qualified conservator-restorer. The principal goal should be the stabilization of the object or specimen. All conservation procedures should be documented and as reversible as possible, and all alterations should be clearly distinguishable from the original object or specimen.

There are of course exceptions but in my experience museum collections focused on transport, be it technical, industrial or military, more often tend to display their objects with a finish rarely found for example in ethnographical or archeological exhibitions. The concept of “patina” and traces of years passed has more often than not been considered less important and the exhibited objects submitted to an often very skilled renovation or restoration to show the object as it was when new or fully functioning. The Swedish Air Force Museum is no exception, showing a unique collection of aircraft in good condition from a century of aviation history.

The condition of the DC-3 wreck makes it quite a rare bird in this context; a marine find where the severe damage is a major contributor to its story. A renovation in the same manner as other items in the collection would have been nearly impossible, and would also have counteracted its very purpose in the museum. The museum wished to exhibit the wreck in the same way it had been resting in the sea for the past 50 years. If the visitor would like to see a DC-3 in original condition it is possible to do in front of the museum.

As a conservator, I must always look to the best of the museum object, not only its individual materials but also the object as a whole. The goal is to preserve objects for future generations, and in doing so using the principle of minimal intervention. The traces of the preservation process should ideally be reversible and invisible to the untrained eye, so a comment from a colleague about “not being able to see what’s been done” can be the best praise. But in practice this is often impossible or at least quite difficult. A simple task like cleaning an object is irreversible, and something as trivial as dirt can be hard to separate from the patina that gives life to an aged object. When a wreck is to be displayed like it is resting on the sea bed, mud and corrosion can go from dirt to something more valuable. But when stability of the metal is the only way to preserve an object compromises are called for.

The conservator must take into account how the individual object can be stored, presented to the museum visitor and made available for research in the future. The treatments made to prevent further deterioration must be made so that future preservation work is not obstructed. There is no “perfect solution” or “quick fix” when the object preserved must have a lifespan of an unknown number of generations to come. There are different ways of presenting our cultural heritage in museums, so decisions must be made in detail what interventions are suitable so that we remain true to the object.

The preservation of the DC-3 wreck has been a joint venture between industrial corrosion experts (CSM Materialteknik, a company specialized in corrosion prevention in industrial products, museum and aircraft specialists (the Air Force Museum) and conservators (the Army Museum). If the aim of the conservator is to preserve as much as possible of every object, the industrial perspective would be to remove or replace everything that is degraded, faulty or could cause

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degradation in the future. The industry has no need for “materials gone bad” and to the conservator there is almost no such thing as a “bad” material, only some that are harder to stabilize than others. I may have drawn these two standpoints to extremes but there is much to be learned from both perspectives in this case. And when it comes down to making the important decisions cost is a significant factor since preservation is a time consuming activity.

Traditional museum conservation can be a time-consuming activity since the conservator’s practical goal is to assure that all materials are as stable as possible and the ideal is to do so without changing the appearance of the individual components or the general impression of the item.

Reversibility and “retreatability” (to be able to renew the treatment) are other principles to keep in mind. This is all just fine until one comes across an object like the DC-3 wreck, almost 30 meters long and accompanied by hundreds of loose parts. The Air Force Museum was going to display the wreck in a large display case, or glass room, so that the visitors could walk around it. It was also to be displayed in the same position as it had been resting in the sea for over 50 years.

Removal of an efficient commercial coating armored with mud can prove to be difficult, so the first cleaning was done by first applying a degreaser (white spirit based) and then cleaning with water under high pressure. The mud had over time found its way into the aircraft structure so some holes had to be made to be able to access the cavities with a pressure nozzle. Bit by bit the wreck was cleaned in this way, making sure to protect and avoid sensitive areas such as the Swedish national symbol of the Three Crowns on side and wings. As they are painted on the aluminium surface they were very sensitive to pressure or abrasion of any kind.

They played an important role in this story since the aircraft attacked was marked with symbols of a neutral country like Sweden.

The chloride levels on the surface of the aircraft were measured continuously during the cleaning until the satisfying result had been reached. However, an aircraft in its original state contains numerous crevices and parts where moisture can penetrate, not to mention an already corroded wreck. It is unlikely that the cleaning process managed to remove chlorides to the extent that one would demand to ensure stability in a smaller and less complicated museum object. The methods for chloride removal from a wreck of this size are limited, so one solution is to maintain stability through preventive measures, i.e. climate or rather moisture control in the exhibition area. From an industrial perspective, the natural thing to do after cleaning was to apply a coating system once more to prevent moisture from getting access to the metal surface. There were two coatings applied: the first one a penetrating product that would also evacuate remaining water or moisture from inside the structure. The second coating is a sealing layer, a drying product with a hard surface.

Unfortunately this second layer turned out to have a slightly yellow tint which gives the aluminium surface an almost bronze-like appearance. From a museum perspective the alteration of the original white metal color to one appearing more yellow is unfortunate. The aesthetics of corrosion prevention is an interesting question and a point where industrial and museum practice should be mutually shared and discussed. There are options to this coating but from a strict corrosion prevention point it is one of the most efficient and rational since the coating does work as an extra security even now when on display. The alternative of not applying any coating at all would have put the preventive side of the preservation in the foreground. The functionality at all times

RESEARCH PAPER

of the climate systems would have to be assured and the cost for more or less complete dehydration of air in a display area the size of an aircraft would need to be taken into account.

green edges of the aluminium sheets showed the presence of copper ions (Figure 5) and the galvanic corrosion problems with this alloy when immersed in sea water.

Aircraft Materials The most common material in a DC-3 is the 2024T aluminium alloy (or 24 ST alclad). The more prominent feature of this alloy, at least from a marine archaeological or preservation perspective, is the relatively high level of copper, around 3.8-4.9% by weight. The surface of the sheet metal is clad with pure aluminium for increased corrosion resistance, but the core metal will still give the sheet its mechanical properties. However, when immersed in the brackish sea water over time the corrosion of the aluminium-copper is not prevented by the cladding. And naturally, for an alloy with properties suited for an aircraft there is no need to consider how it would act when immersed in sea water since it is literally out of its element. None the less, this is part of the challenge when broken and degraded objects are entered into a museum collection. The code of ethics followed by most museums state that the collection must be cared for and preserved for future generations If the Soviet MIG-fighter turned the DC-3 into a wreck in minutes, the years has made it into an archeological treasure.

This find consists of pieces from the size of the body of the aircraft to the fragments of shrapnel coming from the ammunition of the MIG. In the early stage of the process the Air Force Museum went through every piece of material grading it from 0 to 3 on a scale of importance to be able to focus on the more important areas from the start. The museum wanted not to tell the story of the DC-3 as a type but as a unique event since there are DC-3’s still around as veteran aircraft but only one wreck like this one. The parts graded as less important, and they were mostly fragments, were never brought into the collection, but as a conservator I was pleased to be able to have material for tests and to try out methods on parts that were identical to the actual museum object, a rare commodity in a profession where every object is unique in one way or another.

Other metals that have contributed to the “galvanic soup” in and around the wreck are magnesium (the fork and rim of the spur wheel and other thick cast parts), lead and mercury (electronics for example). The magnesium parts of the spur wheel are almost completely mineralized but still holding together. Parts like the rim have however been completely disintegrated.

The copper alloyed aluminium is the main material of the body but on the inside there are a number of materials, most of which can be found in a regular aircraft of that time. The chairs and the inner walls of the cabin are covered with upholstering (leather, textile, animal fibers for filling, rubber bands etc.), the floor is made from wood and iron sheet metal, tables are made from plywood often covered with a plastic surface (melamine or similar polymer) and the electronic equipment is a composite of various modern metals, plastics, glass, ceramics, wood and even cellulose paper.

Types of Corrosion The aluminium sheet metal had been subject to several types of corrosion. The construction of the body with sheets riveted together allows for crevice corrosion. Other materials such as rubber and acrylic glass mounted on the aluminium also provided areas where the corrosion had been more active.

With the presence of chlorides, regular pitting corrosion was found on most surfaces eating its way through the metal. The

Figure 5: Part of panel with instruments where the green tint of the copper corrosion is clearly visible.

The aluminium hydroxide formed as a corrosion product first appeared in the gel form, still saturated with sea water.

But as it began to dry it formed the more commonly seen white crystals, mixed with mud and metal fragments. In its gel form it was quite easy to remove but once dried it formed concretions consisting mainly of aluminium hydroxide, mud and small fragments from the wreck. They would sometimes require a dentist’s drill to remove, with the risk of damaging the underlying layers and remaining surface of the actual object.

While resting on the sea bed for 50 years the wreck had naturally not been uniformly corroded so the condition spanned from “brand new” to completely mineralized or simply gone. The side facing down and thereby partly buried in the mud had some severe corrosion damage, especially the wings. In other archeological wrecks, like wooden ships, one would find the opposite; material buried in the mud usually has a better chance for preservation. Without having any research or tests to support this I have allowed myself to make some speculations about the galvanic situation of a piece of metal partly buried in sea mud. If the buried part is placed in an environment with a lower oxygen level than the part exposed to flowing water it would be possible that the buried part would turn slightly more anodic. Over a number of years this could cause the kind of degradation shown on the DC-3 wreck. As mentioned earlier the sea bed in the area where the wreck had been resting is oxygen free but this has not always been the case. Statistics from the Swedish Meteorological and Hydrological Institute show a variation in oxygen levels in that area and the presence of oxygen at 125 meters in the past 20 years. To be able to do more than speculate about the preservation in relation to the oxygen levels would require much more investigation on both the wreck and the actual conditions at that depth for the past 50 years.

The corrosion and the resulting instability and loss of material are naturally complicated situations, but in some areas adding to this was another essential feature. On the wings and sides of the DC-3 there were Swedish national symbols: yellow circles with three yellow crowns on blue background (Figure 6). They were surprisingly well preserved

October 2012 www.corrosion.com.au p.81

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even though the paint needed some additional conservation to ensure that the symbols stayed that way. In some parts however the corrosion had worked its way under the paint layers so the paint was adhered to an already porous surface.

The combination of metal and paint layers, in museum conservation often referred to as polychrome metal, often calls for a close collaboration between metal and painting conservators. Especially when the metal to which the paint is supposed to adhere is severely corroded.

Figure 7: A receiver prior to preservation: a blend of materials in a state of degradation.

Here I was faced with trying to preserve the thing that is actually the result of degradation: the corrosion. In some cases there was no choice. To remove all corrosion would leave us with very little left of some parts, so when the metal was completely mineralized, it was a matter of consolidating the corrosion products with various conservation products.

The most commonly used product for consolidating porous corrosion products has been Paraloid B72™, an acrylic dissolved in ethanol and/or acetone. The electronic components (Figure 7) are perhaps the best example of the difficulty of removing chlorides from the metals. Once taken out of the sea and dried it is impossible to immerse them into water again to dissolve the chlorides without causing more corrosion. With a complex composite object, using electrolytic cathodic protection, I can never be sure that all metal parts are connected and thus protected. Corrosion will take place within the object and, due to its complexity and the various metals present, will continue to do so as long as there is moisture present.

Figure 6: The author in the process of consolidating metal edges on the aircraft emergency exit door. Not all holes are caused by corrosion; some are in fact shrapnel holes. In the background an example of the state of the electronic equipment.

Electronics The complex electronic equipment, both of the aircraft itself and that fitted into the radio surveillance station presented a major challenge to the conservator. When taking on the task of preserving these parts the first question I asked myself was what would be the purpose or goal of the preservation?

Electronics from the late 1940s and early 1950s was by no means unique so just like the body of the wreck it should be preserved like an archeological artifact, not trying to get the metal looking new and shiny but showing it with all its damage and corrosion. Mud and sediment from the seabed was quite hard to remove since the degradation made it impossible to open the casings of the electronic devices. But there are times when even a conservator is actually pleased to find enough holes, even though they are caused by corrosion, so that the inside of an instrument can be reached.

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Other Materials Even though my focus has been the preservation of metal parts, there are other materials that tell a story. There were parachutes made from silk and as four crew members are still missing the parachutes have been thoroughly investigated to see if they have been used. In the image below (Figure 8) my colleague and textile conservator Anna Ehn Lundgren is shown cleaning a parachute, and from the regularity of the corrosion stains it is possible to see that it has been folded up for a long time and therefore not used by anyone in the crew.

The one item that had benefitted from staying 125 meters below the surface for 50 years were parts made from rubber.

There were objects like rubber oxygen masks, life vests and two life boats found close to the wreck. The conditions have been ideal for preservation of rubber: dark, cold and low in oxygen. After 50 years one of the life vests could even be inflated and held air. But only after a few days exposed to the oxygen of the air the degradation started, and proceeded at a high speed. The rubber was oxidizing, drying and cracking.

The only fast solution to stop the degradation process was to store the rubber material in an oxygen free environment.

They were packed in plastic bags made for this purpose along with a material that would remove the oxygen from the

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Figure 8: Textile conservator Anna Ehn Lundgren investigating and cleaning a parachute. contained air (in this case the product used was RP-K/A™, an oxygen absorber produced by Mitsubishi™). As long as the bags stayed intact, the rubber would remain stable but the bags would need to be replaced at a regular interval. When these objects will be displayed they will need oxygen free vitrines in order not to degrade, or we will simply have to accept that some materials are almost impossible to preserve.

Other more personal items like uniforms, wallets, sun glasses, a briefcase, a shoe or a wedding ring tells another story, that of the missing men and the dramatic last minutes before the impact. A buckle from one of the safety belts was thoroughly examined to see if the layers of corrosion within contained any textile fibers. If they did this could indicate that the seatbelt would have been fastened and someone seated in that chair. It is not very often that conservation and forensic science meet in this way, and I was a bit surprised at how similar our working methods were. Working with the personal belongings brought the otherwise rather technical procedures of conservation down to a personal level, and we were reminded that the wreck has also been a burial site.

The most unexpected conservation experience that came out of the wreck was the state of the emergency provisions. Not that those provisions are rare or strange in a military aircraft, but the one thing that had kept so well; the chocolate bars (Figure 9). They were standard army chocolate bars, and army food is known to have a long shelf life, but this was not expected.

Figure 9: Army chocolate with a shelf life exceeding its paper wrapping.

Displaying a Large Object At the time of the recovery of the DC-3 the Air Force Museum planned a major refurbishment, so it was possible to make special arrangements for the exhibition area. The history of the Cold War was given a space of its own in the basement of the museum, and the wreck placed so that it could be viewed from all sides and from above, though a glass window. To be able to fit the wreck into its designated display area it had to be lifted in before the new building was constructed on top (Figure 10). The glass room provides not only good visibility (Figure 11) for the visitors but is given a constant supply of dry air to minimize the risk of further corrosion. The bronze-like surface appearance caused by the corrosion protection is moderated by a blue tint in the exhibition lighting so that the visitor will not perceive the metal as anything but degraded aluminium.

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Figure 10: Parts of the wreck being lifted into place in the basement of the new display area. Photograph: The Air Force Museum As a conservator the long term result of my work cannot be precisely calculated beforehand. The objects we work with in the museum carry with them a history that we often only know in part, and time has made them both aged and fragile. We can use our experience, but the final result can only be found somewhere in the future. For this reason documentation is a central part of our work so we can follow and evaluate changes over time. If all goes as planned we have managed to slow down, or at best stop the degradation.

Who in their right mind would choose to be a conservator when the fruit of our daily labors may not be found even within one’s own lifetime? One reason may be the possibility of getting so close to history, that we can actually touch it, and study it literally down to its very fiber. Every object is unique, but the DC-3 wreck is definitely a once in a lifetime professional experience.

Bibliography [1.] Christer Magnusson (forensic investigator),Teknisk utredningsrapport över haveri med Tp 79 nr 001 (2007) Försvarsmakten / Swedish Armed Forces [2.] Älmeberg, Roger, (2007) Hemliga Förbindelser, DC-3:an och Kalla kriget [3.] International Council of Museums, ICOM, code of Ethics. http://archives.icom.museum/ethics.html [4.] The Air Force Museum, Linköping, Sweden www.flygvapenmuseum.se [5.] The Army Museum, Stockholm, Sweden www.armemuseum.se

Figure 11: The DC-3 on display in the finished exhibition on Sweden and the Cold War.

p.84 CORROSION & MATERIALS

REPAIRS NEEDED? Does your consultant, engineer, builder, contractor or materials meet the requirements of ACRA? Go to

www.acrassoc.com.au for a searchable list of Consultants, Contractors and Material Suppliers Australia wide.

Australian Concrete Repair Association Ltd Setting the standards in concrete repair for 20 years!

Email: info@acrassoc.com.au

SUPPLIERS & CONSULTANTS CORROSION CONTROL PRODUCTS

Leaders in the Cathodic Protection Industry…Since 1957

SOLID-STATE CATHODIC ISOLATOR®

Mitigation Of AC Induced Voltages • Lightning • AC Fault Current PROUD TO ANNOUNCE OUR LATEST CERTIFICATION

INTERPROVINCIAL CORROSION CONTROL Burlington, Ontario CANADA

TEL: 1-905-634-7751

FAX: 1-905-333-4313

www.Rustrol.com

ENVIRO Tech TM

Inte r n a t i o nPty a l ,Ltd Inc. Australia

Mobile: 0438 888 534 Email: ensolv@bigpond.com Sole Australian Distributor of:

EnSolv

®

Environmentally Friendly replacement solvent for Trichloroethylene

SuperCORR A Ultra thin film lubricant & corrosion prevention compound

3.

2.

1.

Remove poultice with scraper and collect waste into bucket. Wash off residue with low to high pressure water or wash and scrub clean with medium to hard brush. Removal of multi layers of paint may need repeat application. Before repainting, neutralise surface with an acid type of cleaner if necessary.

Leave for 30 minutes to an hour, test with scraper to determine if paint is sufficiently softened. Stripping time depends on number of paint layers, age and type. The product may be left on for 24 hours or even longer. Keep poultice moist. In dry conditions cover with gladwrap, plastic sheets or grease paper.

Apply thick coat of stripper (approx. 3mm) onto surface to be stripped.

Application methods: sprayed on with hopper gun, trowled on or use soft brush.

Mix poultice thoroughly before use.

INSTRUCTIONS:

4.

P 02 9438 2047 | info@letsclean.com.au | www.letsclean.com.au

We recommend all lead based paints be removed by professionals who are properly trained in the methods. Disposal must be in accordance with State Regulations.

captive water washing system

For additional information please ask at point of sale or ring HEIM TECHNOLOGIES.

Clean

5.

1300 854 862 fax: 1300 554 862 sales@rmcoatingsupplies.com.au www.rmcoatingsupplies.com.au 2/16 Monterey Rd Dandenong Vic, 3175 PO Box 8239 Tarneit Vic, 3029

LEAD PAINT REMOVER

6.

phone: email: web: office: postal:

HERITAGE No1

7.

For all sales and general enquiries

NATURAL PAINT REMOVAL POULTICE

Telephone (02) 9438 2047 Facsimile (02) 9906 3328 www.letsclean.com.au

SALES OFFICE

6/09/2012 8:57:09Strip AM

First Aid: If contact with skin and eyes wash with running water. If swallowed do NOT induce vomiting. Material Safety Sata Sheet: Download from www.letsclean.com.au/heritage.html

pty ltd

A division of Let’s Clean Pty Ltd. ABN 68 003 272 811 3/93 Greenwich Road, Greenwich NSW 2065 or PO Box 36 Artarmon NSW 2064 Australia

Coating Supplies RM

nsolv - ad.indd 1

Sydney | BriSBane | MelBourne | Perth

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

www.hobson.com.au

SUPPLIERS & CONSULTANTS

David Pocock MANAGER

22 Irvine Street Bayswater WA 6053 T: 08 9721 2265 F: 08 9271 2235 M: 0409 112 010 E: david@tfgpumpline.com.au www.pumpline.com.au

David Dawson National Sales & Operations Manager

Phone: 1800-RENT-DH (736 834) Mobile: 0450 008 259 Fax: (02) 8525 8850 ddawson@rentdh.com www.rentdh.com

DeHumidification Technologies PTY LTD 113 Bonds Road Riverwood NSW 2210 Australia

Strip paint and urethane remover

Clean low pressure • micro abrasive • vortex cleaning system

Protect

RustMasters complete corrosion control

P 02 9438 2047 | info@letsclean.com.au | www.letsclean.com.au

Russell Fraser Sales Pty Ltd SuPPLying inSPection & teSting equiPment

References: Engineering Building, Sydney Uni; GPO, Sydney; Trades Hall, Sydney; Maclaurin Hall, Sydney; St. Paul’s Cathedral, Melbourne; Bonython Hall, Adelaide; Kings Cross Hotel, Sydney; St Mary Star Of The Sea Church, Melbourne; Macquarie Lighthouse, Sydney

www.letsclean.com.au

• Ultrasonic Thickness Gauges • Holiday Detectors • Coating Thickness Gauges • Pit Gauges • Borescopes & Magnifiers • Surface Replication products

JOS Australia &

SYDNEY t: 02 9545 4433 F: 02 9545 4218 rfs@rfsales.com.au www.rfsales.com.au

Pty Ltd

E-Mail: info@letsclean.com.au Ph. 02 9438 2047 3/93 Greenwich Rd Greenwich NSW 2065 Sydney Australia

ABN 68 003 272 811

N I C H O L A S C O R R O S I O N P T Y LT D

Dr David Nicholas Ph.D, B.Sc (Hons), FIE Aust, CP Eng

Principal Consultant Tel: 02 4952 6593 Int: (+612) Mob: 0421 745 059 8 Bambara Close, Lambton, NSW 2299, Australia Email: david@nicholascorrosion.com.au

Materials and Corrosion Consultancy to the Water Industry

Manufacturers and Suppliers of: • Dessicant Dehumidifiers • HCU- Humidity Control Units • Temporary Humidity Control Systems For Applications in: • Surface preparation and coating • Condensation and corrosion prevention Munters Pty. Limited Sydney – Brisbane – Melbourne

Toll free: 1800 008 379 Fax: (02) 88431589 Email: dh.info@munters.com.au www.munters.com.au

Corrosion, Materials Failure & Mould Investigations Remediation Specification, Contract Administration Industrial and Environmental Chemistry Structural and Civil Design for Durability Contact Dr ANTHEA AIREY BSc(Hons) PhD MBA MRACI CChem email: anthea@atconsulting.com.au ph: 08 92650400 12/18 Harvest Terrace, West Perth WA 6005

KURT RUSSELL Sales Representative

Abrasive Blast Media Supplier

SUPER GARNET Exclusive Distributor for Australia & New Zealand www.mineralscorp.com

AU Free Phone 1800 309 734

sales@industrial-minerals.co.nz NZ Free Phone 0800 646 372

p.86 CORROSION & MATERIALS

SUPPLIERS & CONSULTANTS

D R MAY Inspections David May Welding Supervision Welding Inspection NDT Specialist Coating Inspection Inservice Inspection

Leading Suppliers of NDT Equipment for the Corrosion Industry

Geelong Office: 193 Station Street, Corio, Victoria 3214 Australia Postal Address: P.O. Box 1080, Corio, Victoria 3214 Australia Tel: +61 3 5275 3339 Fax: +61 3 5275 0585 Mob: 0412 520 699 Email: dmay@drmay.com.au

Unit 23, 58 Box Rd Taren Point NSW 2229 Tel: 02 9524-0558 • Fax: 02 9524-0560 Email: ndt@ndt.com.au • Web: www.ndt.com.au

Cathodic Diecasting

Abelmet

Abel Metal Services Pty Ltd

• Mg & Alloy Ingots • Mg Anodes • Backfill Mail: PO Box 90, Moorebank, NSW, 2170 Phone: 02 9602 7740 Fax: 02 9602 7780 Email: mckimmie@abelmet.com.au Web: www.abelmet.com.au

Manufacturing anodes since 1984 Queensland (Head Office)

Phone: +61 7 5476 9788 Fax: +61 7 5476 8268

Melbourne

Phone: +61 3 9755 3770 Email: sales@cathodicdiecasting.com.au

ABN: 93 821 370 828

www.cathodicdiecasting.com.au

ANNOUNCEMENT

Cathodic Diecating - small advert 3-2-10.indd 1

3/3/10 10:51:21 AM

The new name andPROTECTION address for Ian Godson & Associates: CATHODIC

Infracorr Consulting PL.

Agent for:

LIDA® – Mixed Metal Oxide Anodes • Sacrificial Anodes • Silicon Iron Anodes • Transformer Rectifiers • Reference Electrodes

Prevent corrosion on your:-

D E NORA

Australasian Principal Elcometer Service Centre

�/��� Burwood Rd Hawthorn East VIC ���� –Zinc, Aluminium Magnesium Ph: +�� (�)�and ���� ���� • Calcined Petroleum Backfill www.infracorr.com • Surge Protection, Insulation

• Strip, Rod, Tubular, Ribbon, Disk and Wire

Infracorr

–Copper, Zinc and Silver

PIPELINES, TANKS, BRIDGES, WHARVES, OFFSHORE PLATFORMS

Tel: +61 (03) 94672520 or 0413 201562

Corrosion Durability Repair

Email: robertcox@pipecorr.com.au • www.pipecorr.com.au

Phone: 1300 503 610 Email: sales@phillro.com.au www.phillro.com.au

Victoria New South Wales Brisbane Western Australia Distributors all States and Auckland N.Z.

Committed to Professional Service, Competitive Pricing and Customer Satisfaction

ANNOUNCEMENT

The new name and address for Ian Godson & Associates:

Infracorr Consulting PL. �/��� Burwood Rd Hawthorn East VIC ���� Ph: +�� (�)� ���� ���� www.infracorr.com

Infracorr

Front

Corrosion Durability Repair

Gareth van Loggerenberg Corrosion and Coating Failure Investigations Fitness for Purpose and Remnant Life Assessment Expert Witness and Litigation Support Corrosion, Materials & Mechanical Engineers Applied Scientists, Metallurgists, Coating Inspectors NDT Technicians Arthur.Austin@alsglobal.com Australia Wide +61 7 3718 0300

TITANUM ELECTRODE PRODUCTS

t: +61 (0) 8 9256 4499 f: +61 (0) 8 9256 4599 m: +61 (0) 408 931 072 e: gareth@telpro.com.au w: www.telpro.com.au Unit 2, 26 Baile Road Canning Vale Western Australia 6155

October 2012 www.corrosion.com.au p.87

Water Jetting

Blasting

Paint Equipment Dust Collectors

AirPreps

Dehumidifiers Containment

Blasting Equipment

Instruments

Vacuum Units Decon Units

Abrasives

Training

Whether you choose to RENT or BUY.... ....we have your next job covered!

Have you got a large blasting job coming up? Do you need more sprayers to help you meet your deadline?

We have a vast range of products available when you need them – from Abrasives to Vacuum Systems. Our fleet is fully maintained and checked prior to shipping, so you are guaranteed first class quality and reliability when you are ready to start work.

Our Fleet can be hired for virtually any length of time to suit your requirements. If hiring for an extended period of time – no problem! You have the option of purchasing the product outright at a very reasonable price.

So let Blastmaster take the hassle out of preparing for your next job – call us today on 1800 882 229.

For all your Surface Preparation and Coating requirements, contact us today.

Blastmaster 1-12 Bruce Avenue, Marleston, South Australia 5033 Tel (08) 8292 2000 Fax (08) 8292 2001 Email sales@blastmaster.com.au © Blastmaster 2012

1800 882 229 • www.blastmaster.com.au

Form M1571