Corrosion & Materials August 2012

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Vol 37 No 4, August 2012 ISSN 1326-1932

Inside this Issue: Corrosion & Prevention 2012: Keynote Speaker Abstracts Project Profile: Engineered Maintenance of Newcastle Port Wharf Structures Technical Note: Energy Savings in the HVAC Environment Technical Note: Salt Fog Testing University Profile: RMIT University Professional Practice Paper: Cathodic Prevention of Reinforced Concrete Seawater Cooling Towers

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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: Zinc anodes attached to navigation aids at Ribuck Industries. Image supplied by Cathodic Diecasting.

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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

7

ACA Platinum Members

9

ACA Gold Members

10

News

18

ACA Branch News

20

ACA Standards Update

24

2012 Corrosion & Prevention: Keynote Speaker Abstracts

26

Technical Group Review: Coatings Technical Group Meeting Review

28

Technical Group Review: Concrete Structures & Building Technical Group Seminar Review

29

Technical Group Review: Water & Water Treatment Technical Group Seminar Review

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

31

Coatings Group Member Profile

32

Industry Qualifications: Vocational Training for Protective Coatings and Abrasive Blast Industry

34

Member Tales from Abroad: Selling the Know in China

36

Project Profile: Engineered Maintenance of Newcastle Port Wharf Structures

42

Technical Note: Energy Savings in the HVAC Environment

44

Technical Note: Salt Fog Testing

46

University Profile: RMIT University

48

Professional Practice Paper: Cathodic Prevention of Reinforced Concrete Seawater Cooling Towers

53

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

Social Media that we all hear about can be and will continue to evolve and may make Corrosion & Materials more interactive with our members in real time as comment on articles are posted live.

The term Digital First we are hearing about as our newspapers start to restructure may not apply, as typically our readership is not about the latest breaking news in Corrosion technology, but could there be some place for it?

Peter Dove President

Receiving the June issue of Corrosion & Materials the first thing I noticed was it seemed to be heavier than I remembered. So I pulled a back issue from 10 years ago to confirm my suspicion. We’ve gone from 32 pages back then to 64 pages in our last issue.

It’s a bit like property investment which doubles every 10 years. Does this mean in 2022 we’ll have 128 pages?

Somehow I doubt it, because Corrosion & Materials will continue to evolve.

Will it even be printed on paper?

In a digital format Corrosion & Materials could build a Video Capability where the background scans around the process and the text for the article is read in the foreground.

p.6 CORROSION & MATERIALS

Digital media will move more quickly and will be much more demanding on our staff and editors as it will most likely need to work on multiple platforms.

Corrosion & Materials growth and future has little to do with the paper it’s written on but with building connections with our community.

Great publishing will always be about more than content. It’s about building relationships and forums for our association’s communications.

The rise of smart phones and tablets represents both opportunities and challenges for Corrosion & Materials.

Tablets allow opportunity to integrate text, video and interactive graphics seamlessly and create more engaging communication. The challenge will be how to get there.

Despite that, printed publications like Corrosion & Materials offer a unique experience. They don’t demand to be read immediately and completely, you can pick them up and you can put them down as often as you like. They are tactile and have a unique presence.

They add character to a coffee table

and don’t have to be hidden under the bed from your mother.

To quote an article I read “publishing, digital or otherwise, is fundamentally about building connections that inform, excite and inspire”.

If that’s our future then why is it so hard to get our message out?

Engineers and asset owners are still making the same mistakes of the past.

Fundamentals are being ignored or forgotten about, specifications are not being followed, environmentals of coating applications are not understood, inappropriate products are being used, bimetallic joints are failing, stainless steel welding is not being passivated, sharp edges are not being ground; the list goes on.

George Bernard Shaw said “life is not meant to be easy, my child; but take courage: it can be delightful.”

So we still have a long way to go in educating the public in all matters of corrosion mitigation. Your assistance with ideas in getting the message out through ACA Foundation projects would be appreciated by the ACA staff so we can then all take delight in solving corrosion problems and reducing the cost of corrosion.

As George Bernard Shaw also said “the single biggest problem in communication is the illusion that it has taken place.”

ACA PLATINUM MEMBERS

Platinum Members

Standard

Jotun blue

Black and white

List accurate as of 27th July 2012

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

CEO’S MESSAGE

A renewed focus on service delivery ACA has grown tremendously in recent years. Elsewhere in this edition we have reported that membership is well on the way to in excess of 1700. New education and certification programs are being introduced. The number of training programs including those provided on an in-house basis is at an all-time high. The frequency of technical group meetings is increasing and Branch level activity is impressive. New seminar programs are under development for the Darwin region and Queensland.

Together with the Board, ACA staff are finalising some substantial new membership benefits which will be announced in the near future.

Members will also have noticed the reintroduction of e-newsletters on a regular fortnightly basis.

In December last year ACA increased staff by appointing a Branch and Membership Service Officer. Solange Brave has made a significant

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In June Jacquie Martin was appointed to manage and improve ACA’s service delivery to members and other clients.

Jacquie’s role will include working with other staff to ensure that quality information is provided to members on a regular and timely basis, utilising the most appropriate methods. She will also manage venue selection and facilities used for ACA’s education and training programs as well as assisting in the development of new membership benefits.

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These appointments bring the number of staff to 12 with a full time equivalency of 10.

In late July the executive committee met and considered what further growth in staff is necessary to continue to improve the range of benefits available to members. It is now likely that further announcements will be made before the end of 2012 on new staff.

ACA is proud that it has a vibrant and growing membership. It continues to respond to traditional and new challenges and through the recent staff appointments and proposed new appointments will ensure that delivery of services to members is at the core of everything with which it is involved.

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

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ACA GOLD MEMBERS

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List accurate as of 27th July 2012

August 2012 www.corrosion.com.au p.9

NEWS

ACA membership and influence continues to rise ACA’s membership reached 1670 at the end of June this year realising an increase of more than 500 new members since the beginning of 2009.

In percentage terms, this increase is a +44% result.

According to ACA CEO Ian Booth, the target figure for membership for the whole of 2012 was 1670 and this has now been exceeded. A new target of 1750 for the 2012 calendar year has been set and staff are confident the new number can be achieved.

When the new target is achieved ACA will have gained an impressive 50% membership growth over 4 years,

something which most similarly structured organisations in the region and internationally would like to emulate.

Solange Brave was appointed as ACA’s Branch and Membership Service Officer towards the end of 2011. Having a dedicated member of staff who can concentrate on engaging with existing and potential members over membership matters has improved service delivery in this important area.

The approach that ACA takes to membership recruitment is based on attraction rather than an all-out

marketing of the association and benefits of membership. By talking with industry participants who have already had an exposure to ACA activities we are finding that many can easily see the benefits of membership and the access to an extensive range of resources and networks which ACA provides.

Solange Brave is available to assist with any membership matter and she may be contacted at the ACA’s Melbourne office on +61 3 9890 4833 or by email to sbrave@corrosion.com.au.

Standards available for purchase through ACA support Foundation ACA has set up a system through which members and other industry participants can make online purchases of standards and other publications available from SAI Global. SAI Global is the main sales point for all standards in Australia and the Asia Pacific region.

Each purchase will generate a small fee for ACA which ACA will in turn donate to ACA Foundation Limited to support the Foundations activities, particularly

increased education and development opportunities for the industries that both ACA and the Foundation service.

ACA Foundation Limited Chairman Dean Wall says “The online purchase facility will enable support for the Foundation without any extra expense for those who make purchases”. “The combined efforts of ACA and the Foundation to enable industry to support the Foundations activities

will be great for everyone concerned” said Wall.

Access to the online purchase facility is available directly from ACA’s web site at www.corrosion.com.au.

Further information about ACA Foundation Limited activities is available from Ian Booth at ACA’s Melbourne office on +61 3 9890 4833 or by email to ibooth@corrosion.com.au.

Joint YCG/YEA-V technical event On Thursday 21st June 2012, the ACA Young Corrosion Group (Victoria) presented its second technical event for 2012.

The event, ‘Durability Design and Corrosion Monitoring for Engineers’, was held in conjunction with Young Engineers Australia – Victoria. Despite a typical Melbourne downpour that day/ evening, over 60 attendees heard from two excellent speakers.

Frederic Blin, Associate Director Advanced Materials, AECOM, spoke about durability planning and the life cycle cost consequences of the failure

p.10 CORROSION & MATERIALS

to complete this vital step in the design process. He discussed some of the guiding principles for durability design and highlighted examples of durability risks all design engineers should be aware of.

Mike Tan, Associate Professor Institute for Frontier Materials, Deakin University, discussed a range of electrochemical techniques used for corrosion monitoring. His presentation compared the application of these techniques in field and laboratory conditions highlighting why the correct method must be chosen for particular conditions.

Once again the YCG event proved to be a fantastic networking opportunity for all involve and a large number of attendees enjoyed refreshments both before and after the event.

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NEWS

ACA welcomes new members Corporate Platinum Members Project Quality Resources – PQR www.pqr.net.au PQR is a newly formed QA/QC Consulting & Inspection company, based in Perth and Singapore. PQR specialise in 3rd Party Coating and Welding Inspections, MDRs, Weld Procedures & Qualifications, Project Management and Coating Condition Surveys. PQR look forward to expanding current relationships and welcome the opportunity to work with the Australasian Corrosion Association’s corporate and individual members. PQR can be contacted on 1300 913 357 or info@pqr.net.au

Individual Members

Corporate Bronze Members Acacia Corrosion Control www.acaciacc.com.au Acacia Corrosion Control (ACC) undertakes all Abrasive Blasting & Painting Services on a 10 000sq/m site in the Australian Marine Complex at Henderson, Western Australia (8kms South of Fremantle). This area has a Fabrication Precinct and an Oil & Gas Precinct which all service major projects throughout Australia & Overseas. ACC’s Directors have over 60 years combined experience within the industry.

Aura Engineering Pty Ltd Aura Engineering was established to provide skilled labour solutions to the construction, mining and manufacturing sectors. Aura’s focus

is on ensuring high quality outcomes for their clients by maintaining a strong focus on communication with a commitment to achieving industry standards in a worksafe way.

Aura Engineering offer QA, Welding Inspectors, Welding Supervisors and Pressure Welders.

CSIRO CMSE CSIRO Materials Science and Engineering (CMSE) provide research services and solutions focused on corrosion for Industry including new hybrid coatings, self-healing systems, surface engineering and performance and environmental analysis. CSIRO CMSE developed the internationally awarded Atmospheric Corrosion Model and Corrosion Map of Australia.

Name

Company

Location

Anthony Barr

Port Waratah Coal Services

Newcastle

Renee Barnes

Wood Group

Western Australia

Philip Bird

Marine & Civil Maintenance Pty Ltd

New South Wales

Jake Cao

University of NSW

New South Wales

Denys Cooper

Cooper, Glass & Metal Works

South Australia

Ray Da Costa

Wasco Energy

Malaysia

Nick Deussen

Aztec Analysis

South Australia

WorleyParsons

New Zealand

Anthony Easton Maurice Enright

Northern Territory

Lee Fountain

Western Australia

Jonathan Gilfillan

Western Australia

Daniel Hillis

Western Australia

Graeme Holmes

Graeme Holmes & Associates

Newcastle

David Horvath

Lycopodium

Western Australia

Peter Jessop

PM Engineering Services Pty Ltd

Newcastle

Paul Kelly

Jetcut

Western Australia

TAFE Panorama

South Australia

Alexander (Sandy) McPherson Brian Murphy

Victoria

Ian Phillips

Boatcraft Pacific Pty Ltd

Queensland

Ericson Pistan

MG Kailis

Western Australia

Elmer Rosales

South Australia

William Sharpe

Victoria

Ian Taylor

McConnell Dowell

South Australia

Matt Stichnoth

Vermilion Oil & Gas Australia

Western Australia

Aditya Tembe

Dy-Monk (Aust) Pty Ltd

Queensland

Abhishek Tiwari

Monash University

Victoria

Elias Tsantes

Adelaide Water Proofing Services

South Australia

Michael Ward

Austcoat Pty Ltd

Queensland

Joel Webb

Leesons Sandblasting

Newcastle

Ray Woods

Weld Inspection Services

Tasmania

Jack Zhang

Australian National University

Australian Capital Territory

p.12 CORROSION & MATERIALS

Protective Coatings Training From basic concepts to carrying out quality control tests and producing specifications, these short ACA courses will improve your knowledge of protective coatings.

Introduction to Protective Coatings (1 day) This course provides an introduction to basic concepts of protective coatings; including the various types of coatings, the inspection requirements and considerations when selecting such products.

Course Highlights: Background Information

Coatings Selection & Specification (3 days) This course aims to provide participants with the ability to produce a clear and technically correct protective coatings specification. The course provides theoretical and practical information on coatings selection for corrosion control, largely based on AS/NZS 2312 ‘Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings’.

Inspection is only one part of ensuring a quality coating job, and selecting the correct coating system and writing a good specification are just as important. This course has been developed to provide information to assist the specifier select the best coating system and to write a specification.

Course Highlights: Determining the Corrosivity of an Environment Importance of Design in Corrosion and Coating Life Methods and Standards of Surface Preparation Advantages and Disadvantages of Metallic & Specialist Coatings Different Types of Paints, Their Properties & Where They’re Used Procedures and Factors of Maintenance Painting Factors Which Affect Selection of a Coating System Features of the Coating Systems described in AS/NZS 2312 Understanding the Content of a Specification Writing a Specification

Types of Coatings Coating Inspection Coating Maintenance Coating Selection

Protective Coatings Quality Control (3 days) This course aims to formalise or improve the skills of carrying out basic quality control tests associated with protective coatings projects. It uses formal lectures, demonstrations, and extensive practical exercises as teaching methods.

Course Highlights: Introduction to Project Documentation Introduction to the Corrosion of Steel and Other Metals Coating Technology Introduction Surface Preparation Assessment Assessment of Applied Coatings Understanding and Monitoring Ambient Conditions Standards (applied to selection, application and testing of protective coating systems) Quality Control Tests (with a strong focus on hands-on use of instruments, and recording the relevant information)

Course dates, locations and full registration details available at www.corrosion.com.au August 2012 www.corrosion.com.au p.13

NEWS

Vale: Dr Bill Woodberry Bill Woodberry passed away on 17 June 2012. He was born on 8 October 1922 and went to school in Grafton where his father was an engineer with the railways. Bill did a Bachelor of Engineering at Sydney University, and a Masters at the University of NSW where he was awarded the University Blue for his rifle shooting; a sport that Bill enjoyed for much of his life. He and Lorna were married in 1946.

Bill took up the position of Corrosion Engineer with AGL in the early 1950s when cathodic protection was in its infancy in Australia. He and George Lewis (who passed away in the UK days after the first ‘International Conference on Cathodic Protection Theory and Practice’ in 1982) spent many a bottle of red wine uncovering the secrets of cathodic protection. When Bill left AGL in 1970 to take up the position of Chairman of the Sydney Electrolysis Committee with the Electricity Commission, Bill McCaffrey took over his role at AGL. Bill McCaffrey recalls

that as professional engineers Bill Woodberry insisted they wore suits at all times, even when doing field testing at a temperature of 40°C. I met Bill in 1973 when I took over the role of Corrosion Engineer at AGL. Since then he has been a mentor and friend.

Bill was a total gentleman towards ladies, did not suffer fools at all, was a font of cathodic protection knowledge, and the most principled man I have ever met.

At the 1975 International Corrosion Congress in Sydney an American presenter was giving an abysmal paper on stray current; really talking down to the audience. Bill stood up and tore strips off him. Everyone agreed with Bill but no one else dared to say it. Whilst some people claim not to tolerate fools, Bill practiced it. It was all sorted out in the bar later.

During the 1970s Bill’s employer, the NSW Electricity Commission, allowed

the importation of TV sets that could cause corrosion of electrical earths.

Bill attacked his employer at every opportunity on the immorality of this.

At the Australian Electrolysis Committee meeting in 1981 a senior executive of the Electricity Commission tried to address the meeting to explain why the decision had been taken. As Chairman Bill tore strips off him, would not let him speak and then walked out of the room. Bill did not recant and eventually they paid for him to do a PhD on the subject at the University of NSW. Bill was one of the colourful characters of the early days of cathodic protection in Australia. He was a private man who loved an argument and never compromised on a technical issue. His passionate advocacy of good science in general, and corrosion engineering in particular, is a lasting attribute to Bill and was a positive influence on a large number of corrosion engineers today.

Brian Martin

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NEWS

Vale: Dr Paul McIntyre This is a very rare honour, as the EFC is a confederation of societies and does not normally offer membership to individuals, and he was very proud to have been recognised in this way.

Paul had a 30 year long involvement servicing the needs of materials and corrosion standards and education.

In 2003 he was awarded the TB Marsden prize of the Institute of Materials, Minerals and Mining for his considerable professional achievements in promotion of standards, education and publishing in corrosion and materials. The chair of ISO/TC 156 stated in the award citation: ‘‘Paul has provided more input into the development of ISO standards in corrosion than any other individual.’’

In 2011, at the EUROCORR meeting in Stockholm, and in recognition for his commitment to the European Federation of Corrosion as Scientific Secretary (a position he held for the past fourteen years), Honorary Life EFC Membership was conferred on Paul.

Graduating in 1966 from the University of Newcastle-Upon-Tyne with a 1st class BSc degree in Metallurgy, Paul undertook postgraduate research, also at Newcastle entitled: ‘‘The Hydrogen Embrittlement of Niobium and Vanadium’’, for which he was awarded his PhD in 1970. Paul spent his early career in the steel industry, initially at the British Iron and Steel Research Association (BISRA) then, in 1973, joining the British Steel Corporation in Rotherham as Section Leader, researching environmental fracture and developing new steels with improved resistance to environmentally assisted cracking (EAC). In 1978 he moved further south and joined the Central Electricity Research Laboratories in Leatherhead as Group Leader of EAC, studying stress corrosion, localised corrosion and corrosion fatigue in conventional and nuclear power plant. After the privatisation of the electricity industry, Paul remained with National Power as Consultant in asset management and remaining life assessment of components, including novel and early applications developing

least-cost remedial methodologies such as: RAM (Reliability, Availability and Maintainability) and RCM (Reliability Centred Maintenance) for the procurement, operation and maintenance of power plant. In 1996, Paul became an independent consultant with expertise in life assessment of materials and optimisation of maintenance methods while continuing his life-long interests in environmentally assisted cracking phenomena. For six years, until his illness, Paul worked as a consultant in the Electrochemistry and Corrosion Group at NPL, responsible for running the Lifetime Management of Materials service. His scientific insight and depth of engineering experience was critical to successful analysis of a wide range of failure investigations including fracture of wind turbine bolts, corrosion pitting in a desalination plant, as well as providing informed corrosion control guidance to industry.

During his time in industrial research Paul wrote almost 60 published papers, and over 120 internal reports, pioneering the application of fracture mechanics to hydrogen embrittlement and crack growth in steels.

Stuart Lyon, Editor-in-Chief, Corrosion Engineering Science and Technology

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August 2012 www.corrosion.com.au p.15

NEWS

Vale: Prof. David Scantlebury David graduated from the University of Cambridge in 1965 in Natural Sciences specialising in Metallurgy. His undergraduate Director of Studies was Dr TP “Sam” Hoar. He remained in Cambridge for his PhD degree joining Dr Jack Mayne in the Corrosion research laboratories. He followed Brian Cherry studying ionic conduction in typical paint systems.

David joined Portsmouth Polytechnic as a lecturer and together with Des Barker, helped set up the Corrosion group there. The newly formed Corrosion and Protection Centre in UMIST, Manchester was the ultimate attraction and he joined the Centre as a lecturer. His final position was Professor of Corrosion Science and Engineering still in the Corrosion and Protection Centre but with the University of Manchester.

also a speaker at the 13th ICC 1996 conference in Melbourne.

David’s research interests included:paints and organic coatings for the protection of metals in a range of environments; cathodic protection; corrosion of reinforcing steel in concrete; marine corrosion and calcareous films.

He supervised some ninety six successful PhD students and published in excess of two hundred and twenty papers.

David was awarded the UMIST Millenium Prize in 2000 for excellence in teaching and the U.R. Evans Award by the Institute of Corrosion in 2007 for his “outstanding International achievements in pure or applied corrosion science”.

He liked to visit Australia albeit not often enough. David did a sabbatical in Western Australia, mostly at Curtin University, in 1993. He had been a keynote speaker at the ACA conference in Perth in 2004 and last year in 2011 at the 18th International Corrosion Congress (ICC). David was

David had an influence over most of the UMIST (University of Manchester) Corrosion and Protection Centre graduates that reside in Australia and New Zealand including Peter Farinha, Sarah Furman, Bruce Hinton and Graham Sussex, to name a few.

As a personal note, I knew Dave at my time at UMIST and he was my MSc research supervisor along with Stuart Lyon. He was an entertaining lecturer, a caring supervisor who was appropriately hands-off but still available when you needed him. Dave had a broad sense of humour and was a sociable bugger. Sure he was sometimes opinionated but who isn’t when you are passionate about corrosion science and engineering. He will be sorely missed. We will raise a glass of red to Dave at the ACA conference in Melbourne in November.

Warren Green

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NEWS

Boeing demonstrates multilocation paint capability for Royal Australia Air Force Boeing Defence Australia (BDA) has delivered the first two of 65 repainted aircraft to the Royal Australian Air Force (RAAF) from two separate facilities.

The RAAF accepted a repainted Orion AP-3C aircraft at RAAF Base Edinburgh in South Australia and a C-130H Hercules at RAAF Base Richmond in New South Wales less than three months after contract date. Under the AUD $20 million agreement signed in March, BDA will paint 63 more RAAF fixed-wing aircraft over three years.

The AP-3C maritime surveillance aircraft spent 30 days in Air New Zealand’s paint facility in Christchurch. BDA partner Air New Zealand Engineering Services stripped and painted the aircraft

Coating with

Confidence

while it simultaneously underwent maintenance support services provided

by Australian Aerospace Limited.

“This added a layer of complexity, as we had to ensure that the maintenance activities were scheduled in between stripping and painting the aircraft,” said Dennis Mulligan, BDA Surface Finishing project manager.

Meanwhile, the first of three RAAF C-130H transport aircraft was repainted within three weeks as BDA partnered with regional supplier Flying Colours Aviation in Townsville, Queensland.

“Our successful start on this program is testament to BDA’s commitment to providing the same level of service to the RAAF fleet irrespective of location,

as well as our local-partnership approach that draws on Boeing’s global supply chain and capabilities,” said Kim Gillis, managing director of Boeing Defence Australia.

“The preparation, remediation and painting of tactical derivative aircraft is a natural extension of the sustainment services that BDA currently provides the RAAF at Amberley and Williamtown,” Gillis added.

Over the next three years, BDA will prepare, remediate and paint aircraft across four of the RAAF’s mid-to largesized platforms in multiple locations in Australia and New Zealand.

BDA will soon begin painting the first of 28 Hawk-127 jet fighters at RAAF Base Amberley’s Corrosion Control Facility.

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

BRANCH NEWS

ACA Auckland June Meeting Report The Auckland June meeting was the annual mid-year dinner event and the speaker was Doug Parker, Materials Functional Leader, Fisher & Paykel Appliances. Fisher & Paykel manufacture their well-known range of home appliances at three plants located in New Zealand, Mexico and Thailand.

Doug Parker’s role is to carry out materials research, laboratory testing, and investigation of materials failures employed in F&P appliances around the world. Doug’s presentation was entitled “Corrosion Indoors – What Makes Home Appliances Fall Apart”.

Doug commenced with an account of some issues that have developed since the worldwide introduction of stainless steel (SS) for refrigerators, dishwashers and other home appliances. He outlined how important it is to select the right grade of SS, getting a smooth surface finish on SS and the important application of an acrylic protective coating on SS in some situations. He then outlined some case studies of what can go wrong on SS refrigerators if they are not properly cleaned or

if they are treated with aggressive household cleaners.

Further case studies related to corrosion on a zinc-coated steel dishwasher cabinet due to wet storage staining during transit. One solution to this problem was to employ sheet steel with a zinc-aluminium-magnesium alloy coating. A number of corrosion issues encountered over the years in the “engine department” of refrigerators involving the refrigerant condensers.

Most dissimilar metal corrosion problems that occurred had been solved by improved engineering, better design and appropriate materials selection.

Doug continued with more cases that highlighted the effect of poor electroplating practice on zinc die-cast parts, environmental stress cracking of vacuum-formed polymer, and chemical attack issues on various plastics used in appliances. He described how laboratory testing overcame some of the degradation issues they encountered due to the use of aggressive household cleaners attacking engineering plastics

Doug Parker with some ACA Auckland Committee Members.

Attendees at the Auckland “mid-year Xmas dinner” after the meeting. used in appliances. This issue had been a major source of material degradation problems for all appliance manufacturers over many years due to the introduction of “wonder cleaning products” into the marketplace.

After an extensive Q&A session, Doug was thanked for his excellent presentation by Chairman Mark Sigley.

A number of the attendees then enjoyed mid-year “Xmas dinner” together in The Landing restaurant.

Joint SA Branch & WTIA Site Visit The South Australia Branch of the ACA in conjunction with the WTIA conducted a site visit to the $55m Minerals and Materials building of the Ian WarkTM Research Institute (IWRI) on June 5th. The event included a series of short lectures by IWRI research staff on corrosion and materials science topics including design of protective coating systems, corrosion monitoring case studies and surface corrosion by different liquids.

Dr Scott Abbott welcomed the members and overview of The Wark followed by Kingsley Brown describing some of the scientific challenges in the corrosion

industry which then opened into a brief group discussion.

Assoc Professor Rossen Sedev gave a short talk on Reactive Wetting and Corrosion, followed by Professor Namita Choudhury on Hybrid Coating for Corrosion Protection of Metal and Dr Jason Connor on Corrosion Monitoring and Control in Mild Steel Heat Exchanger Tubes.

Presentations were followed by a tour of the impressive IWRI facilities including the following laboratories and equipment: S urface analysis labs – ToF-SIMS, XPS, Scanning Electron Microscopy (SEM) ineralogy labs – QEMSCAN, XRD, M X- XRF, Atomic absorption spectroscopy (AAS) olymer lab – Thermal analysis P (TGA, DSC), Infra-red (FTIR), Tensile testing machine

p.18 CORROSION & MATERIALS

eneral instrument labs – Particle G sizing, rheology, UV vis absorption, NMR spectrometer icrofluidics and Nanofabrication M lab – micro-milling, bonding and hot embossing, UV lithography, ion etching ineral processing and Mini-pilot M plant labs Following the site tour, attendees continued discussions on corrosion and welding issues over a meal and drinks at the nearby Mawson Lakes Hotel.

The event was a great success with over 53 attendees from the ACA, WTIA, AINDT and IWRI. A special thanks to Kingsley Brown (ACA SA Branch), Simon Doe (WTIA) and Scott Abbott (IWRI) for their efforts in making the night a great success.

BRANCH NEWS

Victoria Branch June Technical Meeting Review Cathodic Protection Technologies was the focus for the June Technical Meeting of the Victoria Branch on Wednesday 13th June 2012.

Hans Slagter of Dehn + Sohne Australia presented on Lightning & Surge Protection - CP Systems while Graeme Gummow of Corrosion Control Engineering presented on Electrical Safety of TRUs with Regard to AS/NZS 3000.

Hans introduced the concepts of lightning, current parameters and standard waveforms used in different industry standards (AS/NZ 1768, IEC61643-1 and IEC62305), which apply to surge protective devices. The main difference is that for direct strikes the 10/350μs waveform shape is used, as opposed to a more conventional 8/20μs for induced surges.

Hans illustrated the difference in their energy levels by showing videos of both pulses being applied at 40kA to some standard unprotected power point and panel wirings, where 8/20 resulted just in flashover but 10/350 completely destroyed the equipment.

In the second part of the presentation Hans concentrated on CP systems lightning and surge protection, giving practical advice on how to apply the Lightning Protection Zone concept.

It is important to protect all inputs and outputs to an exposed CP system rectifier: towards mains power supply, anode and structure connections, as well as reference cells.

Hans made a distinction on applicable protection devices for systems

below and above 12A of output current. In particular, Hans showed in detail the application of Isolating Spark-Gaps in Protection of insulated pipeline flanges.

He covered the selection process of spark-gaps capabilities in relation to dielectric strength (withstand voltage capability) of insulating joints and connection cable lengths. While the spark-over voltage on the device itself is around 30V, the voltage drop in the connecting cable 1m long can go as high as 10kV for a direct lightning 10/350μs strike pulse, resulting in ruptured insulation.

As there are practical limitations on how short the cables can be, the need may arise to use multiple spark gaps in parallel to share the current and reduce the induced voltage to safe levels.

Transformer Rectifier Units (TRUs) probably exceed lawful limits at points of structure exposure.

Graeme identified which clauses in the Code lead to the conclusions about non-compliance and discussed a potential technical work-around that could be considered.

He identified the problem as not so much being a technical issue (as so far there were no related fatalities or injuries) but a possible legal ‘minefield’ if ever raised.

He was joined by Richard Brodribb in discussion and question time, and the conclusion that was left ‘hanging in the air’ was that there must be some further work done on clarifying the Standard, specifically covering the cathodic protection area and safety issues arising.

Hans finished this enlightening and very entertaining presentation focusing on Ex Certification and labelling of spark-gap devices.

Most participants received a copy of Dehn + Sohne’s book ‘Lightning Protection Guide’ which is quite a valuable reference on the topic – it is downloadable in full from Dehn + Sohne’s website.

Graeme shared his thoughts about compliance of CP systems and structure connections to AS/NZS 3000 Wiring Rules.

The AS/NZS 3000 Wiring Rules are effectively the law in Australia, and the closer reading of the Code suggest that the output of many

Dehn + Sohne’s ‘Lightning Protection Guide’.

Newcastle Branch June Meeting On Tuesday 12th June, the Newcastle Branch held a technical presentation at Brown Sugar at Warners Bay. Given

by Andrew Wall who is previously of Boeing Newcastle, the presentation focused on corrosion in FA-18 fighter jets. The evening was attended by 28 members and guests who heard firsthand accounts of the corrosion which

was evident in some of the FA-18 jets based at the Williamtown RAAF base.

The discussion focused on three main areas; corrosion in new aircraft, operational failures and how to maintain an aging fleet. Andrew was able to outline these areas in light of his military and civilian employment in the

RAAF and Boeing. The night was aided by an enthralling visual presentation and spirited question time.

The Newcastle Branch’s next meeting is to The Brighton at Toronto where Warren Green from Vinsi Partners will present on the Port Botany Expansion Project.

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

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 one of the ACA Technical Groups. The standards reporting for 2012 is scheduled against Technical Groups (TGs) as indicated below:

This issue will have a focus for the Cathodic Protection Technical Group and results of the search can be found in Table 1.

was conducted using the following key words and key word groups:

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 23rd May 2012 to 18th July 2012

c orrosion or corrosivity or corrosive; but not anodizing or anodize(d)

Issue 2012

Standards search for TG interests

Feb

Concrete Structures & Buildings

April

Coatings

June

Petroleum & Chemical Process Industries

August

Cathodic Protection

October

Mining Industry

December

Water & Waste Water and Welding, Joining & Corrosion

durability

aint or coating; but not anodizing or p 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 37 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 ‘Cathodic’ – 405 publications found, 9 from AS/ASNZS. Results by Publisher Italian Standards

27

British Standards Institution

26

German Institute for Standardisation (Deutsches Institut für Normung)

26

NACE International

26

Nederlands Normalisatie Instituut

23

Association Francaise de Normalisation

22

Polish Committee for Standardization

20

Comite Europeen de Normalisation

19

Osterreichisches Normungsinstitut

18

Asociacion Espanola de Normalizacion

16

Belgian Standards

16

National Standards Authority of Ireland

16

Standardiserings-Kommissionen I Sverige

16

Ford Motor Company

15

Norwegian Standards (Norges Standardiseringsforbund)

15

Swiss Standards

15

US Military Specs/Standards/Handbooks

15

International Organization for Standardization

11

Standards Australia

9

Standardization Administration of China

8

American Society for Testing and Materials

7

p.20 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Bundesamt F. Wehrtechnik unk Beschaffung

7

Bureau of Indian Standard

6

Brazilian Standards

4

Wirtschafts und Verlagsgesellschaft Gas und Wasser

4

Det Norsk Veritas

3

South African Bureau of Standards

3

American Petroleum Institute

2

American Water Works Association

2

Norsk Sokkels Konkuranseposisjon

1

American Association of State Highway and Transportation Officials

1

Anstat Legislation

1

Energy Networks Association (UK)

1

International Telecommunications Union

1

Japanese Standards Association

1

UK Ministry of Defence standards

1

Results by Subject – Metallurgy – 245 results Corrosion of metals

242

Iron and steel products

1

Non-ferrous metals

1

Products of non-ferrous metals

1

Results by Subject – Fluid systems and components for general use – 105 results Pipeline components and pipelines

86

Fluid storage devices

19

Results by Subject – Manufacturing engineering – 54 results Surface treatment and coating

1

Industrial automation systems

1

Results by Subject – Shipbuilding and marine structures – 49 results Shipbuilding and marine structures in general

49

Results by Subject – Civil engineering – 27 results Construction of waterways, ports and dykes

17

Earthworks. Excavations. Foundation construction. Underground works

10

Results by Subject – Petroleum and related technologies – 16 results Petroleum products and natural gas handling equipment

11

Equipment for petroleum and natural gas industries

5

Results by Subject – Paint and colour industries – 14 results Paints and varnishes

14

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

7

Installations in buildings

2

Results by Subject – Chemical technology – 3 results Products of the chemical industry

2

Analytical chemistry

1

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

1

August 2012 www.corrosion.com.au p.21

ACA STANDARDS UPDATE

Vocabularies

1

Results by Subject – Aircraft and space vehicle engineering – 1 result Coatings and related processes used in aerospace industry

1

Results by Subject – Energy and heat transfer engineering – 1 result Hydraulic energy engineering

1

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

1

Results by Subject – Services. Company organization, management and quality. Administration. Transport. Sociology – 1 result Law. Administration

1

Results by Publication AS 2239-2003

Galvanic (sacrificial) anodes for cathodic protection

AS 2832.1-2004

Cathodic protection of metals - Pipes and cables

AS 2832.2-2003

Cathodic protection of metals - Compact buried structures

AS 2832.3-2005

Cathodic protection of metals - Fixed immersed structures

AS 2832.4-2006

Cathodic protection of metals – Internal surfaces

AS 2832.5-2008

Cathodic protection of metals – Steel in concrete structures

AS 4352-2005

Tests for coating resistance to cathodic disbonding

AS 4832-2007

Cathodic protection - Installation of galvanic sacrificial anodes in soil

RUL ML.1-2008

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

DD CEN/TS 15280:2006

Evaluation of a.c. corrosion likelihood of buried pipelines. Application to cathodically protected pipelines

I. S. CEN TS 15280:2006

Evaluation Of A.c. Corrosion Likelihood Of Buried Pipelines - Application To Cathodically Protected Pipelines

DIN CEN/TS 15280 (2006-06)

Evaluation Of A.c. Corrosion Likelihood Of Buried Pipelines - Application To Cathodically Protected Pipelines

To access these publications, go to https://infostore.saiglobal.com/store and type ‘coatings and corrosion’ into the search box and examine the search results.

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 23 May – 18 July 2012 Key word search on ‘durability’ – 0 citations relating to corrosion Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 15 citations found, 0 from AS/NZS ISO 17752:2012

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

ISO 4404-1:2012

Petroleum and related products - Determination of the corrosion resistance of fire-resistant hydraulic fluids Part 1: Water-containing fluids

ISO/FDIS 19840

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

ISO/FDIS 4628-8

Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity and size of defects, and of intensity of uniform changes in appearance - Part 8: Assessment of degree of delamination and corrosion around a scribe or other artificial defect

I.S. EN 60811-604:2012

Electric and Optical Fibre Cables - Test Methods for Non-metallic Materials - Part 604: Physical Tests Measurement of Absence of Corrosive Components in Filling Compounds (iec 60811-604:2012 (eqv))

I.S. EN ISO 9227:2012

Corrosion Tests in Artificial Atmospheres - Salt Spray Tests (iso 9227:2012)

12/30261969 DC BS 2A 174

100° Countersunk head corrosion-resisting steel bolts (Unified threads), Strength Class 880 MPa, for aircraft

12/30262055 DC BS 4A 104 AMD2

Specification for corrosion-resisting steel bolts (Unified hexagons and Unified threads) for aircraft

12/30266207 DC BS EN 62716

Ammonia corrosion testing of photovoltaic (PV) modules

BS EN 4688:2012

Aerospace series. Paints and varnishes. Corrosion inhibiting two components cold curing primer for military application

BS EN ISO 9227:2012

Corrosion tests in artificial atmospheres. Salt spray

DIN EN 3182 (2012-06)

Aerospace series - Ball bearings, rigid in corrosion resisting steel cadmium plated, for control cable pulleys Dimensions and loads; German and English version EN 3182:2012

p.22 CORROSION & MATERIALS

ACA STANDARDS UPDATE

DIN EN 3278 (2012-06)

Aerospace series - Sleeves, tubular, protruding head, in corrosion resisting steel, passivated (0,25 mm wall thickness); German and English version EN 3278:2012

DIN EN 4687 (2012-06)

Aerospace series - Paints and varnishes - Chromate free non corrosion inhibiting two components cold curing primer for military application; German and English version EN 4687:2012

DIN EN 4688 (2012-06)

Aerospace series - Paints and varnishes - Corrosion inhibiting two components cold curing primer for military application; German and English version EN 4688:2012

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion – 21 corrosion related publications found, 0 from AS/NZS; ISO 13632:2012

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

ISO 2812-3:2012

Paints and varnishes - Determination of resistance to liquids - Part 3: Method using an absorbent medium

ISO 9117-6:2012

Paints and varnishes - Drying tests - Part 6: Print-free test

ISO/FDIS 19840

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

12/30215682 DC BS EN ISO 3233-2

Paints and varnishes. Determination of the percentage volume of non-volatile matter. Part 2. Determination by measurement of the dry-film density

BS EN 4688:2012

Aerospace series. Paints and varnishes. Corrosion inhibiting two components cold curing primer for military application

BS EN 4689:2012

Aerospace series. Paints and varnishes. Two components cold curing polyurethane finish. High flexibility and chemical agent resistance for military application

DIN EN 4159 (2012-06)

Aerospace series - Paints and varnishes - Determination of resistance to microbial growth; German and English version EN 4159:2011

DIN EN 4171 (2012-06)

Aerospace series - Paints and varnishes - Test method for determination of phosphoric acid index; German and English version EN 4171:2011

DIN EN 4195 (2012-06)

Aerospace series - Paints and varnishes - Test method for determination of chromate leaching; German and English version EN 4195:2011

DIN EN 4687 (2012-06)

Aerospace series - Paints and varnishes - Chromate free non corrosion inhibiting two components cold curing primer for military application; German and English version EN 4687:2012

DIN EN 4688 (2012-06)

Aerospace series - Paints and varnishes - Corrosion inhibiting two components cold curing primer for military application; German and English version EN 4688:2012

DIN EN ISO 8503-1 (2012-06)

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 1: Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blast-cleaned surfaces (ISO 8503-1:2012)

DIN EN ISO 8503-2 (2012-06)

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel - Comparator procedure (ISO 8503-2:2012)

DIN EN ISO 8503-3 (2012-06)

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 3: Method for the calibration of ISO surface profile comparators and for the determination of surface profile - Focusing microscope procedure (ISO 8503-3:2012)

ISO/FDIS 16145-1

Ships and marine technology - Protective coatings and inspection method - Part 1: Dedicated sea water ballast tanks

ISO/FDIS 16145-2

Ships and marine technology - Protective coatings and inspection method - Part 2: Void spaces of bulk carriers and oil tankers

ISO/FDIS 16145-3

Ships and marine technology - Protective coatings and inspection method - Part 3: Cargo oil tanks of crude oil tankers

BS EN 16058:2012

Influence of metallic materials on water intended for human consumption. Dynamic rig test for assessment of surface coatings with nickel layers. Long-term test method

DIN EN 10169 (2012-06)

Continuously organic coated (coil coated) steel flat products - Technical delivery conditions (includes Amendment A1:2012)

DIN EN ISO 8503-4 (2012-06)

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 4: Method for the calibration of ISO surface profile comparators and for the determination of surface profile - Stylus instrument procedure (ISO 8503-4:2012)

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 publications found Key word search on ‘cathode’ or 'cathodic' – 1 Standard publication found, 0 from AS/NZS 12/30256971 DC BS EN 12473

General principles of cathodic protection in seawater

Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 0 Standard publications found, 0 from AS/ANZS Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ – 0 publications found Keyword Search on 'anodize' or ‘anodized’ – 0 publications found

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

KEYNOTE SPEAKER ABSTRACTS

corrosion & prevention

Proudly presented by: Major sponsor:

keynote speaker abstracts

The Corrosion & Prevention 2012 technical committee has reviewed and accepted 122 abstracts of which have been allocated either as an oral or poster presentation. All abstracts can be viewed at www.acaconference.com.au and below are the abstracts for the conference keynote speakers.

Bruce Ackland Bruce Ackland & Associates Pty Ltd, Australia A Perspective of Cathodic Protection On the 22nd January 2012, the world celebrated the 188th anniversary of cathodic protection. The festivities were not only about that great year of 1824, but were an acknowledgement of how the technology has successfully developed and evolved. The first part of this paper highlights the extraordinary diversity of applications and examines some of the widely popular and more obscure places where cathodic protection is observed.

The second part presents a personal view of laboratory and field research needed to refine our understanding and improve the effectiveness of the applied technique.

Tony Hughes CSIRO, Australia The Impact of Modern Research Tools on an Old Problem – The Devil is Always in the Detail Corrosion science is undergoing renewal for a variety of reasons. At one level regulatory frameworks for human health and environmental pollution are driving changes in the types of chemicals that are used to prevent corrosion such as with chromate replacement or volatile organic chemicals. Advances in materials science, both in the discovery of new methods to make high surface area materials as well

p.24 CORROSION & MATERIALS

as new chemicals have broadened the scope for the discovery of new corrosion inhibitors. High throughput chemical discovery as well as high throughput performance assessment is increasing the rate of discovery and testing of new formulations.

Developments in physicochemical and electrochemical characterisation in combination with high throughput characterisation have provided new tools for understanding the materials science of the systems that are developed. Finally, the costs of maintenance for ageing structures is driving a need for coatings that actively respond to corrosion thereby requiring higher functionality of paint additives such as sensing and signalling. This paper explores these new advances in the context of the author’s research into corrosion protection of the high strength aluminium alloy AA2024-T351 used in aircraft manufacture.

Paul Natishan US Naval Research Laboratory, USA Enhanced Corrosion Resistance of Stainless Steels Interstitially Hardened with Carbon or Nitrogen under Paraequilibrium Conditions Surface hardening of stainless steels using traditional high temperature (~950°C) carburization is not employed in applications requiring corrosion resistance, due to the formation of chromium carbides, which deplete chromium from the steel microstructure (“sensitization”),

and thereby decrease the corrosion resistance. In recent years, a surface modification processes using gasphase or plasma interstitial hardening (IH) under paraequilibrium conditions has been developed for introducing substantial amounts of carbon and/or nitrogen into stainless steels without formation of detrimental carbides or nitrides. Paraequilibrium refers to the concept that diffusion kinetics of substitutional solutes such as Cr and Ni diffuse more slowly than interstitial solutes, such as carbon or nitrogen.

Substitutional solutes are effectively immobile, whereas interstitial solutes can diffuse into the alloy to depths of 20-30 µm. Surface carbon or nitrogen concentrations on the order of 12% or greater can be obtained resulting in a hardened surface. This modified region has been referred to as the “case”, S-phase or expanded austenite. The large concentration of interstitial solute also induces a significant lattice expansion, which due to the constraints provided by the unmodified core, results in compressive stresses greater than 2 GPa. Interstitial hardening with carbon and/ or nitrogen of number of stainless steels including austenitic stainless steels 315 and A286 and duplex stainless steel 2205, improves the hardness, wear resistance, fatigue resistance, and corrosion resistance in salt water environments. The effects of IH-treatment on mechanical properties and corrosion resistance of these stainless steels and the nature of the enhanced mechanical properties and passivity will be discussed.

KEYNOTE SPEAKER ABSTRACTS

Graham Sussex Sussex Materials Solutions Pty Ltd, Australia A Journey with Stainless Steel It is the 100th year since the first, rather dirty, martensitic stainless steels were unexpectedly produced in Europe. The austenitic and even duplex stainless steels were developed in the first third of the century and used in a growing range of industries and on landmark buildings. Food, chemical and mineral industries increasing used, mainly austenitic, stainless steel but the architectural and light commercial uses mushroomed as new production methods allowed cleaner steels. They also permitted a wider use of ferritic and duplex grades particularly as raw materials prices fluctuated.

The successes in a variety of applications with various grades will be outlined together with some of the challenges of what is now a global supply market with some less usual grades appearing from new producers – often after incorporation into third party suppliers.

However, with successes come failures or sub-optimal performance often due to ignorance or cost driven changes.

Some notable problems will be described with the practical solutions that frequently should have been known before the event.

This presentation will concentrate on practical issues and a couple of simple demonstrations very much in line with the ethos of P F Thompson – who was 27 before stainless steels appeared.

Geraint Williams Swansea University, United Kingdom The Use of Electrochemical Scanning Techniques to Elucidate Corrosion Mechanisms in Magnesium and its Alloys With the use of several case studies, this work aims to demonstrate the usefulness of advanced

electrochemical scanning methods, such as scanning vibrating electrode (SVET) and Kelvin probe (SKP) techniques to gain new insight into the localised corrosion of Mg. In-situ SVET investigations of unpolarised Mg specimens immersed in corrosive electrolyte enable local current density distributions be mapped as a function of time. The corrosion of commercial purity specimens immersed in concentrated sodium chloride solution is characterised by the appearance of circular, blackened areas which expand at a constant rate and evolve hydrogen vigorously.

In situ, repetitive SVET scanning reveals that the circumference of an expanding corrosion “disc” is an intense net local anode, while its centre is strongly cathodic and that any localised corrosion currents emerging from the intact uncorroded film-covered Mg surface are negligible by comparison. These findings are consistent with a mechanism involving cathodic hydrogen evolution on the dark, film-free region which galvanically couples with anodic attack of the intact Mg surface and do not fit a proposed “anodic” hydrogen evolution mechanism for Mg corrosion.

The influence of Mg purity and alloying element additions on localised corrosion behaviour visualised by SVET will also be presented. The application of in-situ SKP potentiometry to the characterisation of organic coated Mg surfaces will also be demonstrated.

This technique is capable of visualising the dynamic evolution of free corrosion potential patterns associated with filiform corrosion (FFC) of coated magnesium held at high humidity.

Used in conjunction with time-lapse photography in different oxygencontaining environments, the findings are used to propose a “differential electrocatalytic activation” mechanism for Mg FFC. The final part of the talk will focus on work designed to shed new light on the characteristics of magnesium when undergoing anodic dissolution.

For over a century and a half, generations of scientists have been baffled by the unusual behaviour of

magnesium (Mg) where hydrogen evolution is observed in situations when either anodic potentials or currents are imposed. The mass of Mg lost from the anode is generally markedly higher than would be expected from the applied current and the magnitude of hydrogen evolved increases with anodic polarisation.

As a result of this so called “negative difference effect” (NDE), Mg anodes are significantly less efficient than Faraday’s law would predict. In recent years a theory anodic hydrogen evolution via oxidation of Mg to a uni-positive magnesium ion (Mg+) has been widely seen as a plausible explanation of this behaviour, although no direct proof of the existence of such a species has ever been reported. However, several new published works, employing recently developed electrochemical and analytical techniques, have thrown serious doubts over this theory. The final part of the talk will concentrate on work where high purity Mg specimens are galvanostatically polarised in aqueous NaCl electrolyte using various imposed anodic current densities, while simultaneously monitoring the distribution and magnitude of local current densities emerging from the Mg surface using in-situ SVET. The principal aim is to investigate whether a corrosion self-corrosion mechanism, proposed to be an alternative explanation of Mg NDE, occurs under galvanostatic polarisation at potentials significantly more positive than the open circuit potential (OCP) of Mg. It will be demonstrated that significant local cathodes, which can be mapped by SVET, develop over the anodically polarised surface and that a timedependent rise in local anodic current is matched by a similarly sized increase in cathodic current over a wide range of applied currents. The implications of these findings with regard to current theories on the Mg NDE will be discussed.

Registrations Registrations now open www.acaconference.com.au

August 2012 www.corrosion.com.au p.25

Corrosion

TECHNICAL GROUP REVIEW

SPONSORED BY:

and

Coating Du

PROUDLY PRESENTED BY:

rability

ACA Coatings Tech 6-7th June 2012

Coatings technical group meeting review The ACA Coatings technical group conducted a two day meeting entitled Corrosion Prevention and Coating Durability on 6th – 7th June 2012 at the Courtyard by Marriott North Ryde in Sydney.

Abrasive Blaster. As a consequence, TAFE has had many enquiries from all over Australia from contractors wishing to enrol their staff in the Certificate III in Surface Preparation and Coating Application (MSA30309) qualification.

The meeting aimed to explore and share with the audience selected topics to reflect the importance of appropriate coating system selection and contractor compliance and education to achieve good corrosion prevention outcomes.

This presentation was about this qualification and course, how it is delivered and assessed, how your staff can be enrolled and the government funding opportunities that are available.

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.

The Six Main Causes of Problems with Coatings and Corrosion on Steelwork and Metalwork Mark Dromgool, KTA Tator Modern protective coating materials used for corrosion control are technically sophisticated but, all too often, the protection resulting from their use falls short of their potential.

Coatings failure analysts see many instances of poor coating performance.

What is enlightening is that the causes of poor performance, problems or decreased durability often fall to a short-list of causes. This presentation identified and explained six of the most common causes and explain how contractors can minimise or avoid these; thereby saving money, time and reputation.

Certificate III in Surface Presentation and Coating Application (MSA30309) – Flexible and Customised Training for Industrial Painters and Abrasive Blasters Ian Squire and Ben Young, Wollongong TAFE Many large mining, defence and government organisations which issue tenders for major projects around Australia now request that contractors prove that their staff are adequately trained and qualified to perform the duties of an Industrial Painter and

p.26 CORROSION & MATERIALS

Three Things You Need to Know About WHS Legislation Michèle Strömquist, WorkCover NSW WHS legislation has replaced the OHS legislation in NSW. The new legislation is part of shift to harmonise work safety laws across Australia. To comply with the WHS legislation and ensure a safe workplace three key concepts are:

nical Group Mee

ting

• Courtyard by Marrio

tt North Ryde, Sydne

y

The use of protective coatings across multiple industries, including oil and gas, mining and infrastructure, is widespread and a extremely effective approach to controlling and preventing corrosion. The durability coatings varies of protective enormously with modern protective capable of providing coatings very high levels of corrosion protection and durability even in the most extreme - such as high temperatur operating conditions e, chemical contact, environments and severe often combinatio ns of all of these.

However the successful performance of in any environme protective coatings nt or operating condition depends more than just the on chemicals in the can! The final coating performance is only realised when cured as a dry film a surface, and the on coating achieving this. Increasingl contractor plays a vital part in y, coating manufactu coating contractors rers and are being required lasting products to and longer warranties. provide longer the training of coating Subsequently contractors by both manufacturers and coatings industry bodies is more relevant important than ever and before.

For the coating application contractor the technological keeping abreast of advances is coupled duty to comply with the onerous with ever changing work place safety environmental requiremen and ts and the increasing an ever more litigious liabilities in society.

This seminar aims to explore these issues and share the audience selected with topics to reflect of appropriate coating the importance system selection compliance and education to achieve and contractor good corrosion prevention outcomes.

For registration

and further detail

s see www.corro

sion.com.au

Industrial Coatings – Are We Expecting Too Much?

The Human Element.

Mike Rooney, Contract Resources “Industrial Coatings – are we expecting too much? The Human Element” explores the challenges facing the contractor and the workforce in meeting specifications both in the blast yard and on site. Such challenges include worker selection and training, a “greying” workforce, competition and more technically demanding specifications.

Selection of the Right Instrument for the Coating Inspection Application Paul Jenkins, Phillro Industries

2. You need to know your business and manage all foreseeable risks.

The legislation is performance based and there are less prescriptive requirements in relation to managing risk.

In Coatings Inspection there are many different inspections called for; from measurement of the correct surface preparation and cleanliness, to climatic conditions and final coating inspection.

There are several different test types available using a variety of instruments which are designed for comparative visual inspection as a guide to very accurate electronic measurement. Some of these instruments are designed for a specific range of measurements and it is important that the operators of these use not only the correct instrument for the job but also one that caters for the correct range of measurements. This presentation was about identifying the correct instrument type with a range that best suits the job at hand.

3. Consultation and representation remains a cornerstone of work safety but there is a new approach and new terminology and a new requirement to consult with other businesses on work health and safety matters.

Environmental Considerations for Specifiers and Contractors to Ensure Coating Durability: e.g. C3 vs C5 Environments Jaimie Shaw, International Protective Coatings

What’s All This PCCP Business about Anyway?

Stuart Smith, PCCP

This presentation took a brief look at the practical aspects of specifying performance in different atmospheric corrosivity categories. AS/NZS 23122002 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 pre-determined categories. The presentation covers:

1. The new legislation recognises that everyone has a part to play to ensure all work and workplaces are safe. You need to identify who has obligations, what the obligations are and doing, everything that is ‘reasonably practicable’ to these are met.

Each year across Australia we spend millions of dollars doing what should be unnecessary maintenance due to poor coating selection or poor application.

PCCP was set up in 1992 with the objective of accrediting applicators who could demonstrate compliance with a set of defined standards.

TECHNICAL GROUP REVIEW

sing AS/NZS 2312-2002 in real life U 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; Environmental & Performance Benefits of Powder Coat Finishes Gareth Connell, Akzo Nobel This presentation provided an introduction to the environmental and the longer term performance benefits of powder finishing steel and aluminium.

A Truly Surface Tolerant Coating for the Harshest Environment Roger McElhone, Australasian Industrial Wrappings and Coatings This presentation provided an overview of the performance of the traditional Petrolatum Tape coatings used in the marine environment. Petrolatum Tape has enjoyed over 40 years of preventing corrosion on wharf piles in the splash zone. New development with the Tape was reviewed and also some short comings in outer cladding / mechanical shields. Case studies demonstrating well over 20 years of excellent corrosion prevention, achieved with minimal surface preparation, and surpassing any other existing coatings’ performance were discussed.

Durability in the Australian Environment Peter Golding, Galvanizers Association of Australia

Hot dip galvanizing is the most durable and economical coating for long-term protection of steel from atmospheric corrosion. Specifiers can maximise the life of galvanized steel structures through good design and fabrication, and knowledge of the local environment. This session guided specifiers through the basics of maximising galvanized steel durability in Australia.

Chemical Pretreatment for Metals Cost and Performance Advantages Trevor Green, Chemetall By selecting the correct Chemical process to create a conversion coating on the metal surface, and combining it with the best wet paint or powdercoat system, the full range of exposure conditions can be met. Discussion focused on the advantages of each system when applied to lengths of extrusion, sheet and assemblies and the Standards they meet. Production facilities mean that multiple units can be coated at the minimum cost and in a manner that is environmentally sound and present minimum hazards to the workers.

High Voltage Continuity Testing Choosing the Right Voltage and MIO Pigmented Coatings – Problems with Measuring the Thickness Ted Riding, Jotun

discussed the optimum position for this test regime. In addition, the use of Micaceous Iron Oxide (MIO) pigment is increasingly used in protective coatings and the properties of this pigment present some unusual challenges in establishing acceptance criteria for thickness measurement.

Certification and Verification of Inspection Instruments Paul Jenkins, Phillro Industries In the past few years we have seen an upward trend in the call for the provision of certified instruments.

Unfortunately our experiences indicate opportunists are cashing in on vulnerable instrument owners and some confusion with end users, purchasing officers and auditors in understanding the different types of certification and how they apply to their instruments.

This presentation described the types of certification and how they apply to specific types of coatings inspection instruments, the importance of avoiding the risks posed by fraudulent operators and verification of the authenticity of certificates and those testing and providing them.

Proudly Sponsored by:

The use of high voltage continuity testing is widely used for final verification and acceptance of coatings (especially in immersed, buried or severe chemical contact areas).

However, there is a large difference in the recommended settings for the equipment and this presentation

Solving Your Problems Protecting Your Assets Your one-stop shop for integrated high performance anti-corrosive coatings and concrete repair/remediation

We work with you to ensure your assets stay protected for longer Toll Free Australia: 131 474

Toll Free New Zealand: 0800 808 807

pc-australasia@akzonobel.com

www.international-pc.com

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

TECHNICAL GROUP REVIEW THE AUST RALASIAN CORROSIO N ASSOCI ATION INC SEMINAR

Concrete Structures & Building technical group seminar review The ACA Concrete Structures & Building technical group conducted a one day seminar entitled Concrete Repair & Protection: Some Recent Experiences on 21st June 2012 at the Crowne Plaza in Newcastle.

Recent Developments in Conventional Concrete Repair and Protection Materials including Structural Strengthening Andrew Sarkady, BASF Construction Products

The aim of the seminar was to enhance corrosion awareness and to encourage dialogue on the most recent technologies and approaches available for the repair and protection of reinforced and prestressed concrete structures and buildings.

Modern day concrete repair often requires more than just patching and protective coating. Much of our aging infrastructure requires an upgrade to its loading capacity due to corrosion of reinforcement or change in use. This presentation explored economical ways in which consultants, applicators and clients can help extend the effective life of existing infrastructure by the use of externally bonded FRP (Fibre Reinforced Polymers).

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.

Case Studies of Recent Concrete Repair and Protection Methods with an Update of Corrosion Inhibitors Performance James Aldred, AECOM Effective concrete repair can be an important component to ensure that a structure achieves its required performance and service life. There are a wide range of materials and systems that can be applied. This presentation looked at the suitability of different systems and materials such as corrosion inhibitors and supplementary cementitious materials in different applications. A number of case studies were discussed.

Case Studies of Concrete Repair Methods and Approaches in the Coal Processing Industry Brad Dockrill, Vinsi Partners Vinsi Partners Consulting Engineers (Vinsi) during at least the last 10 years has been involved in a number of varied concrete repair projects on coal processing sites. This presentation put forward a number of case studies where unique site constraints common to coal processing sites played a major role in dictating the methodology of repair type and the manner they were managed.

p.28 CORROSION & MATERIALS

Recent Developments in Cathodic Protection Anodes for Concrete Andrew Dickinson, Parchem Construction Supplies There have been a lot of new developments in recent years in the field of sacrificial galvanic anodes to protect reinforced concrete as a corrosion mitigation solution with a number of new galvanic anodes having been trialled and used on full scale projects across Australia and overseas.

This presentation discussed some of these trials and project installations and provided an overview where the technology has come from and where it can be used to complement a remediation strategy and extend the life of reinforced concrete structures.

A Contractors Perspective and Recent Experiences of Concrete Repair and Protection to Industrial, Building and Bridge Structures Ian Donoghue, Structural Systems This was a presentation of Case Studies of recently completed Concrete Repair projects. This presentation discussed various construction issues identified during these projects and what actions and process changes would assist with reducing the impact of these adverse project outcomes for all stakeholders within the remediation industry

Concrete Re and Protec pair

Some Recent Exption: eriences

PROUDLY PRESENTED BY:

Date: 21 June 2012

• Venue: Crowne Plaza

Asset owners and managers are required reinforced and prestresse to maintain d concrete structures buildings for longer and periods and with tighter budgets. tighter and Many structures and buildings are required for many years and even decades their design lives beyond because requirements, increased of longer operating life of mine and the like.

Concrete repair and protection is becoming more prevalent and there have been many advances in available materials, technologies and in recent times.

Consultants, material approaches contractors and suppliers, asset in this regard. Practicalowners all have stories to tell examples and case are warranted. studies Time

Schedule

8.15 – 8.45

Registration

8.45 – 9.00

Welcome and Seminar Opening Case Studies of Recent and Protection MethodsConcrete Repair with an Update of Corrosion Inhibitors Performance James Aldred, AECOM, Sydney Case Studies of Concrete Repair Methods and Approaches in the Coal Processing Industry Brad Dockrill, Vinsi Partners, Newcastle 10.20 – 10.40 Morning Tea 10.40 – 11.20 Recent Developments in Repair and Protection Conventional Concrete Materials including Structural Strengtheni ng Andrew Sarkady, BASF Constructio n Products, Melbourne 11.20 – 12.00 Recent Developments in Cathodic Protection Anodes for Concrete Andrew Dickinson, Parchem, Newcastle 9.00 – 9.40

9.40 – 10.20

Newcastle

The Australasian Corrosion Structures and Buildings Association’s Concrete Technical Group a seminar to enhance is hosting encourage dialogue corrosion awareness and to on the most recent and approaches technologies available protection of reinforced for the repair and structures and buildings.and prestressed concrete The seminar will be of value to structure building owners and and managers, engineers, architects, contractor involved in optimising s, suppliers and researchers operations to ensure structural safety and availability is not compromised by corrosion and deterioration.

Time 12.00 – 12.40

12.40 – 13.40 13.40 – 14.20

Schedule A Contractors Perspective Experiences of Concrete and Recent to Industrial, Building Repair and Protection and Ian Donoghue, Structural Bridge Structures Systems, Brisbane

Lunch

A Contractors Perspective Experiences of Concrete and Recent Cathodic Protection to Structures Phil Karajayli, Savcor ART, Sydney 14.20 – 15.00 An Owners Perspective and Recent Experiences with Repair Concrete Road Bridges and Protection of Michael Moore, Roads & Maritime Services, Sydney 15.00 – 15.20 Afternoon Tea 15.20 – 16.00 Open Floor Speakers Forum and Discussion and Seminar Close 16.00 – 17.30 Post Seminar Drinks

A Contractors Perspective and Recent Experiences of Concrete Cathodic Protection to Structures Phil Karajayli, Savcor ART Cathodic Protection is still recognised worldwide as the most effective means of arresting corrosion of steel reinforcement in concrete for chloride contaminated structures.

The technique is well established in Australia with applications ranging from bridges and wharves to buildings and industrial structures. Case-studies of recent applications and long term monitoring and effectiveness of the technique were presented.

An Owners Perspective and Recent Experiences with Repair and Protection of Concrete Road Bridges Michael Moore, Roads & Maritime Services Roads and Maritime Services (RMS) has numerous reinforced concrete structures located in a severe coastal marine environment. In recent years RMS has been exploring costeffective solutions for the long-term rehabilitation of these structures. This presentation discussed the RMS strategy and provided a summary of some recent experiences.

TECHNICAL GROUP REVIEW THE AUST RALASIAN CORROSIO N ASSOCI ATION INC SEMINAR

Water & Water Treatment technical group seminar review The ACA Water & Water Treatment technical group conducted a one day seminar entitled Corrosion Issues, Prevention and Asset Rehabilitation in the Water and Waste Water Industry on 26th June 2012 at the Mercure Grosvenor Hotel in Adelaide.

The seminar aimed to explore some of the ways in which utilities can plan for asset rehabilitation and replacement as well as different methods of corrosion prevention used within the water and waste water industry.

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.

The Cost and Impact of Corrosion of Infrastructure in the Australian Urban Water Industry Paul Vince, SA Water In 2010 the Australasian Corrosion Association undertook a study to investigate the costs of corrosion in the Australian urban water industry and to explore the avoidability of these costs.

The study looked at direct and indirect costs including failures, leakage, chokes, capital and maintenance. The results of the study were presented including recommendations to avoid future costs.

The Need for Intelligent Water Networks for Managing Corrosion Costs Donavan Marney, CSIRO Australia’s existing urban water networks consist of long lengths of spatially distributed, buried infrastructure which are subject to complex interactions with surrounding soils, installation, operating loads and the water that they convey. Ensuring security of water to our cities, goes beyond the dams and desalination, but has to include the critical pipe infrastructure in our cities, which

distribute the water via complex networks to our population. In some cases these pipes are of the order of 100 years old; and these older segments of infrastructure are usually located in very awkward to get at locations where failures give rise to much negative publicity, and can have profound effects on the people and business that rely upon the service. It follows that the water industry faces significant challenges to maintain secure and reliable service in the context of the corrosion of ageing infrastructure, urban growth, the desire to close the water loop and with investment capacity constrained by user affordability.

Major operational inefficiencies in existing urban water systems are attributed to the lack of spatial and temporal detail obtained in monitoring use and discharge across water, wastewater and drainage systems.

The current lack of technology to reliably quantify actual customer demands and discharges that are imposed on urban water systems over time means that capital planning of future infrastructure investment and operational response to extreme events (i.e. sewer pump station outages) and are inefficient. Hence, networks are usually significantly oversized to accommodate “worst-case” scenarios.

At the same time the community is confronted by these challenges, the world is experiencing rapid technological innovation that presents the opportunity to transform existing ‘dumb’ water networks into ‘intelligent’ ones, to cater for decentralised systems, to drive water networks to work harder and perform better - and to do so whilst continuing to provide a safe and reliable service. This work considers the challenges of creating intelligent networks and discusses key benefits for the water and wastewater industry, and their ability to meet knowledge gaps and reduce costs associated with corrosion and corrosion maintenance.

Corrosion Issues, Pre vention and Asset Rehabilitat ion in the Water and Waste Water Industry PROUDLY SPONSORED BY:

PROUDLY PRESENTED BY:

Date: Tuesday 26th

June 2012 • Venue: Mercure

The cost of corrosion in the water industry estimated to be in Australia more than $900 million (AUD) annually.is Corrosion in the water waste water networks. industry occurs in both water and This corrosion affects items of infrastruct ure including pipelines, different valves, tanks as pumps, well In addition to this, as treatment and filtration plants. a large amount of water networks water and waste in Australia are reaching the end original design lives. of their To manage this issue, assessment, prevention adequate and rehabilitation to be employed. methods need Time 8.15 – 8.45 8.45 – 9.00 9.00 – 9.40 9.40 – 10.20 10.20 - 10.50

Schedule

Grosvenor Hotel,

Adelaide

Different methods are employed to prevent corrosion on these items including protective coatings, resistant materials, corrosion cathodic protection designs to help ensure systems and correct that items achieve a long life.

A challenge for water utilities lies in how asset renewal as best to plan for well as the best methods to repair replace assets as and they reach the end of their lives.

This seminar aims to explore some of the ways in which utilities can plan for asset rehabilitati on and replaceme as well as different nt methods of corrosion within the water prevention used and waste water industry.

Registration Welcome & Seminar Opening – David Mavros, SA Water The Cost and Impact of Paul Vince, SA Water Corrosion of Infrastructure in the Australian Urban Water Industry The Need for Intelligent Water Networks Donavan Marney, for Managing Corrosion CSIRO Costs Morning tea

10.50 – 11.30 Desalinatio n – An Overview of Durability Issues John Harris, AECOM 11.30 – 12.10 Rehabilitat ion of Concrete Waste Water Assets Incorporati Nick Critchley, Savcor ng HDPE Corrosion 12.10 – 13.00 Lunch Protection Liners 13.00 – 13.40 Incorporati ng Corrosion Kinetics into Drinking Water Jega Jegatheesa Distribution System n, Deakin University Models to Predict 13.40 – 14.20 Case Corrosion Hotspots Study – Corrosion Induced Failure Brad Dockrill, Vinsi of Vertical Stressing Partners Bars in Concrete 14.20 – 14.50 Afternoon Water Reservoirs tea 14.50 - 15.30 Methods of Rehabilitation for Reinforced Andrew Dickinson, Parchem Constructio Concrete Waste Water Infrastruct ure 15.30 – 16.20 Open-floor n Supplies Speakers’ Forum 16.20 – 16.30 Summary & Seminar Close

Desalination – An Overview of Durability Issues John Harris, AECOM John provided a general discussion on durability issues associated with large desalination plants (the Australian experience), namely the appropriate selection of design lives, design for durability standards and guidelines and provide an overview of the main materials and issues associated with durability in large scale desalination plants.

Rehabilitation of Concrete Waste Water Assets Incorporating HDPE Corrosion Protection Liners Nick Critchley, Savcor Concrete structures in the waste water environment are often subject to high concentrations of H2S gasses above ‘normal’ flow levels. Over time these gasses can cause deterioration of concrete cover and if left untreated can cause major structural issues. As waste water structures are generally difficult to access in terms of confined space and flow control requirements, protection of these concrete surfaces is a high priority to asset owners. One option for the protection of these concrete surfaces is the installation of HDPE liners during initial construction or as a part of a structure rehabilitation process. This presentation looked at some of the pros and cons of HDPE liners in the waste water environment, case studies, and accepted and new testing techniques.

Incorporating Corrosion Kinetics into Drinking Water Distribution System Models to Predict Corrosion Hotspots Jega Jegatheesan, Deakin University Understanding the current knowledge of corrosion kinetics available through accelerated corrosion tests in laboratories as well as field studies will help to incorporate that kinetics into the hydraulic modelling of a drinking water distribution system. At present US EPA has excellent software

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

TECHNICAL GROUP REVIEW

that could both model the hydraulics (EPANET) and corrosion kinetics (MSX) of a drinking water distribution system and the incorporation of corrosion kinetics due to disinfectants, biofilm (that is generally present on the inner walls of a distribution system pipes) and other water quality parameters will help to identify corrosion hotspots in a distribution system. This presentation provided a methodology to develop corrosion management protocols for a distribution system through the application of EPANET along with MSX. Case Study – Corrosion Induced Failure of Vertical Stressing Bars in Concrete Water Reservoirs Brad Dockrill, Vinsi Partners During the past five years Vinsi Partners Consulting Engineers (Vinsi) has encountered a number of concerns in the design and construction of select water reservoirs. This presentation

highlighted two recent case studies where Vinsi observed the failure of vertical stressing bars in reservoir walls whilst undertaking structural risk assessments of water assets. Had these failures not been identified and rectified the consequences could have been catastrophic. These case studies show that, for reservoirs (of this type), it is more likely to be a case of when rather than if failure will occur.

Methods of Rehabilitation for Reinforced Concrete Waste Water Infrastructure Andrew Dickinson, Parchem Construction Supplies

methods available it can sometimes be difficult to know which methods are the most appropriate for a given situation. The presentation discussed the main methods of deterioration found in water and waste water concrete infrastructure and some of the main methods of rehabilitation with reference to some past and present project case studies of their use.

PROUDLY SPONSORED BY:

There are a number of different methods for rehabilitating deteriorating reinforced concrete in a waste water environment for today’s asset owner; some of these include the use of inert liners, epoxy coatings and calcium aluminate mortars. With numerous

YCG Upcoming Events

YCG Upcoming Events The Young Corrosion Group (YCG) is open to anyone who is below 35 years of age or has been in the industry less than 10 years.

The Young Corrosion Group was established to assist people new to the industry to make connections with a wide range of people across the industry, to provide learning opportunities and professional development and to facilitate young corrosion specialists to grow their careers and networks.

Upcoming YCG Events include

Recent YCG Events include

orrosion in Action Networking Event C – Sydney

CG Technical Event, 28th March, Y Melbourne

6:00pm

Careers in Corrosion, 4th May, Perth

Tuesday 14 August

urability Design and Corrosion D Monitoring for Engineers, 21st June, Melbourne

CBD Hotel, 4th Floor, 75 York Street (corner of King Street), Sydney Attendance is free, however please RSVP by Friday 10 August to ycg@corrosion.com.au

th Annual Young Corrosion Group 4 Networking Event – New Zealand

algoorlie Site Visit, 28th & 29th July, K Kalgoorlie CG Pacific Marine Batteries (PMB) Y Site Visit, 8th August, Adelaide

6:30 pm Thursday 30 August The Drake, Auckland City Attendance is free, however please RSVP by 4 August to ycg@corrosion.com.au

If you would like more information about YCG and events in your region, contact Katherine Webber at ACA on +61 3 9890 4833 or email ycg@corrosion.com.au

p.30 CORROSION & MATERIALS

COATINGS GROUP MEMBER PROFILE

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

A: Queensland Painters and Maintenance Services (QPAMS) were established in July 2009.

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

A: QPAMS started with 4 employees.

Q: How many do you currently employ?

A: QPAMS currently employ a mixture of employees and contractors. Rod and Gary manage the Industrial division.

Ben manages the commercial division.

All up we would have around 26 people on average at any one time.

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

A: We cover the following markets: il & Gas (pipelines, power O generation, storage etc.)

Tank linings Water infrastructure Marine (Port work) Airports Chemical plants

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

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

A: Our base is Townsville, but we service all of Queensland and the Northern Territory. We have completed work in other states when requested.

A: QPAMS is site based.

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

A: We have a number of crews – depends on the work we have.

A: The core business for our Industrial division is mobile work centred around: ( 40,000 PSI) UHPWJ – surface preparation, concrete scabbling, demolition and cleaning etc.

S ilo, pipeline, tank preparation and painting, tank linings (including dry abrasive preparation) urrently completing four water C reservoirs for two separate City Council’s. ll steel structures – painting A and maintenance Intumescent coatings application Floor preparation and coatings

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

generation is fuelled by flammable liquids our UHPWJ blasting was essential in these ‘hot work’ areas.

Many dignitaries including the QLD premier have visited this site and commented on the presentation. This is a project that we are been proud to be associated with. We have also fully painted its sister site in Roma during that period as well.

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

A: Never compromise on quality and safety, industrial coating application failures are unforgiving. The wealth of a company is its employees, never compromise on safety. If a job is worth doing its worth doing safely. Invest in quality and safety management certifications.

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

A: QPAMS has an internal scheme for training its employees. We find that the culture of the company is transferred to our employees better this way.

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

A: Our speciality is all types of mobile work difficult to reach areas, UHPWater Jetting, night work, confined space, working at heights, shutdowns, touch up work, blasting and painting, full encapsulation of work. We specialise in getting priority work completed on time.

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

UHPWJ preparation at the Bottom City Reservoir.

A: The most satisfying project we have completed to date is for the local power station in Townsville operated

by Origin Energy. We have painted the majority of the plant. As power

UHPWJ at an Origin Energy Power Station.

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

INDUSTRY QUALIFICATIONS

Vocational Training for Protective Coatings and Abrasive Blast Industry Since 2010, TAFE NSW - Illawarra Institute has successfully delivered the Certificate III in Surface Preparation and Coating Application (MSA30309) qualification to over 150 students around Australia. The course is both flexible and innovative and has been designed for both new and experienced workers in mind who work as Abrasive Blasting operators and Painters applying Protective Coatings.

Course content covers every facet of an abrasive blaster and painter’s duties.

As well as setting up, operating and shutting down various abrasive blasting equipment and airless and conventional spray, workers are taught the principles of corrosion, the galvanic series, climatic conditions, paint composition and compatibility, calculating surface areas and paint quantities, spread rates, wet and dry film thicknesses, corrected volume solids after thinning, correct paint mixing, quality assurance and basic inspection required of a painter and blaster.

In addition, basic surface preparation of surfaces such as ferrous and non ferrous metals and timber, fibreglass and concrete and also documentation such as SWMS’s, JSA’s, MSDS’s, PDS’s and Specifications as well as job planning and environmental sustainability are taught as part of this course.

p.32 CORROSION & MATERIALS

Ian Squire, who is one of the teachers delivering the course, has describes the challenges and successes of the course so far: “Most of our students, both past and present, work on a vast array of projects all over Australia. Some are located both offshore as well as in remote mine sites and we have also found that many of our students either come from a non English speaking background or have literacy issues and are of varying ages.

They have either come straight out of school or have been in the industry for many years and it has been quite a while since they last studied”.

As a result, TAFE NSW – Illawarra Institute have adjusted their delivery and assessment methodologies to be flexible enough to cater for these geographical and educational challenges. Students now have the choice of studying online and/or face to face and a book of student notes have also been developed to help students who prefer to use paperbased notes. The course website also has an online translator for non English speaking students and the written content is supplemented with interactive presentations with videos and schematic diagrams and voiceovers as well as links to external websites containing additional information.

TAFE NSW - Illawarra Institute has also commenced rolling out a fast track program for experienced workers so that they can gain their qualification quickly. This involves a combination of Recognition of Prior Learning (RPL) and pure assessment with training then being provided if a student has gaps identified once the assessment has been completed.

The course has also developed a mentoring program for new workers so that they have somebody to turn to on the job. The mentor also ensures that the new worker quickly becomes familiar with the blasting and painting equipment that he/she are going to be using and can set it up and use it correctly and safely. This in conjunction with the theoretical knowledge that the new worker is learning, helps him/her to understand why they are performing a particular task. Previously they would have been told to perform that task but not understood why.

“The feedback that we have received from students and industry has been very positive. For example, we have presented the course website and delivery to some of the large mine operators in Queensland and they were very surprised by the depth and detail of the content in the course and have endorsed it. In fact some of

INDUSTRY QUALIFICATIONS

the current companies that we have been working with have won some considerable contracts because their guys have been completing the course.

They have told us that many of the guys who have successfully completed the qualification are now starting to take more pride in their work because they are more accountable for their work and cannot maintain ignorance” said Ian Squire.

Topic 1 – Interact with Computer Technology Topic 2 – General Occupational Health & Safety Topic 3 – Plan and Organise work Topic 4 – Workplace Communications Topic 5 – Perform Computations.

Topic 6 – Quality Control and Procedures Topic 7 – Surface Preparation Topic 8 – Abrasive Blasting Topic 10 – Coatings and their Application

7. Surface Preparation Activity 1, Part 1 – Corrosion, Environmental Considerations, Relative Humidity and Dew Point Activity 2 – Introduction to Surface Preparation and Substrates Activity 3 – Surface Preparation by Hand Tools and Solvent Cleaning Activity 4 – Fillers, Gap Fillers and Sealants Activity 5 – Flame Cleaning Activity 6 – Acid Pickling, Acid Washes and Rust Converters Activity 7 – Power Tool Cleaning Activity 8 – Preparation of Non-Ferrous Metals Activity 9 – Preparation of Concrete and Masonry Surfaces Activity 10 – Preparation of Fibre Glass Activity 11 – Preparation of Timber Activity 12 – Overview Presentation of Surface Preparation

Abrasive blasters and painters have been listed as a skills shortages occupation by the federal government and as a result can attract considerable training funding, which Wollongong TAFE can help employers access.

For more information on this qualification contact Ian Squire on +61 2 4229 0564 or 0407 314 189 or ian.squire2@det.nsw.edu.au

8.Abrasive Blasting ctivity 1 – Introduction to A Abrasive Blasting ctivity 2 – Preparing surfaces A prior to Abrasive Blasting

10. Coatings and their Application Terms of Corrosion and Coatings ctivity 1 – Introduction to A Paint Application ctivity 2 – Introduction to A Conventional Spray ctivity 3 – Conventional Spray A Systems and Components (Part 1 and Part 2) ctivity 4 – Cleaning and A Maintenance of Conventional Spray Guns ctivity 5 – Troubleshooting A Conventional Spray Guns and Systems

ctivity 3 – Types of Blast A Equipment

Activity 6 – Spray Gun Technique

ctivity 4 – Wet Abrasive Blast A Cleaning (Hydro blasting)

ctivity 8 – Air compressors, A Transformers and Regulators

ctivity 5 – Health and Safety A Requirements for Abrasive Blast Cleaning

ctivity 9 – Air and Fluid Lines A and Couplings

ctivity 6 – Work Method A Statements and Risk Assessments for Abrasive Blast Cleaning ctivity 7 – Personal Protective A Equipment (PPE) for Abrasive Blast Cleaning ctivity 8 – Breathing Air and A Abrasive Blast Helmets Activity 9 – Types of Abrasives

Activity 7 – Spray Booths

ctivity 10, Part A – Airless A Spray Painting ctivity 10, Part B – Plural A Spray Components ctivity 11 – Spray Tips, Filters A and Hoses ctivity 12 – Application A Techniques and Troubleshooting for Airless Spray

Activity 10 – Surface Profile

ctivity 13 – Airless Spray A Accessories and Equipment

ctivity 11, Part 1 – Visual A Photographic Standards

ctivity 14 – Air Assisted A Airless Spray

ctivity 11, Part 2 – Abrasive Blast A Cleaning Standards

Activity 15 – Electrostatic Spray

Activity 12 – Surface Cleanliness

ctivity 16 – Environmental A Conditions

ctivity 13 – Environmental A Conditions

Activity 17 – PaintFilm Thickness

ctivity 14 – Compressed Air and A Air Requirements

ctivity 19 – Coating Types A and Systems

ctivity 15 – Blast Hose & A Associated Equipment Activity 16 – Types of Nozzles ctivity 17 – Ventilation & A Lighting Activity 18 – Communications ctivity 19 – Equipment Set Up A and Testing

Activity 18 – Paint Locations

ctivity 20 – Product Data A Sheets (Review) ctivity 21 – Single and Two A Part Materials Activity 22 – Paint Mixing Activity 23 – Pot Life Activity 24 – Storage Activity 25 – Batch Numbers Activity 26 – Volume Solids Activity 27 – Coverage Activity 28 – Compatibility ctivity 29 – Inspection A Equipment Activity 30 – Inspection Standards Activity 31 – Specifications

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

MEMBER TALES FROM ABROAD

Selling the Know in China It was a warm November night in Newcastle in 2010 when I got a call from a former client who was working in North East China on a manufacturing build for a new fleet of trains for Australia.

“We’ve got a problem with some painted components of the train build, and I thought you might be able to fix it – you should be able to get it sorted in about three weeks…come on up – it’ll be great!”

Work wise, I was in wind down mode leading into Christmas, so I jumped at the opportunity, and after a few trips to the Chinese consulate, and some quick packing of warm clothes, I was en route to a city called Changchun, somewhere I’d never even heard of before.

What greeted me was minus 25° temperatures and not much more than 35% humidity – clearly not the ideal conditions for paint to dry.

Often referred to as the Detroit of China, this bustling industrial city of over seven million people has now been home for the last 18 months, with six months to go on a two-year contract.

The “paint problem” I had to fix was multi faceted: 1. The coating product being used was relatively new to North East China 2. There was no existing painting facility or workshop 3. The complex language barrier 4. Very pressing production schedule deadlines A painting contractor with a good track record in the automotive industry had been engaged, and I was given a blank slate to work from to establish the new facility we required, to train the workforce and to get the finished components back into the production schedule in less than six weeks.

The language barrier was probably the most challenging thing to address, given that coatings and corrosion language is very specific and at times, extremely technical.

I knew what I was talking about in English and the contractor knew his stuff in Chinese. However Lucy, my

Yes, that is paint sitting outside in the snow. ts". "stree ware One of the hard Not even the middle of winter yet…

and there’s quite a few feet of snow… p.34 CORROSION & MATERIALS

translator, was a 33 year old Chinese national who had never seen paint dry in her life, let alone have any understanding of the intricacies of surface preparation, application techniques and curing processes to be able to easily figure out the right words and phrases to translate back into her first language to pass onto the painting contractor.

The learning curve was steep for everyone involved, but inside six weeks, our first train set of the window pans and locker doors was delivered to the production line to be installed in the trains.

The 800 square metre painting factory that I designed needed to supply three train sets of painted aluminum window pans and locker doors per month (this equates to 1104 individual components), with some basic tools and materials at my immediate disposal to achieve this in a rather tight time frame.

I am, by nature, a lateral thinker and love a good challenge – so together with a Chinese contractor keen to develop Western practices and

Training begins with the Chinese workforce.

This is what winter looks like on a good day.

MEMBER TALES FROM ABROAD

The spray booths in action.

Window pans in the factory.

The steel tin jammed together exhaust pipe

The Prep Team.

processes, we created a facility that included two preparation areas, two down draught spray booths and a curing room with climate control to address the curing needs of the polysiloxane, a vital aspect that had, up until now, had been completely overlooked by previous contractors.

I worked in conjunction with PPG’s technical application team to train the local work force in the application techniques required for the vandal resistant coating specified for the internal painted surfaces of the train.

Developing consistency over all aspects of the process was a very important key to our ultimate success, and I am pleased to say that to date, the process that I established continues to be stable and continues to pump out a world class product every month.

My success with this led a two-year contract with the project to address a number of other coatings and corrosion related issues.

With less than six months to go before the end of that contract, there is never a dull moment, and my life and career is certainly richer for the experience gained in Changchun.

The scale of manufacturing in China never ceases to amaze me. The site that I work on is over six square kilometers in area with 8,500 employees all

in this country - everything is recycled…

working for the one company, producing a wide range of passenger trains for rail networks all over the world. There are three job sites of this size in this city alone.

Working overseas is a fantastic experience and one that my wife and I plan to continue given the right opportunities and projects, but it is not without its frustrations and challenges that are markedly different to those I would face on a job site back in Australia.

In a place the size of China, there is access to a huge workforce, but my experience thus far has been that the basic skill set is not yet equivalent to the standards we naturally assume to be available to us in Australia.

What I have observed is that there are some very clever engineers, and then there is labour, so the big piece of the puzzle that is missing in China is well educated and skilled tradesmen, something I consider to be due to the lack of formal and structured trades based training and education.

For organizations like the ACA and NACE, along with their members, I believe there currently is (and will continue to be for some time yet) a great opportunity to do what I call “Selling the know “ – that is selling and distributing knowledge gleaned

Spring Festival - Decorations everywhere. from years of practical and technical experience that a workforce in a country like China is very hungry for.

Where to from here for me?

My plan is to continue to “Sell the know” - maybe another project in China, something in South East Asia, India, Africa, or the Middle East.

There will always be corrosion and coatings issues, with people and projects needing solutions.

Craig O’Brien Craig O’Brien is a Level 3 NACE Coating Inspector with close to 30 years experience in protective coatings and corrosion. He has worked across a broad range of sectors, including construction, manufacturing, as well as heavy and light industrial projects.

He holds a Certificate IV in Painting and Decorating and a Certificate III in Automotive Spray Finishing through TAFE NSW. By the end of 2012, he will also hold a Certificate III in Surface Preparation and Coating Application.

All certificates are through TAFE NSW. Craig considers education and training to be an ongoing factor in his career, with plans to undertake applicable ACA or NACE courses every year for his continuous professional development.

August 2012 www.corrosion.com.au p.35

PROJECT PROFILE

Engineered Maintenance of Newcastle Port Wharf Structures Introduction Exporting over 103 million tonnes per annum, the Port of Newcastle is one of the world’s largest single coal export ports. In addition to coal, the Port handles over 40 different non-coal commodities. Forecasts indicate that Newcastle Port Corporation (NPC) can expect to exceed 180 million tonnes per annum by 2015 in coal trade alone.

Newcastle Port Corporation operates 365 days per year, 24 hours per day. It has 18 operational berths, 7 dedicated to the handling of coal and 11 allocated to the handling of non-coal trade. NPC also owns, operates and maintains 195 navigation aids, 16km of roads, 4.5km of rail, 51 buildings, 2 breakwaters

and over 7km of seawalls. Heritage structures near the entrance to the port also fall within the NPC asset register.

supported on reinforced concrete or steel piles. Figure 1 shows an aerial view of the Port of Newcastle.

The Ports assets are located in an aggressive marine environment so the Corporation is acutely aware of corrosion induced deterioration and the need for corrosion management and maintenance approaches to sustain service lives of structural and building assets.

The berth, wharf and jetty structures that NPC are directly responsible for are summarised at Table 1 Other berth and wharf structures within the Port are leased and are the responsibility of the tenants.

Port of Newcastle wharf and berth structures The wharf and berth structures of the Port of Newcastle are of reinforced concrete construction (decks, substructure beams and rear walls)

The age of the NPC wharf and berth structures varies from 32 to 63 years.

Some are therefore at or beyond their design lives. However, decades of future service lives are required of the structures so pro-active, engineered, maintenance and corrosion management is necessary.

Figure 1: Aerial view of the Port of Newcastle.

p.36  CORROSION & MATERIALS

PROJECT PROFILE

Wharf or Berth Structure

Elements Description

Year Constructed

Fitzroy Street Wharf

Reinforced concrete pile caps, headstocks and deck

1949 (south end) 1956 (north end)

Reinforced concrete piles West Basin No. 3 (refer Figure 2)

Reinforced concrete crane beam, longitudinal beams and deck

West Basin No. 4 (refer Figure 2)

Reinforced concrete crane beam, longitudinal beams and deck

East Basin No. 1 (refer Figure 2)

Reinforced concrete longitudinal beams and deck

East Basin No. 2 (refer Figure 2)

Reinforced concrete longitudinal beams and deck

Channel Berth (refer Figure 2)

Reinforced concrete beams and deck

Dyke 1 Berth (refer Figure 2)

Reinforced concrete dolphins. Reinforced concrete headstocks, prestressed planks and reinforced concrete slab for Road Bridges.

1967

Reinforced concrete piles 1967

Reinforced concrete piles 1964

Reinforced concrete piles 1964

Reinforced concrete piles 1978

HP2 steel piles 1971

HP2 and H section steel piles Dyke 2 Berth (refer Figure 2)

Reinforced concrete dolphins. Reinforced concrete headstocks, prestressed planks and reinforced concrete slab for Road Bridges.

1971

HP2 and H section steel piles Mayfield 4 Berth

Steel beams, reinforced concrete beams and deck HP2, H section tubular and sheet steel piles

Kooragang No 2 Berth

Reinforced concrete longitudinal beams, end beams and deck

1965

Reinforced concrete piles and tubular steel fender piles Kooragang No. 3 Berth

Reinforced concrete longitudinal beams, end beams and deck

1980

Tubular steel piles Table 1. Newcastle Port Berth and Wharf Structures Summary

K3 Wharf Dyke Berths

East Basin No.1 and No.2

Channel Berth

K2 Wharf

West Basin No.3 and No.4

Figure 2: West Basin, East Basin, the Channel Berth and Dyke Berths within the Port of Newcastle.

Condition assessment of structures Condition surveys have been necessary of all structures so as to determine the mechanisms of deterioration, the extent of deterioration and to enable prognoses of future deterioration.

Structural assessments and structural capacity checks have also typically

Figure 3: Kooragang K2 and K3 Berths.

been undertaken. Scenario analyses of remedial, maintenance and corrosion management options have been utilised. Informed decisions have therefore been possible by NPC. Various consulting engineers have worked with the Corporation to undertake the condition surveys,

structural assessments and remedial options analysis. The independence of these consulting engineers has been paramount as conflicts of interest associated with the supply of materials, equipment or laboratory testing services would compromise recommendations.

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

PROJECT PROFILE

Maintenance and corrosion management approaches The maintenance and corrosion management approaches being adopted by NPC for substructure elements of wharf and berth structures have been engineered and tailored to meet required future structure service lives, budgetary constraints, release of maintenance funding and lowest life cycle costs.

The maintenance and corrosion management approaches being adopted include: Do nothing. enetrant treatment (and reP application) of select concrete elements to prevent reinforcement corrosion initiation.

Figure 4: Ribbon mesh anode installation into slots.

Conventional concrete repair.

I mpressed current cathodic protection (CP) of select concrete elements. etrolatum tape wrapping to mean P low water level (MLW) of steel tubular or steel H-section (UC or UBP) piles.

P (galvanic or impressed current) C for in-water steel pile sections.

Combinations of the above.

These approaches have only been applied to those wharf and berth substructure elements that need them.

For example, there is not a need to cathodically protect the whole reinforced concrete substructure sections of any berths, only those elements that need CP. Combinations of remedial options are routinely utilised.

Concrete CP systems overveiw Impressed current anode systems include catalysed titanium ribbon mesh, mixed metal oxide coated ribbon and discrete anodes (proprietary and tailor-made). Transformer rectifier units (TR units) vary in number and type. Remote monitoring and control systems (RMCS) were installed to some TR units. The RMCS units had operational reliability issues from commissioning and no remote monitoring and control of the CP system has been performed (and the RMCS units have subsequently been discarded). Monitoring has been easily and cost effectively undertaken by manual means throughout the life of the CP systems (Green et al, 2010b; Green et al, 2011a).

p.38  CORROSION & MATERIALS

Figure 5: Ribbon mesh anode suspension from reinforcement at spalled areas.

Figure 6: Shotcrete reinstatement over ribbon mesh anode.

PROJECT PROFILE

For substructure beam or deck soffit elements, ribbon mesh and ribbon anodes grouted (cementitious) into slots (refer Figure 4) or chases cut into the concrete surface have been utilised. At badly spalled areas the ribbon mesh anodes were suspended from the reinforcement using plastic fixings prior to application of shotcrete, refer Figures 5 and 6.

The grouts and the shotcretes used were proprietary cementitious and CP compatible with known electrical resistivity characteristics and increased alkalinity (buffering capacity) to resist acidification (since the electrochemical reactions at the anode to grout interface are oxidising, producing acidity) (Layzell et al, 1998; Green et al, 2010b; Green et al, 2011a).

The above-water sections of concrete pile substructure elements have discrete anodes installed. The discrete anode systems are proprietary conductive ceramic-titanium based or tailor-made catalysed titanium, installed into drill holes, which are then in turn grouted with proprietary cementitious grouts.

As for the ribbon mesh and ribbon anodes, the proprietary cementitious grouts used were CP compatible (Green et al, 2010b; Green et al, 2011a).

Steel pile protection methods Most of the NPC wharf, berth and jetty structures are steel piled including carbon steel tubular, H-section (UC or UBP) and sheet. In the past the rate of corrosion of carbon steel piles in Newcastle Harbour has been so low that corrosion protection methods have not always been necessary. Some 4 - 5 years ago NPC maintenance staff observed “bright-orange” localised corrosion of some steel piles at around low water level, within the lower half of the tidal zone and within the in-water sections. The “bright orange” localised corrosion at or near low tide is of the characteristic appearance of accelerated low water corrosion or ALWC, refer Figures 7 and 8 (Green et al, 2010a). The “bright orange” localised corrosion evident to the below water pile sections has been assumed to be microbiologically influenced corrosion (MIC) (Green et al, 2011b).

Newcastle Port Corporation has an Asset Management Plan for their various structures and buildings. When ALWC and MIC was identified to the steel piles of their wharf structures a specific ALWC/MIC Management and Remediation Strategy within the Asset Management Plan was considered necessary. A literature search was

Figure 7: ALWC of tubular pile (typical).

Figure 8: ALWC corrosion of sheet pile (typical). the first step so that an appreciation could be gained for how others have dealt with ALWC (and MIC). Readily available literature and major databases were searched.

The literature search identified that the corrosion protection and maintenance strategies that are applicable to marine ALWC and MIC are those based on well established conventional methods, primarily cathodic protection (galvanic or impressed current), wrappings/tapes, coatings of various types and concrete encasement/jacketing (Green et al, 2010a; Green et al, 2011b).

Currently only steel tubular or steel H-section (UC or UBP) piles of wharf and berth structures in Newcastle Port are scheduled for protection. Sheet piles are to be repaired and protected at a later date. The protection methods considered appropriate from the literature search for Newcastle Port steel tubular and steel H-section piles were: etrolatum tape wrapping to mean P low water level (MLW); and athodic protection (galvanic or C impressed current) for in-water sections.

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

PROJECT PROFILE

Significant perforation of the tubular steel piles supporting Dolphins of the Channel Berth occurred due to ALWC and MIC to the extent that the berth had to be closed. Structural repairs to the piles needed to be engineered to enable the berth to be re-opened and used (Green et al, 2010a; Green et al, 2011b).

Other maintenance and corrosion management approaches Penetrant treatment of select concrete substructure elements and substructure sections has been by silane. Reapplication of silane is scheduled at 10 year intervals.

Concrete repair of select concrete substructure elements has been by conventional means involving breakout of concrete to behind reinforcement and till uncorroded, concrete surface preparation, reinforcement coating system application and reinstatement with proprietary cementitious repair mortars (polymer modified and shrinkage compensated). Silane treatment of repair areas is then undertaken.

Sprayed zinc operating as a galvanic (sacrificial) CP system has also been applied to soffit reinforced concrete elements of a number of dolphins of the Dyke Berths. Year 1 performance results are most encouraging.

Conclusions Not surprisingly, corrosion induced deterioration occurs to structural and building assets within the aggressive

marine environment of the Port of Newcastle. It is necessary to assess the condition of assets from which can then be developed an Asset Maintenance Plan. All maintenance and corrosion management approaches need to be considered and scenario analyses of the same are most useful.

Combinations of maintenance and corrosion management approaches have been adopted by Newcastle Port Corporation for their wharf and berth structures including do nothing.

The age of NPC wharf and berth structures varies from 32 to 63 years.

Some are therefore at or beyond their design lives. However, decades of future service lives are required of the structures. Maintenance and corrosion management approaches can be engineered to achieve required future service lives and to meet budgetary constraints, maintenance funding timings and at lowest life cycle costs.

Acknowledgements The authors would like to thank the Chief Executive Officer of the Newcastle Port Corporation for permission to publish this article. The views expressed in this article are those of the authors and are not necessarily of the companies that they represent.

References Green, W, Masia, S, Garnham, C, Purser D and Dockrill, B (2010a), “ALWC Management of Newcastle Port Structures”, Proc. Corrosion and Prevention 2010 Conf., Adelaide, 14-17 November.

Green, W, Masia, S, Garnham, C and Dockrill, B (2010b), “Concrete CP of Marine Wharf Structures – Case Study Experiences in Newcastle Port”, Proc.

Corrosion and Prevention 2010 Conf., Adelaide, 14-17 November.

Green, W, Masia, S and Dockrill, B (2011a), “10+ Years Performance of Concrete Cathodic Protection Systems on Marine Wharf Substructures”, Proc.

18th International Corrosion Congress and Corrosion and Prevention 2011 Conf., Perth, 20-24 November.

Green, W, Masia S and Dockrill, B (2011b), “Steel Pile MIC Management in Newcastle Port”, ACA Symposium on Microbiologically Influenced Corrosion, Melbourne, 10 & 11 August.

Layzell, D J, Moore, M J, Ali, M G and Green, W K (1998), “Condition Assessment and Maintenance of Wharf Facilities within Newcastle Harbour”, Proc. 2nd International RILEM/CSIRO/ ACRA Conf., Melbourne, 21-23 September.

Warren Green, Vinsi Partners Consulting Engineers, Sydney Scott Bacon, Newcastle Port Corporation Brad Dockrill, Vinsi Partners Consulting Engineers, Newcastle

Corrosion Technology Certificate The Corrosion Technology Certificate is designed to train people working in a corrosion related field in the basics of corrosion and its control. The five day course covers the basic principles of corrosion, the forms it takes and the methods of control.

Course Highlights Corrosion & Its Importance The Corrosion Process Predicting Corrosion Reactions Types of Corrosion

The Corrosion Technology Certificate is required to apply for the ACA’s Certification Scheme.

Corrosion in Natural Environments

The remaining dates and locations in 2012 are:

Corrosion Properties of Metals

New Zealand: 1st – 5th October Sydney: 3rd – 7th December

p.40 CORROSION & MATERIALS

Design Improvement

Inhibitors & Water Treatment Protective Coatings Cathodic & Anodic Protection

e t e r c n o C f o n io s o r Cor s e s r u o C s e r u t c u r t S ACA/ACRA Corrosion and Protection of Reinforced Concrete Tasmania, 3-4 October 2012 This course will provide a solid foundation of knowledge about the corrosion of both reinforcement and concrete, so that those working in this field can reach more effective solutions in the prevention and remediation of this ever-growing problem.

Course Highlights The Characteristics of Cement and Concrete Concrete Deterioration Mechanisms Corrosion of Reinforcement in Concrete Survey and Diagnosis of Concrete On-site Measurements Laboratory Measurements Repair and Protection of Reinforced Concrete Repair of Damaged Concrete Cathodic Protection Further Electrochemical Methods Preventive Measures for New Concrete

Corrosion & CP of Concrete Structures Sydney, 21-22 August 2012 This course covers the background theory on corrosion and cathodic protection, including such aspects as selection and design of cathodic protection systems (impressed current and sacrificial), installation of cathodic protection systems, materials and equipment, problem troubleshooting and assessment and repair of structures.

Course Highlights Modes of Concrete Deterioration Assessment and Repair of Structures Corrosion Fundamentals Remediation Options Selection & Design of Cathodic Protection Systems Materials and Equipment Installation of Cathodic Protection Systems Control of Interference Currents Commissioning of Systems Criteria for Cathodic Protection Operation and Maintenance of Systems Problem Troubleshooting System Records and Documentation

Register now at www.corrosion.com.au August 2012  www.corrosion.com.au 

p.41

TECHNICAL NOTE

Energy Savings in the HVAC Environment As most facility managers are aware of, operating your HVAC equipment accounts for 40-70% of their energy bill. As a result engineers work hard to improve their equipment and make it more energy efficient and economical.

So what is it that we can do in Air Conditioning (AC) that can substantially decrease operating costs and / or increase efficiency? One of the core problems facing many facility managers is the degradation of the HVAC equipment and the subsequent inefficiencies such as increased maintenance and energy costs.

An important part of this degradation is due to corrosion in the coils of the chillers.

In most cases the lifespan of the coils will determine the lifespan of the chiller, after all the coils are the weakest link! So in doubling that lifespan hundreds of thousands of dollars in premature capital investments will be saved. There are a great number of anti-corrosion treatments available on the market, some more effective than others.

Options for a facility owner will be as follows: 1. Do nothing and hope for the best.

This is not a good option in the short, medium or longer term as corrosion will continue to ravage your chiller coils and the inefficiencies in chillers can reach levels of increased energy use of 40 to 70%.

Galvanic corrosion in existing coil.

The copper tubes corrode the aluminium fins until they fall apart and disintegrate.

orrosion will occur in every AC C chiller coil orrosion is the most important C factor in the decrease of efficiency of your chiller orrosion is also one of the easiest to C tackle and avoid.

Most chiller coils are built out of aluminium fins around copper tubes. Copper and aluminium aren’t compatible metals and copper being the more cathodic metal will slowly degrade the aluminium fin, make it brittle and thin due to ‘galvanic corrosion’.

Another concern is environmental and industrial corrosion caused by, for example, car exhaust gases, industrial pollution, salt in the air etc. Due to this corrosion the fins will reduce their heat transfer / conductivity very significantly, clog up with adhering dirt and salt, become brittle and will literally fall apart, sometimes in a matter of years.

The solution to this problem is the application of an anti-corrosion coating on the coils. Some anti-corrosion coatings will provide units with a very effective protection. With the correct coating up to 20% in your energy bill can be saved and roughly double the lifespan of the coils.

p.42 CORROSION & MATERIALS

Corroded coils due to salt and pollution.

The clogged-up coils will have: - greatly reduced airflow - therefore lose efficiency - and a substantially higher energy bill - to generate the same outcome.

Coil tested by the BSRIA Institute, an independent research house in the UK. The coil is virtually destroyed after only 4000 hours of salt spray, i.e. six months.

TECHNICAL NOTE

2. T reat existing HVAC units on site with an effective anti-corrosion coating. One of the most successful coatings that can be applied on site is Blygold’s ‘PoluAl XT’ coating.

It is a very effective way to protect chiller coils from further corrosion as the coating is a spray-on application (a so-called ‘post coat application’): a. This coating can be applied in situ b. H as a metal pigmentation so the conductivity of your coils is maintained c. I s UV resistant and has a salt and acid test resistance of 4000 hours.

3. E nsure that all new coils are treated before installation on site.

This is the best and most affordable option. However, this is only relevant for new units and will not be available to existing units.

Options are two-fold: a. There are the so-called ‘pre-coat’ options, which is a coating applied to sheets of aluminium during the production process. These sheets are then cut in strips the width of the coil fins and the holes for the tubes are punched in. Then the coil is put together. ‘Blue Fin’ and ‘Gold Fin’ are the most commonly known of these coatings.

On-site treatment of existing chiller coils.

This treatment will include: - thorough cleaning of the coil - drying - application of anti-corrosion coating from both sides of the coils - covering the fins, tubes and headers.

Gold Fin pre-coated coil tested by the BSRIA Institute in the UK. The coil is corroding significantly after 1000 hours of salt spray, i.e. a month and a half.

Corrosion is most evident around the tubes where there is bare aluminium.

The biggest advantage of this process is that it is fast, automated and cheap. The biggest drawback is that it is not very effective as it will have bare aluminium where the sheets have been cut and the holes been punched. This is around the the edges of tubes and the fins, where corrosion will normally occur.

Other coatings use the dipping process where the coils are submerged. Its advantage is that it is cheaper, but the coating thickness is uneven, most coatings are not UV resistant and the coating can’t be applied or maintained on site. b. The most effective option is to apply the earlier mentioned ‘post-coating’ on the new coils, which means that the coating is applied after the coil has been fully assembled. The coating is applied by spray and the coating will not only cover the fins, but also the connection between the fins and the tubes, the tubes themselves, as well as the headers. This way the coil will be fully protected and stop the corrosion from occurring.

What about the newest coils that are made out of aluminium only? Surely they don’t need protection? Well, we have to disagree here as these MCHX aluminium coils (MCHX stands for Micro Channel Heat Exchanger) obviously don’t have the galvanic corrosion as discussed earlier, but by being exposed to air the aluminium will oxidize and therefore will become thinner and more brittle over time.

An effective coating here can save substantial money too.

We can confidently state that an anti-corrosion coating can be a very worthwhile initiative as it can actually realize substantial savings. As always: the devil is in the detail, so facility managers should make sure they are well informed before making any decisions.

Spray-on application of coating on new coil.

Ray Van Haven, GM Blygold Oceania.

This coating is: - B lygold polyurethane based coating - With metal pigmentation - Only 25 microns thick once dry - Flexible and UV resistant - Salt and acid spray resistance of 4000 hrs - Doubles lifespan of the coils - Saves up to 20% energy.

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

TECHNICAL NOTE

Salt Fog Testing It is over seventy years since the specifications of the neutral salt fog test were first defined by ASTM B117 in 1939. American Society of Testing and Materials method B117 is the standard salt fog environmental test used for accelerated corrosion testing of materials. ASTM B117 is the universal international salt fog test method and the conditions of the test have been widely written into many national standards and industry codes. The conditions of the B117 test method produce an environment containing a salt fog that reacts with exposed specimens. The salt fog method is commonly called salt spray or salt mist testing, however these names are a misnomer as the environment that exists in the test chamber is a strictly controlled salt fog. ASTM B117 formalised the details of the salt fog test in a reproducible format. Salt fog testing had existed in various forms from 1914, however the parameters of the ad-hoc test methods and procedures varied significantly and it was difficult to compare the results of salt fog testing from the variety of methods used by laboratories.

The salt fog chamber is a device to expose samples to an environment of droplets of warm saline solution for a continuous test period. The samples are contacted by chloride ions, oxygen and water. Add elevated temperature to these three components and you have a seriously corrosive environment for any metal surface. ASTM B117 defines the essential parameters of the neutral salt fog test as follows.

5% sodium chloride solution Solution pH 6.5 to 7.2 Specific gravity 1.0255 to 1.0400 g/cm3 Salt < 0.3% impurities hamber and solution atomisation C temperature 35°C Fog collection rate 1 to 2 ml/hr/80mm2 Fog homogeneity etails of permissible solution D contamination etails of chamber conditions and D sample exposure

The ASTM B117 salt fog test method is suitable for metallic samples, with and without metallic and/or non-metallic surface coatings, films and treatments.

The test method does not define the exposure times for specimens. The test method does not define the process of assessing the exposed samples for corrosion and coating damage.

Exposure times and sample assessment are set out in applicable product specifications.

Salt fog testing is used extensively for automotive, building, structural and externally exposed components. The method is primarily used to evaluate the relative corrosion resistance of coated or treated surfaces. Product specification exposure and assessment conditions may be specific to the component or generic specifications.

The product specifications defining the test exposure time and sample assessment are often Original Equipment Manufacturing (OEM) protocols based on extensive testing, in particular testing of components and materials under a range of external environmental conditions. Exposure times can range from as little as 8 hours up to in some cases 10,000 hours.

Corrosion of untreated steel ball. Salt fog exposure 240 hours.

Painted steel component after exposure to 100 hours of salt fog.

Coating has failed in grooves.

Surface corrosion and zinc oxidation on galvanised steel after exposure to 1000 hours of salt fog.

Condition of test panel after exposure to salt fog for 1000 hours.

Steel coated with zinc.

Note edge preparation.

p.44â&#x20AC;&#x192; CORROSION & MATERIALS

TECHNICAL NOTE

on historical trials that identify a salt fog exposure time that assesses whether the component will survive in the external environment for an acceptable period of time. A cynic might say an acceptable period of time is warranty plus one day, however the pragmatist will realise that the wide range of possible external operating conditions will mean that some components are used in very aggressive conditions and others operate in moderate or mild environments. The responsibility of the component manufacturer is to find or develop a product specification that offers acceptable results after a reasonable exposure period.

Corrosion damage on stainless steel, painted steel and galvanized steel surfaces after exposure to 500 hours of salt fog.

Salt fog testing is not an exact replication of natural environment exposure. The continual wetting of the test surface may not allow passive films to form. For this reason cycle corrosion testing has been developed to more closely represent natural exposure.

Cyclic testing includes periods of salt fog, dry and humidity. The basic neutral salt fog test B117 can also be modified by changing the chemistry of the salt solutions. The most common modifications to the method are G85 acetic acid salt spray test (ASS) and B368 acetic acid with copper chloride salt spray test (CASS). The modified methods are primarily used for the rapid testing of chromium plating.

Great care should be taken in handling specimens supplied for salt fog testing.

It is no use expecting an acceptable result by grabbing a hand full of components from a production bin, dropping them in an air mail bag, and sending the samples to the test laboratory. The condition of the surface of the samples prior to testing is critical to the ultimate outcome of the test.

Separating and individually wrapping specimens is recommended.

Corrosion failure on steel component coated with inorganic zinc. Total salt fog exposure 240 hrs.

Exposure times are specific to coating thickness and surface treatment type.

The question is often asked “What is the acceleration of salt fog testing against exposure in the natural environment?” Exposure time in the salt fog chamber cannot be converted to an accelerated exposure time in the field. There is no comparison or correlation between time in the test

chamber and real time in the field. Field conditions vary widely from dry desert atmospheres with no salt exposure and minimal moisture contact, to constant wet marine conditions. In fact is possible that some marine conditions on exposed surf beaches are equivalent to salt fog testing on a 1:1 basis.

In general the product specifications, in particular OEM specifications, rely

Salt fog testing to ASTM B117 is a common corrosion test method because it is cheap, quick, well standardized and repeatable. Salt fog test is widely used in industry for the evaluation of corrosion resistance of coated and treated surfaces on components. The qualification is that there is a poor correlation between the exposure in salt fog chamber and the external operation of a coating. As you are all aware surface corrosion reactions are a complicated process and are influenced by many external factors.

Monty Luke, Principal Metallurgist Bureau Veritas Asset Integrity and Reliability Services Pty Ltd

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

UNIVERSITY PROFILE

RMIT University RMIT University has a well established corrosion group, with a track record of research into materials corrosion and durability, in both condition monitoring and service life assessment.

The group offers a comprehensive range of NDT techniques to assess the corrosion of metals and of reinforced concrete structures.

The corrosion group includes academics from a number of disciplines, providing a wide range of expertise and a multidisciplinary approach. The group is involved in research in a number of different key areas having strong industrial links and also offering consultancy and training to industry.

A number of grant schemes are also available for collaborative research and development projects.

Some of the key current research topics are: i. The impact of corrosion on bond in reinforced concrete: In uncorroded structures the bond between the steel reinforcement and the concrete ensures that reinforced concrete acts in a composite manner. However, when corrosion of the steel occurs this composite performance is adversely affected. Research at RMIT has investigated the relationship between bond and surface crack width. The results have shown a potential relationship which can be used in the assessment of structures to predict the residual bond, enabling a management strategy to be developed for the structures. ii. Corrosion of high performance steel welds; One area of importance in the oil and gas industry, particularly for subsea application, is the corrosion

100 µm

behaviour of high performance duplex stainless steel welds for critical applications such as valves, manifolds, etc. Here, assessment of the weld integrity is carried out in terms of the susceptibility to IGC, SCC, pitting corrosion and weld design for eliminating such forms of corrosion. iii. Corrosion rate monitoring; The group posses a range of state of the art monitoring equipment including Linear Polarisation Resistance (LPR) monitoring kit with Guard Ring. The LPR method has been developed to give a direct measure of the instantaneous corrosion rate of steel reinforcing bars in concrete structures. The instantaneous corrosion rate measurements can be used to ascertain the current condition of the steel, in terms of the corrosion rate, and to predict the future performance of the structure. This data can then be used to select the most appropriate and cost effective inspection and maintenance regime. iv. Coatings for corrosion control; A number of projects (past and present) are focussed on the corrosion assessment of surface coatings for structural engineering applications using accelerated corrosion monitoring techniques such as potentiodynamic scanning.

In particular, the philosophy is coating design to reduce porosity and pin holes and overall improve structural integrity of the coating.

Projects include (i) assessment of PVD refractory metal nitride coatings (TiN, CrN, TiAlN, AlCrN, etc) for use in cutting tool applications; (ii) MEVVA ion implantation of nitride coatings

and stainless steels for improved corrosion resistance and (iii) HVOF or thermally sprayed WC based cermet coatings for aircraft (landing gear) applications. v. Improved Management of Australian Maritime Infrastructure

by Development of a Predictive Management Tool; An ARC Linkage project in collaboration with Monash University, AECOM, Port of Sydney and Port of Portland is developing a 3-Dimensional probabilistic model for the initiation and propagation of reinforcement corrosion in port infrastructure. The project is using Finite Element Analysis software to develop a three dimensional model to predict the ingress of chloride ions, the initiation of corrosion and the propagation of the corrosion to cracking, spalling and structural failure. The model will be used to provide port authorities with a tool to enable the more cost efficient management of their infrastructure. vi. Laser scanning; A research project is being undertaken to use laser scanning to monitor the rate of deterioration due to corrosion. Initial testing is being used to identify crack initiation and the subsequent crack growth caused by corrosion of reinforcing steel in concrete. By taking scans at discreet points in time both the current condition and any changes can be identified.

This is particularly useful for large structures where access or detailed investigation is problematic.

Software is being developed to interrogate the data to determine crack width, length and rate of growth. The second stage of the

100 µm

0.10 mm

Optical micrograph of corroded WC-10Co-4Cr coating cross section showing the presence of micro channels

p.46 CORROSION & MATERIALS

Optical micrograph of corroded WC-10Co-4Cr coating cross section showing large voids

Optical micrograph of corroded WC-10Co-4Cr coating cross section showing large voids

UNIVERSITY PROFILE

Dr Rebecca Gravina, the Chemical Engineering discipline, Dr Liam Ward, Environmental Engineering, A/Prof Sujeeva Setunge and Architecture and Design, Mr Lucas Holden. In addition members of the group have expertise in the interpretation of the data to provide both detailed analysis and predictive modelling to enable the lifetime management of components and structures. This includes the use of electrochemical techniques to both monitor corrosion and to provide protection, such as Cathodic Protection, Desalination and Re-alkalisation.

project will look at corrosion monitoring in steel structures, such as piles, girders and beams. vii. Corrosion of gold jewellery; While low (9 carat) gold jewellery is known to suffer from SCC, recent work at RMIT has focussed on systematically studying the selective dissolution of alloying additions in quaternary gold alloys for jewellery applications in a range of media using potentiodynamic anodic scanning. These studies will have significant implications for the long term durability of these alloys.

Further details may be obtained from researchers in the various areas:

The University has a range of instrumentation available for materials investigation and characterisation including, SEM, XPS, EDX, XRF and LPR. The group is comprised of members of staff from Civil Engineering, Dr David Law, A/Prof Tom Molyneaux,

Metallic corrosion Dr Liam Ward liam.ward@rmit.edu.au 03 9925 1713 Laser Scanning Mr Lucas Holden lucas.holden@rmit.edu.au 03 9925 1956 General Enquiries School of Civil, Environmental and Chemical Engineering GPO Box 2476V Melbourne 3001 Victoria, Australia Tel +61399250321 Fax +61396390138

Corrosion monitoring, Non-destructive testing and predictive modelling Dr David Law david.law@rmit.edu.au 03 9925 0321

0.1 Corrosion Current (mA/sq.cm)

0.09 0.08 0.07 0.06 0.05 0.04

100 µm

0.03 0.02 0.01 0

Uncoated

TiN(0V)

TiN(100V)

Coating

TiAIN1

TiAIN2

TiAIN3

TiAIN4

Corrosion current (Icorr) values for TiN and TiAlN coatings in 1N Nacl at varying bias voltage.

0

sample 1–4

-2 I(logA/cm2)

0.25 Current Density (microA ions/sq. cm)

-1

-3 -4 -5

0.2 0.15 0.1 0.05 0

-6

-1.2 -1.0 -0.8 -0.6 -0.4 -0.2 0.0 0.2 0.4 0.6 0.8 1.0 1.2 E(V, VS.SCE)

Cyclic potentiodynamic scan for gold alloy in 3.5% NaCl showing anodic resions of selective dissolution.

0

6.00E+16 8.00E+16 1.00E+17 Implantation Dose (ions/sq. cm)

2.00E+17

Corrosion current (Icorr) values for Zr Implanted TiN as a function of implantation dose.

Experimental set up for determining the degree of susceptibility to corrosion of steel reinforced concrete blocks.

SEM image of corroded hole on TiN coating surface.

Optical micrograph of the surface of unsealed anodized aluminium alloy sample after salt spray testing (X1000 Mag).

Corroded specimen configuration for instantaneous corrosion rate monitoring of steel reinforcing bars in concrete structures using linear polarisation resistance (LPR) technique.

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

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p.54 CORROSION & MATERIALS

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The NEW easy to use inspection gauge 3 separate gauges in one convenient kit Blastmaster introduces the new PosiTector™ Inspection Kit with the 3-in-1 gauge that measures Coating Thickness, Surface Profile and Dew Point/Climatic Conditions. This compact unit is an asset to have when varied and detailed measurements are required – both at your workplace or out in the field.

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Form M1523