June Corrosion & Materials 2012

Official

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Vol 37 No 3, June 2012 ISSN 1326-1932

Inside this Issue: Technical Introduction: Protective Organic Coatings – An Introduction Industry Insight: Considerations for Radioactive Waste Management in Australia Project Profile: Loy Yang Chimney Cappings Project Profile: Swansea Bridge Rehabilitation Technical Note: Mild Steel Pipeline Weld Corrosion University Profile: The University of Newcastle Industry Insight: Protecting the Protection: What can Patent Filing Trends Tell us About Technology Trends in Corrosion Treatments?

Research Paper: Atomic Emission Spectroelectrochemistry: A New Look at the Corrosion, Dissolution and Passivation of Complex Materials

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www.corrosion.com.au

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p.2 CORROSION & MATERIALS

“Dulux” and “Worth doing, worth Dulux” are registered trade marks. The Squares Device is a trade mark. June 2012. BAP1318

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

Proudly presented by:

Major sponsor:

registrations now open

see www.acaconference.com.au for details June 2012 www.corrosion.com.au p.3

CONTENTS

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

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

The ACA is a founder member of the World Corrosion Organization

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President’s Message

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Chief Executive Officer’s Message

10

News

20

ACA Branch News

22

ACA Standards Update

29

Coatings Group Member Profile

30

2012 Australian roadshow review

32

2012 New Zealand roadshow review

33

Technical Group review: Joint OGC and PCPI meeting

34

Technical Introduction: Protective Organic Coatings – An Introduction

Front Cover Photo: A wharf in southern Western Australia. The soffit of the wharf was the subject of conventional concrete repair and anti-carbonation coating.

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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

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

38

Industry Insight: Considerations for Radioactive Waste Management in Australia

40

Project Profile: Loy Yang Chimney Cappings

44

Project Profile: Swansea Bridge Rehabilitation

48

Technical Note: Mild Steel Pipeline Weld Corrosion

50

University Profile: The University of Newcastle

53

Industry Insight: Protecting the Protection: What can Patent Filing Trends Tell us About Technology Trends in Corrosion Treatments?

55

Research Paper: Atomic Emission Spectroelectrochemistry: A New Look at the Corrosion, Dissolution and Passivation of Complex Materials

65

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: Alex Shepherd

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 8267 4744

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 Professionals: Erwin Gamboa

61 8 8303 5473

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

PRESIDENT’S MESSAGE

review a document from the mid 50’s that has evolved over the years with a fix here and a fix there solution, or do we start with a clean sheet of paper? The board is only bouncing ideas around at the moment, but to progress the constitution review, we will need to also consider our future structure with the current council and operations committee (board) and executive arrangements.

Training continues to be a major part of the activity managed by our central office with several coating and cathodic protection courses successfully conducted this year. The upcoming courses are all available on our website, so look and learn!

Peter Dove President

Ode to the common man Our membership has cracked 1600 and the outlook is for further growth. How will this be achieved?

There are several activities which will pave the way to maintain our association’s relevance to each of us and to develop awareness of corrosion mitigation in the Australian and New Zealand communities. These will be outlined in the new strategic plan.

The Board has developed the strategic plan for our future guidance and development which you will read about in more detail later. The strategic plan has been developed to focus on Governance and Organisational Structure, Membership, Technical, Education and Training, Events, Communication, Advocacy, and Operational Management to maximise membership value and increase the status of ACA within Australasia and internationally.

From the plan, a number of strategies such as membership recruitment and retention are in development to guide ACA staff and to maximise the benefits of the ACA to its members.

The time honoured chestnut of reviewing our constitution has raised its head again. The discussion can now continue after the minor changes made last year. The question that now needs to be asked though is, do we

p.6 CORROSION & MATERIALS

The review, development and conduct of our existing and additional new courses from other associations such as NACE and SSPC as well as inhouse will continue to be presented to meet the needs of our membership and community.

Through active Branch technical programs, technical group seminars, roadshows and our annual conference, we can continue to grow and provide the forum for all of us to network and continue to develop professionally.

Most Branches organise an active technical program during the year and this has been made easier with additional ACA staff to provide Branch and membership support. I know the Victoria, South Australia and Tasmania Branches at least have utilised this resource for tradeshows and seminars.

The support for all Branches is available to utilise as volunteer time becomes scarcer with the current economic pressures.

Analysis of the ACA technical groups provides an insight to the interests of ACA members: Cathodic Protection

15%

Coatings

22%

Concrete Structures & Buildings

13%

Mining Industry

10%

Petroleum & Chemical Processing Industry

11%

Research

7%

Water & Water Treatment

11%

Welding, Joining & Corrosion

10% 100%

With coatings, cathodic protection and concrete structures & building leading our interest as corrosion mitigation techniques, this explains the number of courses directed to the practical application of corrosion science into the mining, petrochemical and water industries.

Speaking of science, we have a strong technical group dedicated to the science of corrosion and its research with many of our members internationally recognised. Research provides new techniques and better understanding of the complex science of corrosion.

As Brian Cherry points out in his editorial in the last edition, Corrosion & Materials needs to support our researchers with authoritative papers on scientific and technical interests which are well refereed by peer reviewers. Looking at the breakdown of members interest and the courses run by the ACA, this should help guide publishers and editors in developing the content of Corrosion & Materials.

But the content of Corrosion & Materials is more than that, it was and will continue to be the main mechanism for communication between members.

It must reflect our values and interests.

As one member put it to me recently, “It needs to be relevant to the common man”, with a balance of practical and technical articles which reflect the interests of all members.

For those planning ahead, the Tasmanian Branch has decided to host the 2014 Conference in the very northern city of Darwin. The Branch should be congratulated for their selfless decision to promote the ACA into the Northern Territory.

I considered finishing off with a joke about corrosion but, with corrosion all you get is a bad reaction.

See you at Corrosion & Prevention 2012 in Melbourne, 11–14 November.

Cheers.

THE AUSTRALASIAN CORROSION ASSOCIATION INC SEMINAR

Corrosion Issues, Prevention and Asset Rehabilitation in the Water and Waste Water Industry PROUDLY SPONSORED BY:

PROUDLY PRESENTED BY:

Date: Tuesday 26th June 2012 • Venue: Mercure Grosvenor Hotel, Adelaide The cost of corrosion in the water industry in Australia is estimated to be more than $900 million (AUD) annually.

Corrosion in the water industry occurs in both water and waste water networks. This corrosion affects different items of infrastructure including pipelines, pumps, valves, tanks as well as treatment and filtration plants.

In addition to this, a large amount of water and waste water networks in Australasia are reaching the end of their original design lives. To manage this issue, adequate assessment, prevention and rehabilitation methods need to be employed.

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

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

This seminar aims 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.

Time

Schedule

8.15 – 8.45

Registration

8.45 – 9.00

Welcome & Seminar Opening – David Mavros, SA Water

9.00 – 9.40

The Cost and Impact of Corrosion of Infrastructure in the Australian Urban Water Industry Paul Vince, SA Water

9.40 – 10.20

The Need for Intelligent Water Networks for Managing Corrosion Costs Donavan Marney, CSIRO

10.20 - 10.50

Morning tea

10.50 – 11.30

Desalination – An Overview of Durability Issues John Harris, AECOM

11.30 – 12.10

Rehabilitation of Concrete Waste Water Assets Incorporating HDPE Corrosion Protection Liners Nick Critchley, Savcor

12.10 – 13.00

Lunch

13.00 – 13.40

Incorporating Corrosion Kinetics into Drinking Water Distribution System Models to Predict Corrosion Hotspots Jega Jegatheesan, Deakin University

13.40 – 14.20

Case Study – Corrosion Induced Failure of Vertical Stressing Bars in Concrete Water Reservoirs Brad Dockrill, Vinsi Partners

14.20 – 14.50

Afternoon tea

14.50 - 15.30

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

15.30 – 16.20

Open-floor Speakers’ Forum

16.20 – 16.30

Summary & Seminar Close

June 2012 Regsiter now at www.corrosion.com.au

www.corrosion.com.au p.7

CEO’S MESSAGE

Continued development under board leadership The past three years or so have seen dramatic changes in the way ACA operates, membership engagement and the growth of the association.

ACA’s board has successfully transitioned from an operational focus to a governance and strategic development role.

Membership has passed 1650, a tremendous improvement and an increase of 150 since November 2011 alone.

Education and training programs are being reviewed and new products will progressively be released over the next year or so.

Our certification programs operate efficiently and refresher opportunities will be available online before the end of the year.

ACA’s web site has been updated and now includes a substantial database of conference and research papers as a resource that members can access at no cost. This resource will be regularly expanded and we expect an additional 1000 or so papers to be added to the databases during 2012. Members will also be able to access and search past volumes of the Journal of Corrosion Science Engineering and we are working with ICorr to develop a resource sharing

p.8 CORROSION & MATERIALS

partnership which will increase access to papers and other publications for members of both organisations.

Importantly, ACA Foundation Limited has recently been granted Deductible Gift Recipient status by the Australian Taxation Office. DGR status will enable individuals and companies to make income tax deductible donations to the foundation’s scholarship fund, a fund which has been established to support corrosion education. ACA and ACA Foundation Limited are committed to supporting education and development in the education and industry sectors to a value of $100,000 per year.

The board has just about finalised a 3 year strategic plan which will see a change in some aspects of ACA operations. Communication and advocacy of what ACA considers important will receive new resources so that the association can better influence industry and governments on corrosion related issues. A new member of staff will commence during June 2012 and this resource will support the way that ACA communicates with its members, the industries in which it works and those who need to hear a regular reminder of the importance of corrosion and corrosion related issues. This appointment will bring staff appointments to eleven.

Members may contact association staff at any time to discuss the development of the ACA. They also have access to a member of the board who comes from their Branch and is well placed to advance issues which are important at a local level. And ACA’s Branch committees also facilitate the delivery of member services at a local level and play a special role in advancing the interests of members within a specific geographic area.

Whilst the future of a number of technical associations, societies and institutes in our region is under a cloud, ACA has enjoyed a tremendous amount of good weather.

Your board, together with Branches and staff are all working to continue the growth of the association and position ACA as a leader not only in the corrosion related fields but also as a major force in the broad materials sector.

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

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 Types of Coatings

Coatings Selection & Specification (3 days)

Coating Inspection

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 Iron and Steel against exterior Atmospheric Corrosion.

Coating Maintenance

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

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

NEWS

RPM acquires Australian auto repair and industrial coatings business RPM International Inc announced in April that its Rust-Oleum Group has acquired HiChem Paint Technologies Pty. Ltd., a leading Australian manufacturer of automotive aftermarket coatings, as well as specialty coatings for industrial applications and home maintenance.

HiChem manufactures and markets a wide range of vehicle repair, general industrial and home maintenance coatings and products for both do-it-yourselfers and professionals sold under the Motospray and HiChem brands. Based in Hallam, Australia, HiChem has annual sales of approximately $23 million.

“This acquisition expands our presence in the Australian market with well-respected brands and enhances our operational capabilities in the region by providing new distribution channels and local manufacturing. HiChem is an excellent addition to our Rust-Oleum Group and will benefit from RustOleum’s innovative new products, marketing savvy and category management capabilities,” stated Frank C. Sullivan, RPM chairman and chief executive officer.

RPM International Inc., a holding company, owns subsidiaries that are world leaders in specialty coatings, sealants, building materials and related services serving both industrial and consumer markets. RPM’s industrial products include roofing systems, sealants, corrosion control coatings, flooring coatings and specialty chemicals. Industrial brands include Stonhard, Tremco, illbruck, Carboline, Flowcrete, Universal Sealants and Euco.

HiChem will continue to be led by its existing management team, including founder and former owner Ivan Moldovan.

Terms of the transaction were not disclosed.

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NEWS

Research to protect water supply The University of Newcastle is examining pipeline corrosion.

Sydney Water is leading a $16 million international research project to help reduce water main breaks.

The research began in January 2012 and is a collaboration project between universities and other industry leaders to investigate when and why water pipes burst.

The project is the largest international research collaboration led by Australia on buried water pipes. Research activities will include, analysing and forecasting pipe failure mechanisms and pipe loadings, developing models for pipe stresses and deterioration and improving data analysis for condition assessment.

Professor of Civil Engineering at The University of Newcastle, Rob Melchers said that “External pitting corrosion of cast iron and steel water mains continues to be a problem for the water industry. This project is examining older water mains and attempting to build models for the long-term corrosion of pipes. It will use the models developed previously within the

group for the marine and fresh water corrosion of steels to build models for corrosion in-ground, allowing for the influence of varying water table and moisture conditions and the aggressive nature of some soils, including possible microbiological influences”.

The Water Research Foundation and Water Environment Research Foundation in the US, and UK Water Industry Research Ltd (UKWIR), are also partners in the project.

Sydney Water has contributed $5.5 million to the project.

Sydney Water’s Managing Director, Kevin Young said that “Sydney Water is providing a 1.5 km real life pipe test bed in Strathfield to research and assess the condition of pipes. Various access chambers and sensors will be placed along the pipe to trial equipment and make observations”.

The other Australian project participants are Water Corporation, Melbourne Water, Hunter Water, South Australia Water, South East Water and City West Water, Monash University, University of Newcastle and University of Technology Sydney.

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NEWS

Boeing wins contract to paint Royal Australian Air Force fleet Boeing subsidiary Boeing Defence Australia (BDA) has been awarded a three-year contract to perform aircraft surface finishing services for the Royal Australian Air Force (RAAF) aircraft fleet.

and to provide continued employment for employees at our Corrosion Control Facility at RAAF Base Amberley in Queensland.”

BDA’s flexible solution includes setting up a surface finishing services capability at RAAF Base Williamtown, New South Wales.

From 2013, Williamtown will become the primary facility for painting F/A18 classic Hornets, while Amberley will immediately focus on the Hawk127. BDA supplier Air New Zealand will provide paint finishing services for the AP-3C Orion at its facility in Christchurch, with maintenance support provided by Australian Aerospace. The C-130H Hercules will be painted by BDA supplier Flying Colours Aviation in Townsville, North Queensland.

“This win is a testament to BDA’s proven record of exceeding our customers’ expectations with highquality, affordable solutions,” said Kim Gillis, managing director, BDA. “The contract is expected to create up to a dozen new positions in Williamtown

“BDA has a decade of experience providing surface finishing services for the Australian Defence Force, having completed 90 military fixed wing, rotary wing and fast jets at our Amberley facility,” said Murray Brabrook, general manager, Integrated

The contract, worth approximately AU$20 million, involves preparing, remediating and painting AP-3C Orion, C-130H Hercules, F/A-18 Hornet, and Hawk-127 aircraft across multiple locations in Australia and New Zealand.

Carboline has been global leader in the High Performance Coatings industry for over 63 yrs. For corrosion solutions and coating systems that are cost effective, talk to the Protective Coatings Professionals.

Whether it be protective coatings, tank linings or fire-proofing, Carboline’s team of dedicated and trained professionals can assist you in choosing the right solution for your next project.

p.12 CORROSION & MATERIALS

Logistics, BDA. “We look forward to partnering with the Aerospace Materiel Systems Program Office to provide a comprehensive paint solution that ensures ongoing operational effectiveness.”

A C-130H Hercules will be the first aircraft painted in Townsville under the contract in mid-April, followed by a fleet of Hawk-127s at RAAF Base Amberley.

The Royal Australian Air Force’s Hawk-127 fleet will be painted at the Amberley Corrosion Control Facility (CCF).

NEWS

YCG VIC technical evening The Victorian inaugural Young Corrosion Group (YCG) event was held on Wednesday March 28 at the Imperial Hotel, Spring Street, Melbourne.

Far exceeding the expectations of the local YCG committee, registrations for the night soared above 70 delegates from over 30 companies/institutions.

Did the interest derive from the quality of speakers in Ian Godson (Managing Director of Infracorr) and Peter Dove (Principal Materials Consultant at GHD and ACA President)? Was it the city venue? Or was it simply the enthusiasm of youth? Regardless, by the time the speakers were introduced there was barely a seat in the house.

Overall the event was a great success.

“Our goal of providing a forum where our young ruster’s could network, socialise and learn a bit about corrosion mitigation was achieved. Thank you to all who helped us put the event together, including the Victoria Branch for funding the event, the ACA for their support and drive, and Katherine for her efforts in the lead up and on the night” said Dean.

Melbourne. Following this will be the Corrosion Careers Evening on Wednesday 11 July, and we will be running a trivia night later in the year!

Are you a part of the YCG? If you would like to sign up for the YCG emails in your State please contact Katherine Webber on kwebber@corrosion.com.au

The next Victorian technical event will be “Durability Design and Corrosion Monitoring for Engineers”, a joint presentation with YEA-V on Thursday 21st June at Bedford Street, North

Victorian YCG committee representative Dean Ferguson said “The diverse background of participants was one of the most encouraging aspects of the night. Delegates from engineering firms, industry bodies and academia networked with blasters and painters, asset owners and suppliers”.

Peter and Ian’s presentations delivered a simplified overview of complex topics.

Although no one in the room walked away knowing all there is to know about protective coatings or cathodic protection, they did leave with a greater awareness and understanding of the application of these two important corrosion mitigation techniques.

Once the formalities were over there was an opportunity for networking.

Taken wholeheartedly by the attendees, some stayed for another hour, meeting and reacquainting themselves with their peers.

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All your coating supplies and service from one source June 2012 www.corrosion.com.au p.13

NEWS

Warwick-Monash partnership wins major grant Collaborative research between Monash University and its UK partner, the University of Warwick, has been supported with a half million pound investment by the British Government.

chemistry, solar energy, innovative manufacturing, data management and high performance computing, materials and analytical science, and polymer science.

The unique alliance between the universities, established in early 2012, will lead to unprecedented collaboration and international opportunities for both researchers and students.

Warwick’s Vice-Chancellor Professor Nigel Thrift said the EPSRC grant would support activities integral to the wider range of investments planned under the broader Warwick and Monash strategic alliance.

Warwick University was awarded the grant by the UK’s Engineering and Physical Sciences Research Council (EPSRC) under its Building Global Engagements program.

The award will help build strong collaborative partnerships between the Warwick and Monash academic communities in areas of research strength and strategic priority for both universities.

Six core themes have been identified for initial development - sustainable

“The EPSRC funding will help us take this alliance to the next level, establishing even more extensive research links both in terms of breadth and depth, than would otherwise be possible,” Professor Thrift said.

Vice-Chancellor of Monash, Professor Ed Byrne said the grant was an endorsement of the possibilities of the alliance.

complementary nature of our research aspirations and programs,” Professor Byrne said.

“By combining the expertise of academics at both universities we will progress research in critical areas far beyond what each institution could achieve alone.”

The EPSRC funding will assist both universities to identify young research stars to provide a stream of talented individuals whose careers will benefit from international experience at the partner institution.

The partners will also explore how to further internationalise doctoral training programs, and support academic communities at both universities to access new networks and connect to other organisations in the UK, Australia and elsewhere.

“One of the factors in choosing to partner with Warwick was the

Auckland landmark restored An article published in The New Zealand Herald (Landmark restored in the nick of time, May 28, 2012) reported how corrosion was the major factor in the need to restore the Auckland Tepid Baths.

the facade retained and strengthened.

Purification equipment, gas-fired stainless-steel water-heating tanks, sewage pipes and other services can now be easily accessed in a new basement level.”

compressed into it, so condensation, water streaming down walls and dripping from trusses, is eliminated.

The New Zealand Herald reported how the Auckland’s Tepid Baths exposed internal metal roof trusses and the building’s old brick facade were extremely weak, but it was not until builders began taking the structure apart that the scale of the damage became apparent.

The article reported that the roof of the building has seven layers of materials

View of the Tepid Baths swimming pools in Auckland City, New Zealand.

The article quoted Shane Brealey, managing director of NZ Strong, who said “these were salt pools until 1974 and that took its toll. The trusses inside had been corroded from years of salt and moisture and the outside walls had so-called reinforcing bars in them but it was really only hollow pipes.”

Mr Brealey said “the structure was now essentially a new building, up to Building Code standards, with only

p.14 CORROSION & MATERIALS

Architectural firm Jasmax designed the project which will open 23 June 2012.

NEWS

Accreditation of powder coaters The Australasian Institute of Surface Finishing is launching a new Accredited Powder Coater program (APC), with a view to promoting excellence of business standards and performance consistency across the Industry.

“With some 1,000 businesses practicing as self regulated powder coaters, ranging from large producers/ importers of metal, independent job shops, OEM’s, and ‘the down the road coater’, there is a huge disparity in performance and quality within the industry” says AISF Federal President Mr Peter Harrsion.

“There is an increasing need for a more systematic and uniform approach in a very fragmented and competitive market place to achieve improved or higher levels of quality and consistency” he said.

This professional development program enables businesses to

implement a best practice accreditation system to control their powder coating processes. The APC program will be used to monitor, assess and confirm a powder coaters capabilities to comply with all applicable AS/NZS Standards, the Building Code of Australia and other relevant industry specifications and conditions.

The APC program will be launched at the AISF ‘Coating with Confidence’ conference on the 17th – 18th September 2012 in Sydney.

The accreditation system will provide guidance on mandatory and recommended process options.

It will also measure the technical competencies of the applicator, and provide support to AISF members to achieve accredited status.

AISF accredited status indicates to customers and industry professionals alike, a high level of assurance that an applicator has technical skills and competency, follows quality processes and displays ethical behaviour that underpins a strong commitment to excellence.

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

NEWS

Celebrating 100 years of stainless steel The global stainless steel community is marking a century since stainless steels were first created, patented and produced. Over that time, stainless steel has grown to be an integral part of our modern world.

To celebrate, the International Stainless Steel Forum (ISSF) has launched a website www.stainlesssteelcentenary.info in recognition of the history of stainless steel and its innovative applications.

A travelling exhibition about stainless steel was launched in Beijing (China) on 15 May 2012 and will move to a number of other locations around the world.

As well as the list of celebratory events and a centenary video, the website features many interesting facts about stainless steel, stunning images of stainless steel applications from the past century, and a detailed history of this material.

The metallurgists and industrialists who pioneered the stainless steel industry could scarcely have imagined how it would grow. Production has increased dramatically over the past ten years to a record 31 million metric tonnes in 2010 (see Table 1). That growth is only likely to increase as the sustainability benefits of stainless steel become better known.

Its relatively low carbon footprint and 100% recyclability are ensuring that stainless steel will have a major role to play in a sustainable future world.

Although organised under the auspices of ISSF, the 100 Years of Stainless Steel website and exhibition are sponsored

by ISSF and the members of the Team Stainless network. Team Stainless is an informal network of industry associations which represent the stainless steel industry and its main alloying elements. Members include ISSF; Euro Inox; the International Chromium Development Association (ICDA); the International Molybdenum Association (IMOA); and the Nickel Institute.

Year

Production (mmt)

Year

Production (mmt)

2001

19.2

2006

28.7

2002

20.7

2007

28.1

2003

22.8

2008

26.2

2004

24.6

2009

24.9

2005

24.5

2010

31.1

Table 1: Global stainless steel production 2001-2010 (in millions of metric tonnes (mmt))

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p.16 CORROSION & MATERIALS

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23/01/2012 2:00:05 PM

NEWS

ACA gains membership of Standards Australia ACA has joined more than 70 of Australia’s leading industry, government and consumer organisations as a member of Standards Australia. ACA was admitted as a member on 1 June 2012.

Standards Australia’s Members are drawn from bodies and organisations most involved in the development and utilisation of Standards, and that have an interest in the outcomes of Standards Australia’s activities generally.

Chairman of the Board, Directors, and Members of the Accreditation Board for Standards Development Organisations.

The Standards Australia Council comprises the collective of Members’ Councillors and is responsible for the general oversight of standardisation in Australia and the governance of Standards Australia. The Council exercises its control through the following powers as set out in Clause 67 of the Standards Australia Constitution:

ACA has also gained the right to nominate a representative to the Council of Standards Australia.

monitor membership of the Members

Members may appoint one Councillor to represent them in accordance with criteria that reflect the Member’s involvement in the core activity of Standards development.

monitor the Board

Councillors are appointed by Members for the sole purpose of carrying out acts on behalf of the Member (in this case the ACA). This is done by representing the Member’s views in Council, which independently advises the Board of matters of concern to stakeholders.

Under the Standards Australia Constitution, Councillors are delegated authority by Members to elect the

monitor membership of the Council

the main focus being the interchange of issues from Councillors to the Board.

Membership and the nomination of a representative to the Council of Standards Australia is an overdue recognition of ACA’s strong involvement in the standards development process.

The membership is a strategic initiative of ACA’s board and will result in ACA being better able to influence the governance of Standards Australia and the delivery of standards products for the industries in which ACA is involved.

Further information is available from Ian Booth on +61 3 9890 4833 or to ibooth@corrosion.com.au.

ake recommendations to the m Board on activities, procedures and operations – this is exercised by way of a resolution of Council.

Council meets at least annually in November to coincide with the statutory Member’s Annual General Meeting. The annual Council meeting is used by the Board to present to Councillors the performance and plans of the organisation, as well as dealing with a number of procedural matters.

When appropriate a further Council meeting is held during the year with

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

NEWS

ACA welcomes new members Corporate Gold Members IMATECH www.imatech.com.au Imatech Abrasion & Corrosion offers materials technology solutions for abrasion & corrosion to the mining, refining, energy and water industries.

Their national network of facilities offers experienced workshop and site application of ceramic reinforced composites and high alumina ceramics.

IMATECH combine the most up to date technology with unique innovative solutions to overcome traditional industry problems.

Corporate Silver Members Elite Concrete Protection & Repair Elite Concrete Protection & Repair has over 20 years of experience as a specialist contracting service using innovative solutions, techniques and materials to repair concrete & steel structures reinstating the structural integrity and durability of assets. Elite provide solutions for the commercial, industrial, mining and residential markets.

services to the Oil & Gas industry in New Zealand and many other countries. P&P has personnel across the Process, Mechanical and Pipeline, Instrumentation & Electrical, Civil & Structural engineering disciplines and offers Procurement, Document Management and Safety Management, Facilitation and Analysis (HAZOP, HAZID, SMS, SIL) services.

Supreme Metal Component Solutions www.supremesteel.co.nz Supreme Metal Component Solutions is a precision casting and metal component manufacturing company.

They specialise in fabrication and machining conversions as well as ‘designed for investment casting’ components. Industry sectors they service include; defence, mining, oil field services, fluid handling, food and beverage equipment, earth-moving, hand tools and marine. They have a metallurgical and mechanical design service allowing them to play an integral role in supporting customers’ design processes.

Oliver Spray Equipment www.oliverspray.com.au Oliver Spray Equipment has been supplying and installing spray painting, blast cleaning and dust & fume control solutions to Australian industry for over 25 years. The group includes Advanced Airflow Technology, which manufactures spray painting booths and dust extraction solutions. Oliver Spray Equipment believes strongly in products that provide return on investment by improving efficiency through material and time savings and reduced maintenance.

Corporate Bronze Members Andersal Pty Ltd www.andersal.com.au Andersal is a Sydney-based concrete repair and waterproofing contractor.

Andersal support the ACA and have board level representation with the affiliated organisation, ACRA, from the General Manager Henk van den Heuvel over the last 11 years. Andersal take pride in understanding and fixing the root cause of the problem and enjoy a reputation since inception in 1987 for quality long-term solutions.

Plant & Platform Consultants Ltd (P&P) www.pandp.co.nz P&P was established in 1986 and has since provided engineering

C.P. Plating Pty Ltd www.cpplating.com.au C.P. Plating Pty Ltd has provided surface finishing services since 1983

and specialises in processing high volume ferrous articles for zinc electroplating. A powder coating service for ferrous/non-ferrous metallic articles is also offered. Items up to 6.1 x 1.4 x 0.55 m can be electroplated. The powder coating oven has an internal capacity of 3.6 x 1.6 x 1.2 m.

Inspec Consulting www.inspec.net.au InSpec know there is no such thing as a standard coating scheme. Whatever the size and type of facility, InSpec Consulting provide onsite coating inspection services & tailored criteria based surveys & engineered coating solutions to meet any specific real life set of circumstances.

Integrated Petroleum Solutions Integrated Petroleum Solutions specialise in sacrificial and impressed current installations, LPG and fuel tank CP monitoring and fault finding and water and gas main CP monitoring. IPS is located across Australia offering their clients a national service and has over 20 years’ experience in Fuel and LPG service work servicing some of the biggest names in the petroleum industry.

MAC Coatings Pty Ltd www.maccoatings.com.au MAC Coatings specialise in surface preparation and the application of protective coatings and linings for long term asset protection. The company holds ISO accreditation for three standards - Quality, OH&S and Environment. Their key works include, but are not limited to: Abrasive Blasting, High Build Industrial Coatings, Commercial Coatings, High Pressure Water Blasting, Floor Coatings, Denso Wrapping and Non Slip Coatings.

Individual Members Name

Company

Branch

Basam Al-Qaisi

Wattyl

Western Australia

Faisal Alanazi

University of New South Wales

New South Wales

Badieh Soleimani Amiri

Curtin University

Western Australia

Vinod Anand

Curtin University

Western Australia

Leo Angelikas

TAFE Panorama

South Australia

Ash Arya

CSP Coating Systems

New Zealand

Heath Boelen

GHD

Victoria

Ryan Bonadio

G & S Painting Services

New South Wales

p.18 CORROSION & MATERIALS

NEWS

Tomislav Bosnjak

Monadelphous

Western Australia

Tony Brown

Duratec Australia

Western Australia

Paul Bryer

Select Solutions

Victoria

Francis Carroll

APA Group

Queensland

Jessica Chumak

Parlin Pty Ltd

Newcastle

Paul Court

Maxcon Industries

Queensland

Wayne Cullen

Western Australia

Jonathon Darubia

Oil Search (PNG) Ltd

Australasia

Nicholas Davis

University of Adelaide

South Australia

Andrew Hyde

South Australia

Sajjad Jafari

Monash University

Victoria

Rouzbeh Karimi

Curtin University

Western Australia

Tyson Kelly

Transpacific Industrial

Queensland

Matt Lancier

Woodside Energy

Western Australia

Joshua Liwszyc

Jetcut Pty Ltd

Western Australia

Rob MacDonald

CBH

Western Australia

Neil McCleary

Melara Holdings Pty Ltd

Western Australia

John Kittle

Victoria

Christopher McDonnell

Queensland

Neil Marshall

New Zealand

John May

Quality Maritime Surveyors

South Australia

Jordan May

Quality Maritime Surveyors

South Australia

Mike Oehler

Curtin University

Western Australia

Andrew Ouwejan

Metlab Ltd

New Zealand

Yoghesh Pabbi

TAFE Panorama

South Australia

Max Parker

CQ University

Queensland

Richard Parker

Townsville Engineering Industries

Queensland

Jarrad Pearson

P & C Maintenance

Western Australia

David Perbey

Worley Parsons

Newcastle

Elizabeth Perucich

Newcastle

Kym Revill

Desk Top Image

South Australia

Nicholas Riley

Exxon Mobil

Victoria

Heide Saenger

GE Oil & Gas

Western Australia

Mark Schilling Khalid Shaikh

Australasia Munters Pty Ltd

New South Wales

Melissa Slowig

Curtin University

Western Australia

Andrew Smith

Akzo Nobel

Queensland

Chris Teggelove

Complete Metal Protection

Victoria

Maruti Thakur

TAFE Panorama

South Australia

Pranom Thiwwohan

Clough (Thailand) Pty Ltd

Australasia

Michael Verity

Kaelus

Queensland

Anthony Wright Michael Wright

Western Australia RMIT University

Victoria

Lyndon Yeo

Queensland

Jong Ho Yong

South Australia

Angelo Zaccari

Aben Technical Services

Victoria

June 2012  www.corrosion.com.au  p.19

BRANCH NEWS

South Australia Branch visit iron casting foundry On the 27th March, the ACA South Australia Branch had the pleasure of a technical tour of Intercast & Forge. The tour guides were Mr Brett Lawrence (General Manager) and Emanuel Mallia (Quality Engineer).

The Intercast business was founded in 1854, moving to the current location at Schumacher Road in Wingfield in 1998. Since its formation, Intercast & Forge has been a world leader in iron casting technology and innovation. It is the largest production iron foundry in Australia specialising in Grey and Ductile (SG) iron producing in excess of

55,000 tonnes of iron castings per year for customers worldwide.

The facilities are world class using advanced, high tech machines with a very high emphasis on quality assurance and quality control.

The tour was arranged by the ACA SA Branch who invited members from Materials Australia and AINDT to attend. Over 20 members attended and the tour lasted for over an hour of the entire site visiting: The Metal Lab

Furnace Deck Moulding Machine Shell Core Operations Knock Out and Finishing Areas.

The technical tour was followed by a sausage sizzle and networking opportunity provided by Intercast & Forge at the facility. The ACA SA Branch are very grateful to Brett Lawrence for giving his valuable time and effort in allowing members to visit Intercast & Forge.

SA Branch student night On the 10th of May, the South Australia Branch held its first Student Night for 2012 at The Seven Stars Hotel. The evening was aimed at tertiary students to introduce them to the ACA and to provide a networking session with various industry representatives.

David Mavros of SA Water made a presentation about his experiences of being a young corrosion engineer in the water industry. David described what his role at SA Water involves which ranges from protecting infrastructure young and old.

The presentation was followed by the students interacting with several of the ‘older’ ACA members who provided an opportunity for the students to find out more about other

p.20 CORROSION & MATERIALS

aspects of the corrosion industry over a pizza and drinks.

The night was a successful event for the SA Branch with a further six new student members joining as ACA members (five from Panorama

TAFE and one from the University of Adelaide) and 10 ACA members in attendance.

A second SA Branch Student night will be held on the 15th of August 2012.

BRANCH NEWS

ACA Auckland Division May Meeting Report The Auckland Division meeting held at The Landing hotel on the 10th May was addressed by Warren Green, a Partner and corrosion engineer at Vinsi Partners Consulting Engineers, based in Sydney, Australia. Warren has over 25 years’ experience in corrosion engineering. He is also a long-standing member of ACA in which he has held various senior ACA roles. The title of the presentation was “Port Botany Expansion Project – Planning and Corrosion Management”.

The Port Botany expansion project (PBE) comprises a new container terminal on the shore of Botany Bay, Sydney covering an area of about 63 hectares. Durability assessment, durability design and durability planning were an integral part of the delivery phases to minimise long term deterioration of the structural assets and components within the PBE project, which has a design life of 100 years. Concrete and non-concrete assets exist. Design life requirements, environment classification, deterioration mechanisms (including corrosion), durability risk assessment, design solutions, ongoing monitoring, QC during construction and maintenance requirements were all to be addressed.

The presentation was delivered in two parts. Warren first used a flow chart to explain what is meant by Durability Planning on a large infrastructure project such as PBE. He emphasised that for Durability Planning to be successful, materials engineers must be integrated into the design team, and the team must embrace an overarching durability philosophy. The Durability Plan provides the link between design, construction and maintenance on the project. The asset owner becomes part of the durability team and accepts responsibility for monitoring of asset performance after the contract is complete. This includes ongoing condition assessment of all metal, plastic, timber and concrete structures on the project.

In the second part, Warren outlined the workscope and construction of the PBE project. This included shipping berths (1.6 km long), various bridges, roadways and a lot of ancillary infrastructure. He described the Project/Scope/Technical Capability Requirements (PSTR) documentation required on the PBE project in order that the assets would provide specified design lives of 40 - 100 years. A comprehensive study of the environmental conditions at

Port Botany was an important part of the PSTR. The PSTR incorporated specifications for all concrete and non-concrete component materials, including carbon steel, stainless steels, aluminium alloys and geo-textiles.

In conclusion, Warren outlined the benefits of Durability Planning on infrastructure projects, such as meeting a 100 year design life, assuring the asset material performance, reducing maintenance and having a known life cycle cost for all project assets. After an extensive Q&A session, the Chairman Mark Sigley thanked Warren for his excellent presentation.

Warren Green gives the presentation at the ACA Auckland meeting

Victoria Branch trade night Remember the good old days when paint companies would hold a simple trade show, hand out a few painters caps and t-shirts over a quite drink while they spruiked their wares?

Well it all came back to Melbourne on 9 May this year with all the major coating players in one room as the Victoria Branch in conjunction with Surface Coatings Association Australia (SCAA) held a joint trade show. The event attracted 70 registrants who appreciated the opportunity to catch up with most of the many coating suppliers in one place at the same time.

Starting at 4pm to catch the early leavers from their city office in Melbourne’s CBD, a steady stream of visitors passed through the exhibits until the close at 8 pm. They all enjoyed a few drinks, finding and discussing the latest in various coating developments, sharing coating problems and networking for future contacts.

The evening would not have been a success without the generous support of the exhibitors: Blygold ommercial Industrial Painting C Services Denso Australia Dulux Protective Coatings International Protective Coatings Parchem Construction Supplies

Petro Coating Systems Phillro Industries PPG Wattyl Zintec Corrosion Solutions Thanks to the able assistance of Solange Brave who as Branch and Membership Support Officer handled the registrations and venue organising.

Peter Dove of GHD and Rebecca Lee of Bayer Material Science enjoying the trade show

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

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 Petroleum & Chemical Process Industries Technical Group. This proved to be quite difficult given the general title of the Technical Group. Different search strategies were used, and results of the search can be found in Table 1.

A search of SAI Global at http:// www.saiglobal.com/online/ for new Standards, amendments or drafts of AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI, and Standards and

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

amendments of ISO & IEC published from 20th March 2012 to 21st May 2012 was conducted using the following key words and key word groups: durability corrosion or corrosivity or corrosive; but not anodizing or anodize(d) paint or coating; but not anodizing or anodize(d) galvanize or galvanized or galvanizing cathode or cathodic anode or anodic corrosion and concrete, or concrete and coatings The search results showing 64 new Standards Drafts and Amendments in the general search can be found in Table 4. There were 2 new AS or AS/NZS Standards or Draft Publications.

Table 1, below, lists all current publications and standards relating to “petroleum and corrosion” (104 publications), Table 2 “gas and corrosion” (158 publications) and Table 3 “chemical and corrosion” (115 publications) as found at https:// infostore.saiglobal.com/store.

Table 1. Title search by publisher with keywords ‘petroleum and corrosion’ – 104 publications found, 0 from AS/ASNZS Results by Publisher National Standards Authority of Ireland

9

Comite Europeen de Normalisation

8

Association Francaise de Normalisation

7

International Organization for Standardization

7

Italian Standards

7

British Standards Institution

6

Nederlands Normalisatie Instituut

6

Polish Committee for Standardization

6

Belgian Standards

5

German Institute for Standardisation (Deutsches Institut für Normung)

5

Norwegian Standards (Norges Standardiseringsforbund)

5

Osterreichisches Normungsinstitut

5

Standardiserings-Kommissionen I Sverige

5

Swiss Standards

5

Asociacion Espanola de Normalizacion

4

NACE International

4

Interstandard (Russia)

3

American Society for Testing and Materials

2

Standardization Administration of China

2

Bureau of Indian Standard

1

p.22 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Energy Institute (formerly Institute of Petroleum)

1

Ford Motor Company

1

Results by Subject - Petroleum and related technologies – 88 results Equipment for petroleum and natural gas industries

50

Hydraulic fluids

32

Lubricants, industrial oils and related products

4

Petroleum products in general

3

Fuels

1

Petroleum products and natural gas handling equipment

1

Results by Subject - Metallurgy – 21 results Iron and steel products

18

Corrosion of metals

3

Results by Subject - Fluid systems and components for general use - 9 results Pipeline components and pipelines

9

Results by Subject - Chemical technology - 1 result Equipment for the chemical industry

1

Results by Subject - Manufacturing engineering - 1 result Surface treatment and coating

1

Results by Subject - Paint and colour industries - 1 result Paint coating processes

1

Results by Subject - Road vehicles engineering - 1 result Road vehicle systems

1

Results by Subject – Testing - 1 result Environmental testing

1

Results by Publication IP 125:2008

Determination Of Cast Iron Corrosion Characteristics Of Petroleum Products

NACE 34103:2003

Overview Of Sulfidic Corrosion In Petroleum Refining

ASTM D1838-11

Standard Test Method for Copper Strip Corrosion by Liquefied Petroleum (LP) Gases

ASTM D7548-09

Standard Test Method for Determination of Accelerated Iron Corrosion in Petroleum Products

NACE SP 01 76:2007

Corrosion Control Of Submerged Areas Of Permanently Installed Steel Offshore Structures Associated With Petroleum Production

NACE SP 02 08:2008

Internal Corrosion Direct Assessment Methodology For Liquid Petroleum Pipelines

FORD WSS M21P32 A:1999

Engineering Material Specification - Corrosion Protective Coating, Petroleum Type, Sealer Compound

SS EN ISO 13680 Ed. 3 (2010)

Petroleum And Natural Gas Industries - Corrosion-Resistant Alloy Seamless Tubes For Use As Casing, Tubing And Coupling Stock - Technical Delivery Conditions

SS EN ISO 21457 Ed. 1 (2010)

Petroleum, Petrochemical And Natural Gas Industries - Materials Selection And Corrosion Control For Oil And Gas Production Systems

NS EN ISO 4404-1 Ed. 1 (2007)

Petroleum And Related Products - Determination Of The Corrosion Resistance Of Fire-resistant Hydraulic Fluids - Part 1: Water-containing Fluids

SS EN ISO 4404-1 Ed. 1 (2006)

Petroleum And Related Products - Determination Of The Corrosion Resistance Of Fire-resistant Hydraulic Fluids - Part 1: Water-containing Fluids

SS EN ISO 4404-2 Ed. 2 (2011)

Petroleum And Related Products - Determination Of The Corrosion Resistance Of Fire-Resistant Hydraulic Fluids - Part 2: Non-Aqueous Fluids

NS EN ISO 4404-2:201)

Petroleum And Related Products - Determination Of The Corrosion Resistance Of Fire-Resistant Hydraulic Fluids - Part 2: Non-Aqueous Fluids

I.S. EN ISO 13680:2010

Petroleum and Natural gas Industries - Corrosion-resistant Alloy Seamless Tubes for use as Casing, Tubing and Coupling Stock - Technical Delivery Conditions

ISO 13680:2010

Petroleum and natural gas industries - Corrosion-resistant alloy seamless tubes for use as casing, tubing and coupling stock - Technical delivery conditions

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

ACA STANDARDS UPDATE

Table 2. Title search by publisher with keywords ‘gas and corrosion’ – 158 publications found, 2 from AS/ASNZS Results by Publisher National Standards Authority of Ireland

12

Association Francaise de Normalisation

11

British Standards Institution

9

Osterreichisches Normungsinstitut

9

Standardiserings-Kommissionen I Sverige

9

Nederlands Normalisatie Instituut

8

Belgian Standards

7

Comite Europeen de Normalisation

7

German Institute for Standardisation (Deutsches Institut für Normung)

7

International Organization for Standardization

7

Results by Subject - Metallurgy – 51 results Corrosion of metals

33

Iron and steel products

18

Ferrous metals

6

Results by Subject - Petroleum and related technologies – 51 results Equipment for petroleum and natural gas industries

50

Petroleum products and natural gas handling equipment

1

Results by Subject - Electronics – 26 results Electromechanical components for electronic and telecommunications equipment

26

Results by Subject – Testing – 15 results Environmental testing

15

Results by Subject - Fluid systems and components for general use – 15 results Pipeline components and pipelines

11

Fluid storage devices

3

Fluid power systems

1

Results by Subject – Electrical engineering – 3 results Electrical engineering in general

2

Insulating materials

1

Results by Subject – Aircraft and space vehicle engineering – 2 results Aerospace fluid systems and components

1

Fasteners for aerospace construction

1

Results by Publication SAE MA 2538:1992 (R2004)

Gasket, Metal C-ring Seal Nickel Alloy, Corrosion And Heat Resistant, Metric Procurement Specification For

SAE AS 7283:2004

Gaskets, Type 20 Engine Accessory Drive Corrosion Resistant Steel Screen Reinforced Controlled Performance

SAE AS 7325:2001 (R2006)

Gasket, Metal O-ring Corrosion And Heat Resistant Steel Procurement Specification For

ASTM D1838-11

Standard Test Method for Copper Strip Corrosion by Liquefied Petroleum (LP) Gases

ASTM F363-99(2011)

Standard Test Method for Corrosion Testing of Gaskets

JIS Z 2291:2004

Method For High-temperature Gaseous Corrosion Test Of Metallic Materials

EEMUA 194:2012

Guidelines For Materials Selection And Corrosion Control For Subsea Oil And Gas Production Equipment

GB/T 19745-2005

Corrosion tests in artificial atmosphere at very low concentrations of polluting gas(es)

NACE 1C187:2005

Use Of Galvanic Probe Corrosion Monitors In Oil And Gas Drilling And Production Operations

PN EN 60068-2-60:2004

Environmental Testing - Part 2: Tests - Test Ke: Flowing Mixed Gas Corrosion Test

p.24 CORROSION & MATERIALS

ACA STANDARDS UPDATE

AS 60068.2.60-2003

Environmental testing - Tests - Test Ke: Flowing mixed gas corrosion test

QPL 8188 Revision 19 Notice 1

Corrosion Preventive Oil, Gas Turbine Engine Aircraft Synthetic Base - Revision 19 Notice 1

DEFSTAN 91-93/2:2001

Lubricating Oil, Gas Turbine Engine, Synthetic: Corrosion Inhibited, Maritime Joint Service Designation: Ox-22

JIS C 60068-2-60:1999

Environmental testing - Part 2: Tests - Test Ke: Flowing mixed gas corrosion test

CGA C 17:2008

Methods To Avoid And Detect Internal Gas Cylinder Corrosion

AS 4955.1-2003

Transportable gas cylinders - Compatibility of cylinder and valve materials with gas contents - Metallic materials

Table 3. Title search by publisher with keywords ‘chemical and corrosion’ – 115 publications found, 1 from AS/ASNZS Results by Publisher British Standards Institution

11

Italian Standards

8

Association Francaise de Normalisation

7

German Institute for Standardisation (Deutsches Institut für Normung)

7

Asociacion Espanola de Normalizacion

6

Belgian Standards

6

Comite Europeen de Normalisation

6

National Standards Authority of Ireland

6

Nederlands Normalisatie Instituut

6

Norwegian Standards (Norges Standardiseringsforbund)

6

Osterreichisches Normungsinstitut

6

Polish Committee for Standardization

6

Standardiserings-Kommissionen I Sverige

6

Swiss Standards

6

American Society for Testing and Materials

5

International Organization for Standardization

5

Standardization Administration of China

5

NACE International

2

Society of Automotive Engineers

2

Bureau of Indian Standard

1

Interstandard (Russia)

1

Standards Australia

1

Results by Subject – Manufacturing engineering – 77 results Surface treatment and coating

77

Results by Subject – Construction materials and building – 13 results Construction materials

12

Structures of buildings

1

Results by Subject – Chemical technology – 7 results Products of the chemical industry

5

Equipment for the chemical industry

2

Results by Subject – Metallurgy – 4 results Corrosion of metals

3

Testing of metals

1

Results by Subject – Aircraft and space vehicle engineering – 3 results Materials for aerospace construction

2

Ground service and maintenance equipment

1

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

ACA STANDARDS UPDATE

Results by Subject – Environment. Health protection. Safety – 3 results Protection against dangerous goods

3

Results by Subject – Health care technology – 2 results Laboratory medicine

2

Results by Subject – Electrical engineering – 1 result Semiconducting materials

1

Results by Subject – Rubber and plastic industries – 1 result Manufacturing processes in the rubber and plastics industries

1

Results by Subject – Shipbuilding and marine structures – 1 result Shipbuilding and marine structures in general

1

Results by Publication GB 20593-2006

Safety rules for classification, precautionary labelling and precautionary statements of chemicals - Skin corrosion/irritation

GB/T 21604-2008

Chemicals - Test method of acute dermal irritation/corrosion

GB/T 21609-2008

Chemicals - Test method of acute dermal irritation/corrosion

ASTM F1111-08b

Standard Test Method for Corrosion of Low-Embrittling Cadmium Plate by Aircraft Maintenance Chemicals

ASTM F482-09

Standard Practice for Corrosion of Aircraft Metals by Total Immersion in Maintenance Chemicals

ASTM F483-09

Standard Practice for Total Immersion Corrosion Test for Aircraft Maintenance Chemicals

I.S. EN ISO 28706-1:2011

Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion - Part 1: Determination of Resistance to Chemical Corrosion by Acids at Room Temperature

ISO 28706-1:2008

Vitreous and porcelain enamels - Determination of resistance to chemical corrosion - Part 1: Determination of resistance to chemical corrosion by acids at room temperature

I.S. EN ISO 28706-2:2011

Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion - Part 2: Determination of Resistance to Chemical Corrosion by Boiling Acids, Boiling Neutral Liquids And/or Their Vapours

ISO 28706-2:2008

Vitreous and porcelain enamels - Determination of resistance to chemical corrosion - Part 2: Determination of resistance to chemical corrosion by boiling acids, boiling neutral liquids and/or their vapours

I.S. EN ISO 28706-3:2011

Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion - Part 3: Determination of Resistance to Chemical Corrosion by Alkaline Liquids Using a Hexagonal Vessel

ISO 28706-3:2008

Vitreous and porcelain enamels - Determination of resistance to chemical corrosion - Part 3: Determination of resistance to chemical corrosion by alkaline liquids using a hexagonal vessel

I.S. EN ISO 28706-4:2011

Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion - Part 4: Determination of Resistance to Chemical Corrosion by Alkaline Liquids Using a Cylindrical Vessel

ISO 28706-4:2008

Vitreous and porcelain enamels - Determination of resistance to chemical corrosion - Part 4: Determination of resistance to chemical corrosion by alkaline liquids using a cylindrical vessel

I.S. EN ISO 28706-5:2011

Vitreous and Porcelain Enamels - Determination of Resistance to Chemical Corrosion - Part 5: Determination of Resistance to Chemical Corrosion in Closed Systems

AS 2311.3.11-2004

Methods of test for metallic and related coatings - Corrosion and related property tests - Chemical residue tests

Table 4. 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 20 March 2012 to 21 May 2012 Key word search on ‘durability’- 8 citations found, 2 from AS/NZS AS 3706.11-2012

Geotextiles - Methods of test-Determination of durability - Resistance to degradation by light, heat and moisture

AS 3706.13-2012

Geotextiles - Methods of test-Determination of durability - Resistance to certain microbiological agents

SR CEN/TS 15912:2012

Durability of Reaction to Fire Performance - Classes of Fire-retardant Treated Wood-based Product in Interior and Exterior end use Applications

I.S. EN 62059-32-1:2012

Electricity Metering Equipment - Dependability - Part 32-1: Durability - Testing of the Stability of Metrological Characteristics by Applying Elevated Temperature (iec 62059-32-1:2011 (eqv))

I.S. EN 747-1:2012

Furniture - Bunk Beds and High Beds - Part 1: Safety, Strength and Durability

PD CEN/TS 15912:2012

Durability of reaction to fire performance. Classes of fire-retardant treated wood-based product in interior and exterior end use applications

BS EN 62059-32-1:2012

Electricity metering equipment. Dependability. Durability. Testing of the stability of metrological characteristics by applying elevated temperature

p.26 CORROSION & MATERIALS

ACA STANDARDS UPDATE

BS EN 747-1:2012

Furniture. Bunk beds and high beds. Safety, strength and durability requirements

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 19 citations in all, 0 AS/NZS citations ISO/FDIS 14802

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

ISO/FDIS 17752

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

ISO/FDIS 4404-1

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

I.S. EN 3182:2012

Aerospace Series - Ball Bearings, Rigid in Corrosion Resisting Steel Cadmium Plated, for Control Cable Pulleys - Dimensions and Loads

I.S. EN 3278:2012

Aerospace Series - Sleeves, Tubular, Protruding Head, in Corrosion Resisting Steel, Passivated (0,25 mm Wall Thickness)

I.S. EN 4687:2012

Aerospace Series - Paints and Varnishes - Chromate Free non Corrosion Inhibiting two Components Cold Curing Primer for Military Application

I.S. EN 4688:2012

Aerospace Series - Paints and Varnishes - Corrosion Inhibiting two Components Cold Curing Primer for Military Application

I.S. EN 61701:2012

Salt Mist Corrosion Testing of Photovoltaic (pv) Modules (iec 61701:2011 (eqv))

12/30244462 DC BS BS 8573.

Electric cables. Thermosetting insulated, non-armoured cables with a voltage of 600/1 000 V, for fixed installations, and having low emission of smoke and corrosive gases when affected by fire

12/30248745 DC BS 7211.

Electric cables. Thermosetting insulated, non-armoured cables for voltages up to and including 450/750 V for electric power and lighting and having low emission of smoke and corrosive gases when affected by fire

12/30258734 DC BS EN 16407-1.

Non-destructive testing. Radiographic inspection of corrosion and deposits in pipes by X- and gamma rays. Part 1. Tangential radiographic inspection

12/30258737 DC BS EN 16407-2.

Non-destructive testing. Radiographic inspection of corrosion and deposits in pipes by X- and gamma rays. Tangential radiographic inspection

BS ISO 21608:2012

Corrosion of metals and alloys. Test method for isothermalexposure oxidation testing under hightemperature corrosion conditions for metallic materials

BS EN 3182:2012

Aerospace series. Ball bearings, rigid in corrosion resisting steel cadmium plated, for control cable pulleys. Dimensions and loads

BS EN 3278:2012

Aerospace series. Sleeves, tubular, protruding head, in corrosion resisting steel , passivated (0,25 mm wall thickness)

BS EN 61701:2012

Salt mist corrosion testing of photovoltaic (PV) modules

JIS G 0576:2001/Amendment 1:2012

Stress corrosion cracking test in chloride solution for stainless steels (Amendment 1

DIN EN 4704 (2012-05)

Aerospace series - Tartaric-Sulphuric-Acid anodizing of aluminium and aluminium wrought alloys for corrosion protection and paint pre-treatment (TSA); German and English version EN 4704:2012

DIN EN ISO 9226 (2012-05)

Corrosion of metals and alloys - Corrosivity of atmospheres - Determination of corrosion rate of standard specimens for the evaluation of corrosivity (ISO 9226:2012)

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 33 publications found, 0 from AS/NZS ISO/FDIS 13632

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

ISO/FDIS 2812-3

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

ISO/DIS 3233-2

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

ISO/FDIS 9117-6

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

I.S. EN 4689:2012

Aerospace Series - Paints and Varnishes - two Components Cold Curing Polyurethane Finish - High Flexibility and Chemical Agent Resistance for Military Application

BS EN ISO 8503-1:2012

Preparation of steel substrates before application of paints and related products . Surface roughness characteristics of blast-cleaned steel substrates. Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blast-cleaned surfaces

BS EN ISO 8503-2:2012

Preparation of steel substrates before application of paints and related products . Surface roughness characteristics of blast-cleaned steel substrates. Method for the grading of surface profile of abrasive blastcleaned steel. Comparator procedure

BS EN ISO 8503-3:2012

Preparation of steel substrates before application of paints and related products . Surface roughness characteristics of blast-cleaned steel substrates. Method for the calibration of ISO surface profile comparators and for the determination of surface profile. Focusing microscope procedure

BS EN ISO 8503-4:2012

Preparation of steel substrates before application of paints and related products . Surface roughness characteristics of blast-cleaned steel substrates. Method for the calibration of ISO surface profile comparators and for the determination of surface profile. Stylus instrument procedure

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

ACA STANDARDS UPDATE

DIN EN ISO 11127-1 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 1: Sampling (ISO 11127-1:2011)

DIN EN ISO 11127-2 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 2: Determination of particle size distribution (ISO 11127-2:2011)

DIN EN ISO 11127-3 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 3: Determination of apparent density (ISO 11127-3:2011)

DIN EN ISO 11127-4 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 4: Assessment of hardness by a glass slide test (ISO 11127-4:2011)

DIN EN ISO 11127-5 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 5: Determination of moisture (ISO 11127-5:2011)

DIN EN ISO 11127-6 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 6: Determination of water-soluble contaminants by conductivity measurement (ISO 11127-6:2011)

DIN EN ISO 11127-7 (2012-04)

Preparation of steel substrates before application of paints and related products - Test methods for nonmetallic blast-cleaning abrasives - Part 7: Determination of water-soluble chlorides (ISO 11127-7:2011)

ISO 11347:2012

Ships and marine technology - Large yachts - Measurement and assessment of the visual appearance of coatings

ISO 5429:2012

Coated abrasives - Flap wheels with incorporated flanges or separate flanges

ISO/DIS 13179-1

Implants for surgery - Plasma sprayed coatings of unalloyed titanium - Part 1: General

12/30212355 DC BS ISO 13179-1.

Implants for surgery. Plasma sprayed coatings of unalloyed titanium. Part 1. General requirements

12/30255284 DC BS EN 1096-4

Glass in building. Coated glass. Part 4. Evaluation of conformity. Product standard

12/30255914 DC BS ISO 5950.

Electrolytic tin-coated cold-reduced carbon steel sheet of commercial and drawing qualities

12/30258228 DC BS EN 15814 AMD1.

Polymer modified bituminous thick coatings for waterproofing. Definitions and requirements

BS ISO 15208:2012

Continuous hot-dip zinc-coated twin-roll cast steel sheet of commercial quality

BS ISO 15211:2012

Continuous hot-dip zinc-coated twin-roll cast steel sheet of structural quality and high strength steel

BS EN 4443:2012

Aerospace series. Nuts, elliptical clinch, self-locking, MJ threads, in heat resisting steel FE-PA2601 (A286), MoS2 coated, Classification: 900 MPa (at ambient temperature)/425°C

DIN EN 1096-1 (2012-04)

Glass in building - Coated glass - Part 1: Definitions and classification

DIN EN 1096-2 (2012-04)

Glass in building - Coated glass - Part 2: Requirements and test methods for class A, B and S coatings

DIN EN 1096-3 (2012-04)

Glass in building - Coated glass - Part 3: Requirements and test methods for class C and D coatings

DIN EN ISO 13123 (2012-04)

Metallic and other inorganic coatings - Test method of cyclic heating for thermal-barrier coatings under temperature gradient (ISO 13123:2011)

DIN EN ISO 1891-2 (2012-04) (Draft)

Fasteners - Terminology - Part 2: Vocabulary and definitions for coatings (ISO/DIS 1891-2:2012); Multilingual version prEN ISO 1891-2:2012

DIN EN 2491 (2012-04)

Aerospace series - Molybdenum disulphide dry lubricants - Coating methods; German and English version EN 2491:2011

DIN EN 4443 (2012-05)

Aerospace series - Nuts, elliptical clinch, self-locking, MJ threads - in heat resisting steel FE-PA2601 (A286), MoS<(Index)2> coated, Classification: 900 MPa (at ambient temperature)/425°C; German and English version EN 4443:2012

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 Standard publications found.

Key word search on ‘cathode’ or 'cathodic' -1 corrosion related Standard publications found; 0 AS/NZS Publications ISO/DIS 15589-1

Petroleum, petrochemical and natural gas industries - Cathodic protection of pipeline systems - Part 1: On-land pipelines

Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 1 Standard publications found – 0 from AS/ANZS JIS G 0579:2007/ Amendment 1:2012

Method of anodic polarization curves measurement for stainless steels (Amendment 1)

Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 Standard publications found Keyword Search on 'anodize' or ‘anodized’ - 2 publications found ISO/TR 16689:2012

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

DIN EN 4704 (2012-05)

Aerospace series - Tartaric-Sulphuric-Acid anodizing of aluminium and aluminium wrought alloys for corrosion protection and paint pre-treatment (TSA); German and English version EN 4704:2012

p.28 CORROSION & MATERIALS

COATINGS GROUP MEMBER PROFILE

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

A: Cox Coating was established in1989 as a group of companies in the AntiCorrosion industry, however our site itself has been around since 1976.

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

A: When we first started our AntiCorrosion company currently at 34 Leslie Rd Laverton North, we employed up to 37 employees 7 days per week over 2 shifts.

Q: How many do you currently employ?

A: As a group we employ about 15 employees, however at Cox Coating it’s mainly Contractors due to the unstable economy in Australian Manufacturing and everything coming offshore.

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

A: Our other company does (Spraychief Industries Pty Ltd). Cox Coating itself does not, then again we have thought about it and still do, if the right opportunity came along.

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

A: At Cox Coating our main core of business is; Shot Blasting, Industrial Coating, Heat Bonded Epoxies, Powder Coating, Waterjet Blasting and Lead Removal.

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

A: All of the above as well as Road Tankers and Refurbishment.

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

A: Both.

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

A: Cox Coating is situated on a 2.5 acre site, our in-house painting area under cover is 1.5 acres with four separated paints sections. Our in-house blast room can run two operators, so depending on size of material, we can complete 20 to 30 tonnes per day.

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

A: Yes, we pride ourselves on quality control and completing all works put to us in a job process. Any further touch ups or painting works required on site are always completed and we are more than happy to do so.

As we are PCCP Accredited Class 1 – 5, this enables us to be in the running for all lead based removal, therefore allowing us to do works on structures such as bridges and encapsulated sites.

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

A: Mackay QLD Coal Mine .

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

A: To ensure the job is completed to all requirements and keeping a good, steady and trustworthy relationship with your clients to maintain working satisfaction.

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

A: Both.

34 Leslie Road Laverton North VIC 3026 Australia Ph: +61 3 9315 3144 Fax: +61 3 9314 5488 Web: www.coxcoating.com

Pictured below is a train project completed by Cox Coating in Lismore, Victoria. The pictures show the train before and after restoration.

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

seMinar series:

ROADSHOW REVIEW LoCations:

2012 Australian roadshow review Corrosion & Risk Management Seminar Series Corrosion poses great risk to plant and equipment, human safety and the environment. Managing and mitigating this risk can be done through developing and maintaining a management plan, or it may be as simple as altering materials or applying a coating or it might involve other design changes.

This was the focus of the ACA’s 2012 travelling series of technical seminars on corrosion and risk management.

The series was conducted in May across Australia in Darwin, Newcastle, Wollongong, Melbourne, Campbell Town, Adelaide and Perth. Over 250 delegates attended the series which was proudly sponsored by International Protective Coatings and the North Australian Centre for Oil & Gas. 55 presentations were conducted throughout the series covering topics such as design for durability, zinc rich primers, stainless steel, hot dip galvanizing, stress corrosion cracking, welding, non destructive testing, cathodic protection, alloys, case studies and more.

A synopsis of a selection of the presentations: Zinc Loading vs. Performance Requirements for Zinc Rich Primers International Protective Coatings This presentation compared the performance of different zinc level primers under different test conditions and highlighted the problems that may be experienced when relying only on a compositional requirement or on an inappropriate testing requirement when selecting zinc rich primers.

Application of Stainless Steel for Corrosion Resistance North Australian Centre for Oil and Gas Stainless steels are used extensively for corrosion resistance applications.

However, they have some peculiar characteristics that should be

p.30 CORROSION & MATERIALS

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22nd MaY Mercure Grosveno r Hotel, 125 North Terrace, Adelaide

Corrosion and risk ManageMent

It is not hard to imagine the risk that corrosion and equipment. poses to plant What is less considere also poses to human d is the threat this risk safety and to the environment. Managing and mitigating this risk maintaining a managemcan be done through developing and ent plan. Industry is to implement recognised best a regime of inspectio practice ns and risk assessme thereby determin ing the condition nts, of equipment or plant. An evaluatio a section of n may then be made or damage due to of the likelihood of failure corrosion and a measure of severity estimated; key steps of outcome in the development manage or remove of options to mitigate, this as simple as altering risk. Corrosion risk mitigation may be materials or applying involve other design a coating or it might changes.

ACA is holding its annual travelling series corrosion and risk management. Please of technical seminars on your attendance at any of the locations use this form to register for each location as listed here. The will be schedule at www.corrosion.com released in advance and can be accessed .au. Please note because of local that the schedule may contributions. vary

Supported by:

Sponsored by:

PertH

tHUrsdaY 24tH MaY The Old Brewery, 173 Mounts Bay Road, Perth

understood. This talk was about the various issues of using stainless steels.

Designing for Durability to Reduce Construction, Operational and Maintenance Risk in Steel Construction AECOM This presentation covered aspects of initial engineering and design considerations, the risks that they present during construction and the implications for the end-user with regard to maintenance costs and operational risks for the design life of large steel structures.

Corrosion – Managing and Reducing the Risks with Hot Dip Galvanizing Galvanizers Association of Australia This presentation showed how a specifier can proactively reduce the risk of corrosion failure of a hot dip galvanized structure through careful assessment of the aspects of design, manufacture, inspection and maintenance.

Reducing Risk by Application of the Correct Corrosion Resistant Alloy (CRA) Australian Stainless Steel Development Association After discussing how to evaluate the risks of a project using stainless steel according to AS/NZS ISO 31000 Risk Management, the specifics of several applications was covered. The emphasis was on how stainless steel can be used to reduce risk, and how to reduce the fabrication and operation risks in using it.

Corrosion Management for Costeffective Operation of Existing Marine Assets SMEC This presentation illustrated through a series of case studies the benefits of a targeted condition assessment in developing repair options which are tailored to meet the remaining economic life of the asset. This approach not only provides confidence in the deterioration state of the asset but more importantly it provides the asset owner with a technical basis for

Engineers Australia members can choose hours for attendance to record CPD at this event in their logs. Members should personal CPD CPD Policy for details refer to Engineers Australia’s of requirements and conditions.

a more effective forward maintenance plan which can potentially lead to better utilization of capital and operating funds.

Controlling the Risk of Rebar Corrosion in Existing Wharves and Bridges Marine & Civil Maintenance All of the wharves and most of the bridges in Australia are located in an aggressive marine environment which threatens their durability from the day of construction. Concrete structures in such an environment are subject to continual ingress of chloride ions from the salt water, leading sooner or later to corrosion of the reinforcing steel and consequent structural deterioration.

This presentation looked at the variety of techniques that are available to reduce the risk of corrosion damage and extend the life of such structures.

NDT and Monitoring for Concrete Durability and Maintenance PCTE Actions specified at the design stage to ensure concrete durability include activities throughout a structure’s life. The value of these activities is supported by life cycle cost analysis.

On-going testing and monitoring often forms an integral part of cost minimisation and safety enhancement.

There are five points during the life cycle of a structure at which inspection and testing is important.

This presentation examined this concept for the following stages.

At design, during and immediately following construction, as part of regular maintenance, as part of design life extension, and when premature deterioration becomes evident.

Corrosion Risk Mitigation of Aboveground Storage Tanks SVT Engineering Leaks in above ground storage tanks, containing hazardous liquids, pose a risk to safety and the environment.

Due to strict environmental requirements placed on new Oil & Gas projects, management of the corrosion risk is crucial. Risk mitigation strategies developed for these projects include the design and installation of under

ROADSHOW REVIEW

floor cathodic protection systems. SVT Engineering discussed the types of systems available that provide longterm corrosion protection.

Non-Destructive and Remote Visual Techniques for Assessing Corrosion Olympus Ultrasonic testing has long been used to measure remaining wall thickness in corroded parts. A brief explanation of this technology was provided, followed by an introduction to developments in ultrasonic phase array which

Kingsley Brown of AECOM presents in Adelaide.

offer corrosion mapping and better probability of detection. Remote visual inspection is presented as one way of non-destructively assessing corrosion in difficult to get at locations.

Sponsored by:

The ACA takes this opportunity to thank all the speakers and convenors for their valuable time and support during the series. ACA members who would like an electronic copy of any of the presentations conducted during the series can contact Katherine Webber at kwebber@corrosion.com.au

Peter Golding of GAA presents in Adelaide.

Ian MacLeod facilitates the open forum in Perth.

ACA Events July-December 2012 The ACA continues to offer the following professional development opportunities in the second half of 2012. Please refer to www.corrosion.com.au for further details.

Event Title

Event Type

2012 Date

Location

Meeting of the Australian Electrolysis Committee

Cathodic Protection / Australian Electrolysis Committee Meeting

19 July

Adelaide

Corrosion and Infrastructure Sustainability in the Mining Industry

Mining Industry Technical Group Mid-Year Event

27 July

Mackay

Corrosion and Infrastructure Sustainability in the Mining Industry

Mining Industry Technical Group Mid-Year Event

17 August

Singleton / Muswellbrook

Welding & Corrosion Mitigation in the Petroleum & Chemical Processing Industry

Petroleum & Chemical Process Industries / Welding, Joining & Corrosion Technical Groups Mid-Year Event

28 August

Perth

Corrosion & Prevention 2012

ACA Conference

11 - 14 November

Melbourne

June 2012â&#x20AC;&#x192; www.corrosion.com.auâ&#x20AC;&#x192; p.31

ROADSHOW REVIEW

2012 NZ roadshow review THE AUST THE AUST RALASIAN RALASIAN CORROSIO CORROSIO N ASSOCI N ASSOCI ATION INC ATION INC SEMINAR SEMINAR

Corrosion and ManageMent risk Coastal envir in tHe onMent PROUDLY PRESENTED BY:

Corrosion and ManageMent risk Coastal envir in tHe onMent PROUDLY PRESENTED BY:

Auckland 29th May time 9.15 am 9.50 am 10.00 am 10.30 am 11.00 am 11.30 am 12.00 pm 12.30 pm 1.30 pm 2.00 pm 2.30 pm 3.00 pm

2012 • Novotel Auckland

Wellington 31st May 2012

Ellerslie

schedule

time

Registration

9.15 am

Welcome & Open - John Duncan The Effects of Corrosion on Structures Stewart Hobbs, ProConsult Designing for Durability to Reduce Construction, Rob Kilgour, AECOM Operational and Morning Tea

9.50 am 10.00 am Maintenance Risk

Non-Destructive and Remote Visual Techniques for Assessing Richard Nowak, Olympus Corrosion Corrosion Under Insulation Aynsley Laurence, Refining NZ Lunch Materials in the Marine Environment Les Boulton, Nickel Institute NZ Consultant Extending the Life of Marine Assets Using Jacketing Systems Wayne Thomson, Denso (New Zealand)

Afternoon Tea

Durability, CP & Coatings in Marine Environment Sean Ryder, GHD

3.30 pm

Open-floor Speakers’

4.15 pm

Summary & Seminar

Forum

in Steel Construction

10.30 am 11.00 am 11.30 am 12.00 pm 12.30 pm 1.30 pm 2.00 pm

• Mercure Wellingto n

schedule Registration Welcome & Open - John Duncan The Effects of Corrosion on Structures Stewart Hobbs, ProConsult Designing for Durability to Reduce Construction, Rob Kilgour, AECOM Operational and Maintenance Morning Tea

Risk in Steel Construction

Non-Destructive and Remote Visual Techniques for Assessing Richard Nowak, Olympus Corrosion Materials in the Marine Environment Les Boulton, Nickel Institute NZ Consultant Lunch Extending the Life of Marine Assets Using Jacketing Systems Wayne Thomson, Denso (New Zealand) Durability, CP & Coatings in Marine Environment Sean Ryder, GHD

2.30 pm

Open-floor Speakers’

3.15 pm

Summary & Seminar

present during construction and the implications for the end-user with regard to maintenance costs and operational risks for the design life of large steel structures.

Non-Destructive and Remote Visual Techniques for Assessing Corrosion Richard Nowak, Olympus

Forum

Close

Close

Corrosion & Risk Management in the Coastal Environment Seminar Series Following recent events in Christchurch, there is now a renewed focus in New Zealand on asset integrity.

As many cities and towns in New Zealand are situated within a few kilometres of the coast, most industries have to deal with the various problems of corrosion this proximity initiates.

This seminar series focused on discussing how managing and mitigating corrosion effects can be achieved through developing and maintaining an asset management plan which actively monitors asset and equipment condition.

The series, which attracted over 100 delegates was conducted in Auckland 29th May and Wellington 31st May. A synopsis of each presentation follows: The Effects of Corrosion on Structures Stewart Hobbs, ProConsult In this presentation, examples were shown of corrosion in various contexts.

How do we learn from corrosive failures so that the industries involved can then employ better design and building techniques? What are the lessons we need to be aware of within the building/construction industry? Specific reference will be made to concrete and steel structures, and the protection of these structures.

Ultrasonic testing has long been used to measure remaining wall thickness in corroded parts. A brief explanation of this technology was provided, followed by an introduction to developments in ultrasonic phase array which offer corrosion mapping and better probability of detection. Remote visual inspection is presented as one way of non-destructively assessing corrosion in difficult to get at locations.

Corrosion Under Insulation Aynsley Laurence, Refining NZ This presentation outlined Refining NZ’s Corrosion Under Insulation Project. The talk covered strategy and inspection effectiveness, including the Risk Based Inspection methods used in prioritising inspection. It discussed corrosion types and prevention and repair methods, including thermal spray aluminium. Planning and execution cost effectiveness and inspection scheduling were also outlined.

Materials in the Marine Environment Les Boulton, Nickel Institute NZ Consultant The marine environment is particularly severe on metals and premature corrosion failure of plant and equipment situated near the coast is not uncommon. Marine corrosion control involves the selection of the correct material, good design, using high quality coatings, and often using cathodic protection as well. The selection of the right

material is vital to produce long lasting durable structures in seawater and in coastal environments. This presentation outlined the selection of the right materials for use in marine environments, including stainless steels, copper alloys, aluminium alloys and nickel alloys.

Extending the Life of Marine Assets Using Jacketing Systems Wayne Thomson, Denso (New Zealand) Jacketing systems have been used to extend the life of marine pile structures for many years. They include a variety of systems installed to protect timber, steel and concrete piles against further corrosion, erosion and marine biological attack. This presentation was a practical introduction to the different systems available and included examples of successfully installed systems.

Durability, CP & Coatings in Marine Environment Sean Ryder, GHD Sean discussed a variety of different concrete remediation options, and when to use each one. It is GHD’s opinion that there is a lot of sub-par advice being offered to clients by “experts” because they don’t fully understand remediation options available, and what the pros and cons of each are. This presentation highlighted some of the risks associated with this issue.

The ACA takes this opportunity to thank all the speakers as well as John Duncan who chaired both seminars for their valuable time and support during the series. ACA members who would like an electronic copy of any of the presentations conducted during the series can contact Katherine Webber at kwebber@corrosion.com.au

Designing for Durability to Reduce Construction, Operational and Maintenance Risk in Steel Construction Rob Kilgour, AECOM This presentation covered aspects of initial engineering and design considerations, the risks that they

p.32 CORROSION & MATERIALS

Delegates at the Auckland seminar

Representing the Nickel Institute, Les Boulton presents on Materials in the Marine Environment

TECHNICAL GROUP REVIEW

Exploding the Myths!

Exploring the Truth.

Oil & Gas Corro sion Industry Grou p Meeting / Petro & Chemical Proce leum ss Industries Techn ical Group Meet ing

30th – 31st May

2012, Mercure

Brisbane, Brisba ne, Queensland

Proudly presented

by:

Joint OGC and PCPI meeting review

The ACA recently facilitated a joint Oil & Gas Corrosion Industry Group Meeting & ACA Petroleum & Chemical Process Industries Technical Group Meeting. Entitled ‘Rust: Exploding the Myths! Exploring the Truth’, the meeting was held in Brisbane on the 30th – 31st May. The first day was restricted to personnel working within the Oil & Gas industry as direct employees or contractors who are fully embedded with one such organisation. The second day was open to any person concerned with aspects of corrosion in the Oil & Gas industry and a synopsis of the day two presentations are below.

Overview of Recent Developments on Localised Corrosion Testing, Monitoring and Prediction Mike Tan, Deakin University This presentation provided an overview of some recent technological developments in localised corrosion testing, monitoring and prediction, and their applications in the investigation of challenging phenomena related to oil and gas industry. Particular focus was on electrochemical methods including electrochemical noise and the integrated multi-electrode array methods. Some cases were presented to illustrate their advantages and limitations.

Acoustic Emission (AE) for Corrosion Detection Erik De Schepper, ALS Industrial Corrosion is the major cause of structural degradation; the process of corrosion itself usually causes acoustic emission as a result of the fracture and dis-bonding of expansive corrosion products, or as a result of cracking and yielding in case of stress corrosion. This means that the AE method may be used for corrosion detection. This presentation discussed the use of acoustic emission for corrosion detection in storage tanks, reinforced concrete structures, and process equipment.

Case History: Assessment into the Corrosive Contamination within Reinforced Concrete Elements in a Chemical Plant and the Remediation via Chloride Extraction Electrochemical Techniques Robert Bell, ALS Industrial Chloride extraction is a means by which corrosive contamination may be removed from reinforced concrete elements via electro chemical techniques to render a structure returned to its original condition. This is a way in which the service life may be extended and managed to render the structure viable into the longer term.

The presentation offered an insight into the practical implementation and merits of undertaking such an exercise.

Monitoring the Degradation of Coatings and Metal for Asset Health John Colwell & Matt Hales, Queensland University of Technology Corrosion of materials is a multibillion dollar industrial problem, with methods to detect or prevent corrosion being necessary to mitigate its destructive effects. Painting is a major corrosion prevention method, but paints eventually break down leading to exposure of the underlying metal substrate to corrosive environmental elements. Presented were methods for detecting both the breakdown of protective paint coatings and the corrosive environment near exposed metal structures. An outline on the use of corrosion sensors for monitoring corrosion of civil and industrial assets was also presented.

Investigation into Metal loss in High pH Coal Seam Gas well piping Oskar Jarvie & Terry Balson, Origin Energy Early indications during the production of coal seam methane (CSM) suggested that the system corrosion was relatively benign. It was only when some minor failures occurred, followed by inspections, that it was realised there was metal loss occurring via several routes. An ongoing investigation

programme was put into effect that would study specific wells to start to understand the problem. This is a preliminary report because as investigations are still on-going.

Mercury Embrittlement of Cryogenic Heat Exchangers in Natural Gas Production Richard Clegg, Central Queensland University This presentation discussed the phenomenon of mercury embrittlement in aluminium, a prominent cause of failure of aluminium cryogenic heat exchangers in gas processing. A number of recent prominent case studies were discussed along with the results of recent research in the field. The presentation also discussed the fundamental features of the phenomenon and addressed some of the modern mitigation strategies.

A Case Study on Managing C-1/2Mo Equipment in High Temperature, High Pressure Hydrogen Service at BP Bulwer Island Refinery Vukan Ruzic, BP Carbon and low alloy steels can be susceptible to high temperature hydrogen attack (HTHA) when exposed to elevated temperatures in hydrogen rich atmospheres. Recent industry failures and known uncertainty in behaviour of C-1/2Mo material prompted an assessment of refinery equipment to determine the risk of HTHA. The presentation discussed the refinery’s approach to managing the risk in susceptible services, including the development of appropriate inspection plans and replacement schedules.

The ACA takes this opportunity to thank all the speakers and Fikry Barouky who chaired the meeting for their valuable time and support. ACA members who would like an electronic copy of any of the PowerPoint presentations can contact Katherine Webber at kwebber@corrosion.com.au

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

TECHNICAL INTRODUCTION

Protective Organic Coatings – An Introduction Introduction Painting is the application of a liquid coating to a material to protect it. It is considered the oldest method of corrosion control and certainly the most recognisable to people outside the corrosion protection field. Painting’s simple premise – the application of a protective film to protect the underlying material from exposure to the environment – belies the reality of the sophistication behind the technology that is required to do it effectively.

Although protective coatings have been in existence for many years, it was only in the mid 1900’s that the true protection mechanisms of paint coatings were understood.

Prior to then, it was thought that paint coatings worked by providing a complete insulation between the protected metal and the environment.

In fact, the reality was much more complex and led to improvements in the way paint was used to protect metal, most commonly steel.

It is now known that most paints to a certain extent allow moisture and atmospheric components to travel through them in varying quantities.

Rather than being a problem, this property can actually assist in the paint’s corrosion protection of the base metal. Modern protective coatings are highly specialised and have unique characteristics depending on the type of protection required. These modern coatings protect in different ways, are made of different materials and require varied surface preparation and application. Specifiers need to be aware of the different properties available in the large range of protective coatings.

Although many different types of metals are protected by painting, this discussion will focus primarily on structural steel.

How Coatings Work To Protect Metal There are many different types of protective coatings and these also have different mechanisms by which they protect steel.

Barrier coatings protect the metal substrate by preventing the conditions and factors that cause corrosion from

p.34 CORROSION & MATERIALS

reaching its surface. They can be thought of as insulating the metal from the surrounding environment. For example, in coastal environments, without a protective barrier coating, salt may settle on the surface of steel and this salt will increase the conductivity of any moisture present. This will facilitate electron transfer between anodic and cathodic sites, thus setting up a corrosion cell. A correctly specified barrier coating will prevent salt reaching the surface of the steel and therefore inhibit corrosion.

Barrier coatings can also work by preventing oxygen from reaching the metal surface. A barrier coating can be thought of as an insulating layer that excludes the more corrosive constituents of the environment from reaching the surface of the metal.

Note that it is practically impossible to produce a paint coating that is impermeable to water vapour and oxygen. However, by limiting or totally excluding the charged particles and oxygen, key ingredients in the “corrosion recipe”, then the coating can be considered to have performed its function.

Some coatings can also work via cathodic protection. This involves the paint coating being loaded with the dust of a more anodic metal than the substrate it’s protecting. So, in the case of steel, this usually involves zinc dust. These are what are commonly termed “zinc rich paints.” There has to be sufficient metallic zinc in the paint to make sure that there is high enough conductivity to enable effective cathodic protection.

Another method by which coatings can protect is to promote passivation of the surface of the substrate metal.

These are primers that contain inhibitive pigments. They encourage the formation of a passive film at the interface of the metal and the primer.

As the name suggests, they are usually applied directly to the surface of the metal and then provide a stable base for further paint layers.

What are paints made of?

There are many different types of protective coatings, but most are made up of the following:

1. Pigments 2. Binders 3. Solvents 4. Additives Pigments are particles added to the paint to give it different properties.

Despite their name, pigments are not only used for colouring purposes. The main types of pigments are colour pigments, extending or filler pigments and anti-corrosive pigments.

Colour pigments contribute a number of different properties beyond the cosmetic, they also provide opacity.

This is known as the “hiding power” of the protective coating. It describes how well the colour of the substrate below the paint is hidden. The higher the opacity, the less of the lower colour gets through visually, and it means that less paint can be used if this is an important consideration. The selection of certain colour pigments will also improve the UV absorption and protective qualities of the final paint coating.

Extending or filler pigments are also added for a variety of reasons. They add viscosity, contribute to the structure of the paint and can also help to reduce the cost.

Anti-corrosive pigments, as their name implies, improve the corrosion protection properties of the paint. They can perform either as barrier pigments that prevent or retard the progression of corrosive elements through the paint, or they can be active pigments, such as zinc, which provide the sacrificial or cathodic protection described above or inhibitive pigments such as zinc phosphate.

The binder is the “body” of the paint.

In paints without a heavily loaded metal pigment, as used in coatings with cathodic protection properties, it is usually the largest solid component and is generally used as the reference to name the coating type eg acrylic, epoxy, etc. There are many other terms used for the binder and some common ones include medium, vehicle and matrix. The binder is what holds the components of the protective coating together.

TECHNICAL INTRODUCTION

Many protective coatings in their liquid state also contain a solvent. The solvent helps to impart flow and enhances the application properties of the paint. It also dissolves the base resin and allows solid components, i.e. the binder, pigments and fillers to be applied as a wet film. The solvent is volatile and does not remain as part of the protective coating after it has dried. Once the paint has been applied, the solvent evaporates or breaks down, leaving behind the dry film of the protective coating.

Advancements in technology mean that protective coatings manufacturers are reducing the amount of volatile organic compounds (VOCs) in their products to improve their environmental performance. Some protective coatings have no VOCs at all.

Finally, there are also other additives that are added to protective coatings to impart different qualities to them.

These additives can control or improve factors such as viscosity, shelf life, UV resistance, abrasion resistance, drying times and many others.

It is important for designers to realise that protective coatings are sophisticated and there are many different types used in different systems to suit various conditions. The general overview above will be expanded upon in further discussions on the specific qualities of different protective coatings under varied conditions.

Protective Coatings as a Component of Corrosion Protection Systems Protective coatings require significant development and are manufactured in many different variations, but ultimately, the paint has to be applied to the surface of the metal effectively so that it can protect it. Preparation of the surface is one of the key steps, if not the key step, in the successful adhesion of a protective coating and its subsequent satisfactory performance. Effective surface preparation is so important that there are standards devoted to it, both in Australia and New Zealand, and internationally.

In Australia and New Zealand, both the AS1627 series and AS/NZS 2312 provide guidance on surface preparation.

protective coatings, surface preparation has also been researched in recent years, both in terms of ensuring the adhesion of the paint system to the metal and also in its efficacy in corrosion protection.

It is no coincidence that protective coatings are described as coating systems since all of the components of surface preparation, paint selection and system selection combine to make up the overall system.

The Dry Protective Coating There are two main ways in which a protective coating forms its protective film. There is the non-convertible type of film formation, which most closely follows the term “drying” used commonly by most paint users, and there is the convertible or “curing” type where the protective coating undergoes a chemical change during its formation into a protective film.

Convertible coatings, as their name suggests, undergo a conversion process.

The coating becomes solid due to a chemical reaction. The chemical reaction can be initiated via a number of methods: exposure to air (oxygen), by chemical curing agents, exposure to moisture and by the application of heat to the “wet” coating. Convertible coatings may still contain solvents, but the chemical reaction is the key process. The convertible solvent based conversion process is shown below.

Common examples of protective coatings that are cured via a conversion process are epoxies, polyurethanes and polysiloxanes.

In the non-convertible formation, the paint dries from a liquid to a solid as the solvent evaporates. This is shown in the diagram below.

It will be noted that there are references to WFT and DFT in the figures below.

These denote “wet film thickness” and

Solvent Evaporation Loss of film thickness

WFT

Liquid

Semi Solid

Solid

DFT

Substrate

Drying Time

Figure 1: Non-convertible drying process (courtesy Akzo Nobel) Solvent Evaporation

WFT

Surface preparation is such an important process that it will be discussed separately in more detail later, but it is important that designers and specifiers understand that there are many different types of preparation processes and levels depending on the type of paint being used, the substrate to be protected and the conditions under which it has to perform. As with the development of

Examples of non-convertible coatings include chlorinated rubber, vinyl and bituminous paints.

Loss of film thickness

Liquid

Semi Solid

Solid "#$%&

DFT

Substrate

Drying Time

Curing Time

Figure 2: Convertible curing, solvent based (courtesy Akzo Nobel)

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

TECHNICAL INTRODUCTION

“dry film thickness”. Since protective coatings are applied as a liquid, they are “wet” when they initially sit on the substrate. Ultimately, they either dry or cure and the coating process is completed. Coatings containing a solvent will have a different wet film thickness, or WFT, as opposed to when they are dry. This is because some of the volume of the initial coating is lost as the solvent evaporates.

The WFT and DFT are important parameters for coating specifiers and applicators. They basically determine whether the coating is thick enough for the required application. Not meeting the figures, particularly the DFT, will mean that the coating is not at the specifier’s required thickness.

Many coatings will underperform if not applied to the recommended thickness and this can result in major problems and financial loss at a later stage. Like preparation, the testing and inspection of coatings is another major component of the process of applying protective coatings to metalwork.

technique and environment are all significant factors in the performance of a protective coating.

The standard that provides a guide to many of these issues is AS/NZS 2312:2002. The standard is titled “Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings.”

The standard is indeed a guide: it is by no means definitive. However, it does provide a significant amount of information that is useful to designers and specifiers.

Protective coatings have qualities that mean their life in certain environments varies between different coating types and systems. A more expensive coating may not be required if a maintenance schedule is set up that allows a cheaper coating to be effective. Ultimately, it becomes a consideration of life cycle costs for the assets being protected and what type of maintenance schedule is put in place. A more expensive coating may have a higher initial cost, but this could be offset by the significantly decreased maintenance intervals that are required. Also, the importance of the asset should be considered. If the asset is required to have almost one hundred percent availability and failure or removal from service is not desirable or even not an option, then the extra expense of a more sophisticated protective coating system may be vindicated. There are no hard and fast rules as to the selection of coating systems, but AS/NZS 2312 does provide a guide to coating selection in certain atmospheric corrosivity classifications.

has, the more costly it will be to apply.

However, as discussed above, life cycle requirements and maintenance periods will determine the economics of what is required. Some different coating systems for different environments will be discussed later in the series.

AS/NZS 2312 also addresses the issue of the proper steel design to mitigate against corrosion. The correct detailing of steel is one of the most important factors in the success or otherwise of protective coatings. For example, the DFT of a coating will be reduced at a sharp corner compared to the laminar areas of the steelwork. It is good design practice to avoid sharp corners wherever possible or, if this cannot be avoided, that at least provision is made to build up the DFT in such areas by methods such as stripe coating. This is where initial painting is done to help build up the DFT prior to the overall application of the protective coating. (q) Insufficient edge preparation prior to painting (sharp edge)

Structural members generally

Chamfer or round edges prior to painting Protective paint system

Protective paint

d

Steel

Good

Steel

d = 1 mm Chamferred edge Protective paint system Better

r

Steel

r = 2 mm Rounded edge

Figure 5: AS/NZS 2312 suggested requirements for edge corrosion protection for paint systems. Note extra engineering design required to prevent reduced DFT (Standards Australia)

Figure 3: The application of protective coatings on large infrastructure requires careful thought and planning (courtesy of Jotun) Durability of Protective Coatings The durability of protective coatings, like all corrosion protection systems, relies heavily on a number of different factors apart from the coating itself.

Design of the steelwork, suitability for the substrate, preparation, application

p.36 CORROSION & MATERIALS

Figure 4: Petroleum storage tanks are usually located in highly corrosive areas (courtesy of Jotun) Protective coatings are usually designed as a system. This is where coatings, often different types, are used together as a multi-coat system. There will be a primer, some mid-coats and then a top coat. Systems vary depending on the conditions under which the protective coating is expected to perform.

Obviously, the more layers a coating

Another common design problem with steelwork is ponding. This is where the design allows for water or moisture build-up on the steel article. These areas will then hold water for longer, which then leads to potential corrosion hotspots that leave the protective coating vulnerable.

Application of the correct design principles for steelwork and other metals, will greatly enhance the performance of the protective coating.

TECHNICAL INTRODUCTION

Figure 6: Painted bridge rail on Geelong Ring Road, Victoria. Note the detailing of the steel to allow moisture runoff and minimise ponding issues.

Conclusion Protective coatings are the oldest and most widespread method of protecting steel structures. They are constantly under development and their sophistication and performance belies their simple appearance to the casual observer. Protective coatings are an ideal method of both protecting steelwork and providing an aesthetic finish.

Further discussion will focus on the different options available to the specifier in selecting protective coatings and also in the preparation and design of steelwork to maximise the performance of their selected coating or coating system.

Acknowledgements Matt Brown – Akzo Nobel Dean Wall & Geoff White – Jotun Figure 7: Protective coatings have to endure harsh and varied conditions to protect steel (courtesy of Jotun)

Emmanuel Pimentel

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

INDUSTRY INSIGHT

Considerations for Radioactive Waste Management in Australia Introduction Although Australia has no nuclear power industry, all Australians benefit from the medical, research and industrial uses of radioactive materials. Creation and use of these radionuclides produces low and intermediate-level radioactive wastes that require safe management.

Unlike other hazardous wastes which may be chemically toxic, flammable or corrosive, radioactive waste has primarily only one hazardous attribute: emission of ionising radiation. As the hazard associated with radioactivity decreases with time, radioactive waste requires isolation from the biosphere until it reaches natural background radiation levels. In the case of shortlived radionuclides this is typically for periods less than 300 years. For longlived radionuclides this may be for tens of thousands of years. It is generally accepted by the scientific community that a multi-barrier approach, including engineered and geological barriers, retains radioisotopes for the required time period. Design of corrosion resistant waste-forms and facilities is fundamental to achieving this outcome.

Background Radiation occurs naturally in the environment from primordial isotopes and cosmic ray interactions. Primordial isotopes and their decay products include uranium, thorium, radium and radon. Radionuclides continuously produced by cosmic ray interactions with the atmosphere include carbon-14 and tritium. Thus there exists a natural background radiation level to which all humans are exposed. This is a nonzero value, which varies with location, altitude and the solar cycle. Distinct from other wastes and natural radiation, radioactive waste is essentially waste containing radionuclides where isotopes have been formed or concentrated above natural background levels. To mitigate the hazards associated with radioactive waste, management is required until radiation levels decay to exemption levels.

In Australia, categories of radioactive waste are defined under a classification scheme. Under this scheme low, intermediate and high level wastes are defined as those that require greater isolation from the environment than provided by landfill facilities[1].

p.38â&#x20AC;&#x192; CORROSION & MATERIALS

It is generally accepted that isolation of radionuclides from the environment can be achieved over timeframes of 300-500 years by engineering barriers[2]. Consequently low level waste (LLW) is classed as waste for which isolation can be guaranteed by engineered enhancements to nearsurface disposal facilities. In practice, LLW comprises radionuclides with short half lives, typically less than forty years, and limited quantities of long lived radionuclides[1]. The reason for this is the activity, and hence hazard, associated with radioactive waste decreases predictably over time. For instance, after ten half lives, waste activity is reduced by a factor of 210, or to 1/1024 of the original level.

Examples of LLW in Australia include radioactively contaminated paper, plastic and disposable overalls from operation of the Australian Nuclear Science and Technology Organisation (ANSTO) research reactor, smoke detectors, contaminated soil and contaminated concrete.

Intermediate level waste (ILW) has a higher activity and/or sufficient quantities of long-lived radionuclides to necessitate greater isolation than required for LLW[1]. The addition of geological barriers through disposal at depths of tens to hundreds of metres below ground is one method for achieving this[1].

Examples of ILW in Australia include operational waste from ANSTO, disused sealed radioactive sources and concentrates from mineral sands processing. Waste from reprocessing used fuel from the current OPAL and former HIFAR reactor at ANSTO will also be returning to Australia from 2015.

High level waste (HLW) has such a high activity that significant heat is generated by radioactive decay[1].

HLW requires further isolation and containment from the biosphere than required for ILW. With HLW, provision also needs to be made for heat dissipation. HLW is typically produced by nuclear power production and accounts for approximately 2% of the waste arising from such facilities[2].

Australia has no HLW and is unlikely to produce any in the foreseeable future[1].

Importance of Waste Management Like all hazardous wastes, radioactive waste presents potential hazard to the biosphere. In contrast to other hazardous waste, radioactive waste has only one primary hazardous attribute â&#x20AC;&#x201C; the emission of ionising radiation[2].

Hazardous attributes from other waste streams include chemical toxicity, flammability and corrosivity. Although some radionuclides remain hazardous for tens of thousands of years, longevity considerations are not unique to radioactive waste[2]. For example, heavy metals, mercury and asbestos remain hazardous indefinitely. In Australia, the quantity of radioactive waste requiring management represents a very small fraction of the total hazardous waste that is routinely produced and disposed.

The aims of radioactive waste management are to ensure safe management without imposing an undue burden on future generations[3].

Central to the argument of sustainable waste management is the waste hierarchy of controls. The hierarchy of controls considers disposal the least sustainable approach to waste management. More sustainable management options include prevention of waste generation, waste minimisation, material reuse, recycling and energy recovery. Permanent storage of radioactive waste is not considered an option in the long term as it places burden on future generations[4].

Effective management mitigates the risk of accidental exposure and minimises the release of radionuclides to the biosphere. This directly mitigates risk of potential doses to biota from external irradiation, ingestion and inhalation of radionuclides[2].

The National Radioactive Waste Management Act 2012 (the Act) puts in place a legislative framework for the establishment of a radioactive waste management facility on volunteered land in Australia. The facility will ensure radioactive wastes arising from medical, industrial and research activities in Australia are responsibly managed. The facility will consist of a co-located near-surface repository for low level and short-lived intermediate waste and an interim store for longlived intermediate waste.

INDUSTRY INSIGHT

Corrosion Control Many near-surface repositories operate safely around the world including Drigg (United Kingdom), Rokkasho-mura (Japan) and Centre de l’Aube (France)[2].

To meet waste acceptance criteria and ensure efficient use of facility resources, waste is subject to appropriate treatment prior to consignment.

For LLW, treatment usually includes volume reduction operations such as shredding, compression and/or liquid waste precipitation. Such operations are routinely conducted at ANSTO in New South Wales[5]. Volume reduction processes at other facilities around the world include combustion, thermal decomposition, super-compaction and evaporation. As a result of volume reduction operations, the resultant LLW contains minimal moisture; hence external corrosion is the primary consideration for corrosion control.

Typical near-surface repository designs include reinforced concrete vaults to retard diffusion and a catchment system to collect and test any permeating water for potential radioactive contamination[2, 6]. The containers placed in the vaults are usually surrounded by backfill such as grout, soil or clay to further impede moisture ingress[2]. As the vault and backfill materials can only delay diffusion, they must be chosen such that any aqueous species do not promote corrosion with the waste containers themselves. The waste containers, typically carbon steel drums, provide an additional barrier to radionuclide release. Unlike the vault and backfill, waste containers prevent all radionuclide release while

the container remains unperforated[7].

Long-term container integrity can be ensured with sufficient corrosion allowance, or through use of corrosion resistant materials. Corrosion resistant materials commonly used for LLW disposal include high density polyethylene and stainless steel grades 304L and 316L[8, 9]. Together these engineered barriers enhance the natural isolation characteristics of the site and can provide retention of radionuclides from the environment for required periods up to 500 years[2].

For long-lived ILW, overpack and wasteform selection is paramount to ensuring ongoing safe storage and viability of future disposal routes.

Similarly to containers for nearsurface disposal, overpack design guarantees radionuclide retention until perforation[10]. Materials considered for overpacks range from cast iron, carbon steel and copper to austenitic stainless steels, titanium alloys and nickelbased alloys[8, 9]. Wasteforms produced through immobilisation techniques such as vitrification, cementation and bituminisation provide an additional barrier to radionuclide retention.

Furthermore, long-term leach resistance and durability of wasteforms is understood by comparison to natural analogues, such as basaltic glass.

After ultimate disposal, chemical compatibility of the wasteform with the host rock will control radionuclide transport over periods up to tens of thousands of years.

Conclusion Australia has a low and intermediate level waste inventory arising from

the use of radioactive materials in medicine, industry and research. This inventory must be safely managed to protect the environment, minimise risk of accidental exposure and prevent undue burden on future generations.

There is wide global experience in management of low level and short lived intermediate level waste in near-surface repositories. Facility and waste package design can retain radionuclides from the biosphere for the required periods of up to 500 years.

Long-lived ILW can be successfully isolated for even longer periods of time using additional geological and waste immobilisation barriers.

Acknowledgements This has been written to reflect current radioactive waste management practices in Australia. The content reflects the view of the author and does not necessarily reflect that of the Australian Government or the Department of Resources, Energy and Tourism.

References

[1] Australian Radiation Protection and Nuclear Safety Agency (ARPANSA) (2010), Safety Guide. Classification of Radioactive Waste. Radiation Protection Series No. 20.

Australia: Australian Radiation Protection and Nuclear Safety Agency (RPS No. 20).

[2] Nuclear Energy Agency (NEA) (2010), Radioactive Waste in Perspective. France: Organisation for Economic Co-operation and Development.

[3] Cooper, J. R., Randle, K. and Sokhi, R. S. (2003) Radioactive Releases in the Environment. Impact and Assessment [online]. United Kingdom: John Wiley & Sons, Ltd. [Accessed 8 Jan 2012].

[4] International Atomic Energy Agency (IAEA) (2005), Radioactive Waste Management Status and Trends – Number 4. Vienna, Austria: International Atomic Energy Agency.

(IAEA/WMDB/ST/4).

[5] Australian Nuclear Science and Technology Organisation (ANSTO) (2009), Managing Radioactive Waste and Used Reactor Fuel. Australia: Australian Nuclear Science and Technology Organisation.

[6] Murray, R. L. (2009), Nuclear Energy. An Introduction to the Concepts, Systems, and Applications of Nuclear Processes. 6th ed. United States of America: ButterworthHeinemann.

[7] Weber, J., and Simpson, J. P., Aspects of containers for high-level waste disposal. In: Working Party on Nuclear Corrosion. (1989) Corrosion in the Nuclear Industry. Great Britain: The Institute of Metals, pp. 52-56.

[8] Yim, M. S., and Murty, K. L. (2000), Materials issues in nuclear-waste management, Journal of the Minerals, Metals and Materials Society, 52 (9), pp. 26-29

Legend Topsoil

Multi-layered system – various layers (natural or manufactured)

[9] Speidel, M. O., Rennhard, C., and Pedrazzoli, R. M., High-strength corrosion-resistant candidate nuclear waste containers. In: Working Party Report. (1992) Corrosion Problems Relating to Nuclear Waste Disposal.

Great Britain: Bourne Press, pp. 7-9.

[10] Zuidema, P., The importance of engineered barriers for the final disposal of radioactive waste. In: Working Party Report. (1992) Corrosion Problems Relating to Nuclear Waste Disposal. Great Britain: Bourne Press, pp. 1-6.

R. A. Stohr Department of Resources, Energy and Tourism, Australian Capital Territory

Low level waste Water drains & compacted foundation Protective barrier

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

PROJECT PROFILE

Loy Yang Chimney Cappings Project Outline The stainless steel flue cappings on top of one of the main exhaust stacks at Victoria’s largest Power Station Loy Yang Power were suffering from extremely corroded cappings, stiffeners and windshields. Absafe Pty Ltd. won a select tender to complete this work to Loy Yang Power’s specification.

This required significant welding and repair works followed by application of a high temperature tolerant paint system.

One of the main problems with this project was that all of the welding, blasting and coating work needed to be undertaken whilst the flue was active. This work needed to be completed on a very tall slender structure that is over 260m high (~70+ storey building) which is also located in a very exposed location.

To re-instate the structural integrity of the flue capping a new set of stiffeners around the circumference of the capping needed to be welded in. Depending on the measured depth of corrosion and pitting a number of plates were required to be replaced.

The pitting of the capping was irregular, being far more severe where it faced the prevailing wind and the nearby cooling tower. The degradation was concentrated on the raked upper surfaces which illustrates the corrosive effects of the flue gases in combination with other local environmental effects such as local weather patterns.

Flue Capping Location

Figure 1: Loy Yang Power Station .

Loy Yang Power in the La Trobe Valley.

p.40 CORROSION & MATERIALS

PROJECT PROFILE

Existing Chimney Capping

New row of stiffening ribs. Local repairs to raked conical sections.

Guttering and Downpipes replaced

Figure 2: Isometric of a single flue capping.

In consultation with Sunil Philips who is Loy Yang Power’s engineering representative additional plates were required to be replaced on the side facing the cooling tower. Reductions in the scope of work were made on the lee side. These decisions could only be made once blasting had been completed and the full extent of the problem was exposed.

Figure 3: Deep pitting visible on raked conical sections.

Loy Yang Power specified that the new material for the capping is to be Grade 2205 Duplex stainless steel which has excellent corrosion and chemical resistance - essential for this environment. The guttering and downpipes which are located further down from the mouth of the flue are formed from grade 316 stainless steel, reflecting the lesser degree of corrosion resistance required.

Finally all newly repaired areas and existing surfaces were to be blasted with garnet to Sa 2½ standard – near white metal and a two part epoxy phenolic paint system was to be applied to the top and a conventional epoxy applied to the windshield which is in a less corrosive environment.

Figure 4: Blasting of flue capping in preparation for welding on of new set of stiffeners between the existing ones.

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

PROJECT PROFILE

Active plume drives plasma sparks into the sky.

Access Obtaining access to the top was greatly enhanced by the original chimneys designerâ&#x20AC;&#x2122;s foresight to incorporate a small maintenance lift which ascends to the deck under the top of the chimney.

This small lift was used to lift all of the scaffolding, men and materials to the upper deck. This included over 5 tonnes of garnet, ~30 bays of scaffolding and a 10 kVA generator set for welding equipment. The height of chimney meant the existing power supply suffered a large voltage drop and so was not suitable for high current applications like welding.

270m up on top of the scaffold.

OH&S The OH&S elements of the project were in many ways the most demanding.

A careful risk analysis was undertaken; a key consideration was that weather conditions can and do quickly change on the chimney.

The most dangerous condition is a downdraft where the exhaust plume is pushed down by local atmospheric and wind effects over the top of the chimney, surrounding the operatives on top of the chimney, often quickly with little warning.

Deep pitting of flue despite duplex stainless steel.

p.42â&#x20AC;&#x192; CORROSION & MATERIALS

This creates a low oxygen environment with high levels of sulphur dioxide.

This situation required that self contained breathing apparatus be on hand for everyone and be ready for quick deployment. The atmosphere was continuously monitored with MSA Altair 4 gas quick alert monitors.

PROJECT PROFILE

Erecting the scaffold required the installation of a circumferential safety line to eliminate the risk of a fall over the edge and absolutely no predisposition to vertigo from the installers.

Challenges Welding The welding was conducted throughout using conventional MIG welding equipment gas shielded with Argon gas. The windy environment required a high level of monitoring to ensure that the wind did not disperse the shielding gas.

The welding itself represented several challenges especially at the top. The unbreathable air when welding around the edge of the flue annulus required us to equip the welders with a remote air supply that was integrated into their welding masks.

Wind effects The wind created more difficulties with this project than any other aspect of the works. At this height, wind speeds can become so strong that the chimney sway makes use of the lift impossible, walking difficult and utterly prohibits any access to the scaffold.

The effects on the site personal were noted with dramatic increases in fatigue, effects on welding shielding gases and difficulty completing what would appear on face value to be a simple task.

Welding Shielding Gas Conventional shield gas Argon was used.

When the wind speed exceeded 25km+ wind this dispersed the welding gas, despite shielding, preventing welding.

Coatings Absafe applied an epoxy phenolic coating Intertherm 228 on the heat affected zone that is at the top section of the flue capping and coated the cool zone (i.e: rest of the section) with Interplus 356. Care had to be exercised during application as steel surface temperatures at the very edge are up to 50°C. Generally this region had to be done in the early morning when temperatures were at their lowest.

outlines how issues such as height, access and wind speeds can make a straightforward task a challenge with the wind, breathing equipment and height presenting impediments to reasonable completion times.

It is noteworthy the impact that local atmospheric condition can have.

Namely the side of the flue downwind of the cooling tower was effectively ruined by corrosive pitting, whilst other flue caps shielded from the wind were in dramatically better condition.

Boiler Trips – Emergency shutdowns Precautions need to be taken with the design of the scaffolds as the thermal expansion and contraction of the flue between the boiler being on and off translates to 1m vertical flue movement.

Careful attention to the design of lateral supports of the scaffold was required to allow this potential vertical movement, as tying in conventionally would place catastrophic vertical loads on the scaffold.

Summary The repair project illustrates the effects of corrosive atmospheric products even on materials that are specifically selected for their corrosion resistance. The project also

Finished flue.

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

PROJECT PROFILE

Swansea Bridge Rehabilitation Summary Swansea bridge, constructed circa 1989, is a high profile opening bridge on the Pacific Highway at Swansea, NSW (refer Figure 1).

This project received the highly commended award from Engineers Australia in 2011. The related paper presented to Austroad 2011 conference also received a Merit award.

Due to harsh marine exposure, the bridge substructure elements have suffered from reinforcement corrosion induced deterioration. A long life and environmentally sustainable rehabilitation option was required to be adopted to minimise community disturbance and achieve best value for money. There were numerous engineering challenges which were overcome by utilising sound and innovative engineering practice.

Introduction The original channel crossing at Swansea was a drawbridge built in the early 1880s. This was replaced in 1909 with a bridge, which incorporated a roadway, later to become the Pacific Highway.

A comprehensive condition investigation was undertaken which assisted in careful selection of a most cost effective yet durable rehabilitation.

Concrete cathodic protection (CP), a state of the art rehabilitation technique utilising DC electric current to combat reinforcement corrosion, was selected to provide a new life to this prominent bridge (refer Figures 2 & 3).

Figure: 1 Aerial View of Swansea Bridge (the left bridge is the southbound bridge).

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

The current crossing has two opening bridges spanning the entrance to Lake Macquarie. The older northbound bridge was opened in 1955 and the second southbound bridge (Swansea Bridge) was opened in 1989 (built circa 1986). Each of the bridges contains two lanes for traffic and provides pedestrian and cycleway access.

Swansea Bridge is approximately 175Â m long, comprised of precast piles, cast in situ pile caps and pier columns, cast in situ edge beams, precast prestressed concrete deck planks

(spanning between pier columns), and deck top slab.

A range of repair options was considered for suitability and a cathodic protection (CP) option was selected for some members whereas a more cost effective silane coating option was adopted for other members.

Silane is type of coating that is applied on concrete surface to limit further ingress of chloride ions. The primary compound of a silane coating is either Isobutyltriethoxysilane or Iso-octyltriethoxysilane.

Numerous engineering challenges were overcome by utilising sound engineering practice as there are very few instances where such a system was installed to a lifting bridge in Australia or overseas.

Benefits to the community and focus on customer needs Swansea Bridge is a high profile bridge and demolition and new construction was not an acceptable or sustainable solution to the community. The asset

PROJECT PROFILE

Figure 2 DC current applied through the anodes and cables, to stop corrosion to the reinforcement.

Figure 3 Direct current supply unit.

owner, Roads and Maritime Services (RMS) NSW, required a cost effective rehabilitation design in line with community expectation.

current (DC) used in impressed current CP, a sacrificial anode CP was designed for the deck planks. CP to the deck planks was postponed to a later date.

Considering the deterioration mechanisms identified and the extent of physical damage, the following two repair options were considered: Option 1: Conventional concrete patch repair and silane coating ption 2: Combination of concrete O patch repair, CP and silane coating.

After undertaking an engineering cost estimate, Option 2 was selected to provide best value for money for RMS. CP was not selected for all members from both technical and cost considerations. The following combination was adopted: oncrete patch repair to all C existing damage

Innovation in design, construction, maintenance and management One of the very unusual observations on this bridge was wetness of the deck soffit towards certain piers due to unique wind actions and turbulence that prevailed under the bridge.

The wetness assisted suction of airborne chlorides and posed significant threat to the integrity of the prestressed concrete deck planks. A sacrificial anode CP system was designed only for the wet section and a cost effective silane coating was proposed for the dry section of the wet planks. Due to the potential damaging effect on prestressing tendons by the direct

Impressed current CP application in tidal area is a challenge and there were a number of failures reported subsequent to the installation.

Specialised types of CP application were designed to minimise the likely problems. Coating materials were also carefully selected to provide long life and were suitable for the gases produced by the CP current. Note that the CP reactions produce gases that need to escape to the atmosphere. The coating material, therefore, should be

Figure 4: Distinctive Wet Areas.

Wet Area

pplication of CP system to the A following elements:

Piles

Pile caps

Pier columns

Deck soffit – wet areas (refer Figure 4). pplication of coating systems to A the edge beams and deck plank soffit dry areas.

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

PROJECT PROFILE

permeable to the CP gases. The coating material is also expected to provide long life to the CP system by restricting water ingress and hence limiting anode backfill deterioration.

Concrete CP, that utilises DC electric current to combat reinforcement corrosion, is still a developing technique worldwide. It provides long term corrosion protection to reinforced concrete structures (life in excess of 40 years with CP, compared to typically 5-10 years’ life with traditional concrete patch repair). Maintenance and management of the bridge will be a simple exercise with the rehabilitation option designed.

Environmental sustainability Due to long life achieved with minimal use of new materials and no requirement for demolition, CP is considered a truly sustainable option.

A detailed innovative and unique study was also made to determine the effect of CP current on marine life, flora and fauna. It was a GHD internal research work with assistance from a study undertaken by others including a report for the RMS by the Ecology Lab on “Cathodic Protection Systems on Built Structures: Effects of Marine Fauna” dated December 2007. Our assessment concluded that: here should always be plenty of T marine growth on piles with no discernable difference between CP and non CP piles. ocal fish should continue to feed L as normal off the marine growth on

structures with CP. Schools of fish are expected to hang around anodes like they do with anything suspended in the water. Dolphins, seals, turtles, stingrays, sharks and even small whales are all expected to swim under the bridge without any problems. he CP anodes for the section above T the mid-tide level will have no influence on the marine fauna. For the elements below the mid-tide level, the effect of CP current to the marine life or marine growth should be minimal or nil. ny potential effect was further A reduced by judicious CP design. For example, only sacrificial anode CP was designed for the steel piles which will have no or minimal effect on the marine life. Similarly, impressed current CP anodes were embedded in concrete to minimise the risk to marine life, flora and fauna.

Use of sound engineering practices and principles GHD has used its in-house developed computer models to predict the service life of the bridge. Since the deterioration was not uniform for all the elements, specialised repair was targeted only for certain elements which enabled formulation of a cost effective yet technically sound long term rehabilitation for the bridge.

The rehabilitation design has considered minimisation of waste by reducing the amount of concrete removal required. The detailed ecological study undertaken to assess the effect of this rehabilitation design on the marine

life, flora and fauna is considered to be unique and innovative.

An engineering challenge A defect free and durable CP system for the tidal and splash zones has been seen as a challenge. GHD worked closely with RMS and the Contractor (Marine and Civil Maintenance) to devise a rehabilitation design that would be durable in the differing exposure conditions of tidal, splash and atmospheric areas.

Careful selection of targeted repairs assisted RMS in managing the required budget for the rehabilitation work.

Significance of the work CP is a specialised repair technique for existing structures. It can also be used in new construction. The mass engineering practice has limited knowledge on this less used yet very effective corrosion control measure for reinforced concrete structures. Careful and innovative investigation and design yielded a very successful and sustainable CP system for this bridge.

The ecological study of CP on marine life, careful and targeted selection of specialised repairs to certain elements, and sound engineering practice principles used in selection of durable CP design, provided the most durable yet cost effective repairs to this deteriorated bridge structure.

Mohammad Ali GHD

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.

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

The dates and locations in 2012 are: Perth: 16th – 20th July

Course Highlights Corrosion & Its Importance The Corrosion Process Predicting Corrosion Reactions Types of Corrosion Corrosion in Natural Environments Design Improvement Corrosion Properties of Metals Inhibitors & Water Treatment

New Zealand: 1st – 5th October

Protective Coatings

Sydney: 3rd – 7th December

Cathodic & Anodic Protection

p.46 CORROSION & MATERIALS

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 June 2012â&#x20AC;&#x192; www.corrosion.com.auâ&#x20AC;&#x192;

p.47

TECHNICAL NOTE

Mild Steel Pipeline Weld Corrosion * This article is based on a presentation by Igor Chaves of the 2012 ACA Road Show Seminars.

Estimates on the cost of corrosion worldwide are in excess of AU$2.2 trillion a year (including AU$13 billion in Australia and AU$246 billion in the USA). These costs include replacement or rehabilitation of facilities and equipment and ultimately are passed on to the consumer, either directly or through increases in utility and service charges.

For engineers the potential for structural failure is always of major concern. For this reason there is a strong interest in the rate of corrosion, and in particular for pipelines, the rate of pitting corrosion. Some typical recent results are shown in the Figure (Chaves and Melchers 2011). It shows the growth in pit depth as a function of exposure time as measured on welded mild steel coupons tested under immersion seawater conditions. The black and red lines represent the pit depths for different parts of the welds. The green trend represents what is still the traditional approach for representing the depth of pitting - it has been used for more than half a century.

The Figure shows the green line as the so-called power law, which consists of a bi-logaritmic model c(t)=A·tB typically adopted to describe corrosion loss as a function of time of exposure, where A and B are constants obtained

p.48 CORROSION & MATERIALS

3.0

2.5

Parent Metal Max Pit Depth Parent Metal Mean Pit Depth Heat Affected Max Pit Depth Heat Affected Mean Pit Depth Power Law Predicted Pit Depth

2.0 Pit Depth (mm)

Welding is widely recognized as a powerful and reliable technique for the construction industry and for infrastructure. Most of these involve the use of mild and low alloy steels and they can be found in many heavy industrial applications including pipelines. However, when exposed to the marine environments mild and low alloy steels are prone to corrosion, mainly in the form of pitting attack, and usually this is particularly severe in the Heat Affected Zone of welds. This may influence the long-term safety and reliability of welded structures in marine environments. Unfortunately corrosion can occur even with the use of modern prevention and mitigation techniques such as protective coatings and cathodic protection, particularly if these are not well-maintained or where they are not feasible.

1.5

1.0

0.5

0.0 0.0

0.5

1.0

1.5 2.0 Exposure Period (years)

2.5

3.0

3.5

Figure 1. Pit Depth data for observed mean and maximum trends for Parent Metal and Heat Affected zones. empirically (Melchers 2005a). Its prediction can be quite conservative at the early stages of pitting but it is quite unconservative (optimistic) for longer term exposures and this should be of concern for infrastructure applications. The reason for the poor long-term prediction is that much corrosion research is focused on the risk of corrosion initiation and also with relatively short-term pit depth progression; typically measured in terms of hours, days or sometimes weeks. In contrast, structural engineers tend to be more concerned with the progression of corrosion with long periods of time (years, decades) and therefore with the rate of longer-term structural deterioration once corrosion has commenced. However, long term data is scarce, and anecdotally reported in the literature and corrosion handbooks (Southwell et.al. 1960, Blekkenhorst et.al. 1986, Smialowska 1986 and Melchers 2005b).

For both rational economic decisionmaking and for structural engineering assessments there is an increasingly need to estimate the likely progression

of infrastructure deterioration with time. Structural reliability theory provides a sound framework for this.

Unfortunately, currently available models for corrosion consider the parameters which may affect pitting corrosion and hence the reliability of pipelines, to be deterministic variables rather than as random variables.

Statistically speaking, an engineering random phenomenon is associated with possible outcomes. Such outcomes or events may be identified through the value or range of values of a function, which is so denominated ‘random variable’. While the value of a random variable may be defined with a range of possible values, in contrast a deterministic variable assumes a definite value.

In reality, there is always some level of uncertainty associated with environmental influences and material parameters. To take this into consideration it is necessary to employ probabilistic methods and probabilistic analyses. These are necessary inputs to account for the level of acceptable risk in design and,

TECHNICAL NOTE

ultimately, for the optimum allocation of available economic resources. This is done by accounting the uncertainty, or statistical parameters, associated with each individual random variable within the analysis. In other words, the numerical values of the random variables are associated with specific probability or probability measures (e.g. mean; standard deviation), which are then assigned according to certain rules, so called probability distributions.

There are some differences of opinion as to whether the weld metal is less resistant or more resistant relative to the base metal. However, it is wellknown that susceptibility to pitting depends on differences in the material composition and microstructure, and this may be influenced by the high temperatures involved in the welding process and the subsequent cooling rate. Both are affected by the welding procedures used (e.g. base metal indentifying equiaxed grains of ferrite and pearlite while weld zone comprise of columnar grains of acicular ferrite characterizing a quenched steel and heat affected area displaying a more finer grained region of equiaxed pearlite and Widmanstatten ferrite).

References: Blekkenhorst F, Ferrari GM, Vander Wekken CJ and Jsseling FP (1986), Development of high strength low alloy steels for marine applications, Part 1: results of long term exposure tests on commercially available and experimental steels, British Corrosion Journal 21(3) 163–76.

Chaves IA and Melchers RE (2011), Long-term marine corrosion of welds on steel piling, Proceedings of the 18th International Corrosion Conference, paper 173, Perth, Australia.

Melchers RE (2005a), The effect of corrosion on the structural reliability of steel offshore structures, Corrosion Science 47(10) 2391-2410.

Melchers RE (2005b), Statistical characterization of pitting corrosion – Part 2: Probabilistic Model, Probabilistic modelling for maximum pit depth, Corrosion 61(8) 766-777.

Southwell CR, Forgeson BW and Alexander AL (1960), Corrosion of metals in tropical environments, Part 3 – Underwater corrosion of ten structural steels, Corrosion 16 (3) 87–96.

Szklarska-Smialowska Z (1986), Pitting corrosion of metals, National association of corrosion engineers, Houston, Texas.

Weld, Heat Affected and Base metal.

From an industrial point of view, corrosion is accounted for during the design phase by means of a corrosion allowance. Recent study (Chaves and Melchers 2011) shows that the corrosion observed in the base metal is less than that in the HAZ and this continues also long-term. These observations should give a degree of confidence for extrapolation of medium to longer term data.

Although the above discussion is confined largely to pitting corrosion as an independent deterioration mechanism, in practice corrosion is not an independent issue for risk and remaining life assessments. Corrosion interacts with applied stresses, fatigue, mechanical damage and, most importantly, with protective systems such as cathodic protection, paint coatings and management practices.

In practice these interactions cannot be ignored, even though the actual interactions are not in all cases fully understood. Evidently, these interactions for particular applications also provide a rich field for further research in which probabilistic models will be important.

This is considered to be an exciting and demanding challenge.

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

UNIVERSITY PROFILE

The University of Newcastle Corrosion Research at The University of Newcastle

analysis equipment EDS, XRD) as well as bacterial testing facilities.

The corrosion research group in The University of Newcastle’s Centre for Infrastructure Performance and Reliability grew out of the increasing need for structural and other engineers to deal with the reliability and safety of existing infrastructure, particularly when it is showing signs of deterioration such as through corrosion. From its early days over 20 years ago when it was involved in the structural reliability assessment of pipelines with external corrosion losses, through modelling of the corrosion in holds in bulk carrier ships with iron ore and coal cargoes and later in ballast tanks of Navy vessels, the group is now active in a range of corrosion and corrosion reliability projects.

These receive generous support from the Australian Research Council in the form of Discovery Projects (i.e. for ‘blue sky’ research) and through Linkage grants with private industry focussed on specific industry needs.

Funding is also received from various industry groups such as a consortium of key organizations in the Australian water industry and consortium of international partners in a project for the offshore oil industry. Funding has been received also from the EPSRC (UK), the Lloyds Register Educational Trust Research Centre of Excellence (Pusan, Korea), some Australian research groups and also from the EEC’s Marie Curie BIOCOR program.

The main focus of the group’s activities is to improve understanding of the progression of corrosion with time and the development of mathematical models for the prediction of longerterm corrosion loss and maximum depth (and extent) of pitting and localized corrosion. Such models are essential for high-quality reliability analysis and future life prediction of new and of existing infrastructure.

The modelling includes spatial and temporal variability aspects essential for high quality probabilistic modelling and as input to probabilistic reliability analysis and life prediction.

Much of the group’s research is fieldbased to ensure realistic exposure conditions. The group has longstanding access to the Hunter Water Belmont Beach site for atmospheric corrosion testing and to the NSW Fisheries Research station site at Taylors Beach where it has been active for many years and has a specially controlled corrosion testing facility that includes micro-organism sterilization equipment. It also has access to a number of other sites around Australia, including Darwin Port, Australian Institute of Marine Sciences near Townsville, Newcastle Port, Navy base at Jervis Bay, DSTO Hobsons Bay site, Queenscliff Cruising Yacht Club, Hobart water police site and Port Arthur Heritage and Conservation site.

Laboratory equipment available to the group or owned by it includes a range of microscopes (optical, SEM, TEM) and

p.50 CORROSION & MATERIALS

Two of the staff in the group have been awarded prestigious Australian Research Council Professorial Fellowships. These allow them to commit themselves to full-time research. The group has received special recognition for its applied research on Microbiologically Influenced Corrosion. Most of its key research programs involve some aspects of the impact of MIC on infrastructure corrosion.

The research carried out by the group has received international recognition with many keynote lectures, extensive citations and the award of a range of research prizes. These include the TP Hoar Prize (Institute of Corrosion, UK), Guy Bengough Award (Institute of Materials, Minerals and Mining, UK) and the ACA’s Young Researcher Award, the Marshall Fordham Research Prize (4 times), the AC Kennett Award and the Corrosion Medal. There are corrosion research links with University of Portsmouth UK, Swerea-KIMAB in Sweden, Maritime University in Vladivostok, University of Queensland, Monash University, Sydney University, University of Technology Sydney, Curtin University and Swinburne University.

Current research projects 1. Coastal and inland atmospheric corrosion Developing models for the prediction of corrosion loss and for maximum pit depth of structural steels (mainly mild steel but also a little on weathering steels) as a function of micro-climatic influences. For this we are using both long-term field data reported in the

literature and data being collected at a number of sites on the Eastern Australian seaboard as well as a range of inland sites with varying degrees of atmospheric pollution.

Environmental conditions for all these sites are monitored and samples for bacterial analysis obtained. The modelling work uses the model and approach previously developed for marine immersion conditions. This includes the effect of bacterial activity on influencing the underlying electrochemistry of the reactions.

2. Pitting corrosion of steel in seawater and the effect of nutrients on bacterial activity Early work carried out in the group showed the critical role of bacterial activity on corrosion of steel, both soon after first exposure and also later.

An interesting finding was the strong correlation between bacterial activity, nutrient levels and pitting. This continues to be explored in a special rig at Taylors Beach (at NSW Fisheries) where steel coupons are exposed in parallel streams including natural seawater, seawater sterilized through filtration and UV radiation and natural seawater streams with small doses of added fertilizer. These modifications do not change the chemical properties of the seawater significantly and should not significantly affect the usual electrochemistry. However the biological conditions are altered considerably. This has important implications for corrosion in polluted waters. The outcomes could have major environmental implications as well as throwing new light on pitting behaviour.

The mathematics and statistics of pitting and localized corrosion also are under scrutiny, with the development of new models for the progression of maximum pit depth and the consequent revisiting of Extreme Value models for pitting variability. This work is being aided by the availability of maximum pit data from steel and other plates and surfaces after more than 30 years exposure.

3. Corrosion of steel sheet and other piling There is much concern, particularly in European but also in some Australian harbours about so-called Accelerated Low Water Corrosion (ALWC). This

UNIVERSITY PROFILE

occurs mainly just below the lowest astronomical tide level. It contrasts with classical observations that show most corrosion occurs at about high tide level. The reasons for ALWC are not clear but bacterial activity has been implicated in several studies, not all unequivocal. The underlying corrosion and bacterial processes currently are not well understood and there is no modelling or predictive capability at present. Tests conducted by the Newcastle corrosion research group at 13 different locations around the Eastern Australian coast line have shown that there is a high correlation between nutrient pollution and the occurrence of ALWC. This has major environmental and infrastructure implications. The work is continuing to attempt to unravel why perforation occurs in some locations and not in others and why some orientations apparently are more prone to ALWC than others. The outcomes are expected to lead to much better prediction capability for the occurrence of ALWC. 4. Corrosion of welds for subsea structural steel pipelines It is normally considered that corrosion at welds in steel is most severe in the heat-affected zone. Most of this information is based on laboratory data and experiments and there is very little predictive capability for the depth of pitting and its severity over long exposure periods. This project was initially initiated by Australian consulting engineering firm AMOG Consulting in Melbourne since there was little design and assessment guidance for corrosion of the welds on oil and similar pipelines. It used steel coupons with typical pipeline welds exposed to natural seawater. It also has access to samples cut from older steel piling. The data has allowed the mapping of changes in maximum pit depth and the corrosion loss for extended periods of exposures (up to 30 years). These observations are correlated with weld chemistry and metal microstructure.

5. Corrosion of cast iron and steel cement lined water mains External pitting corrosion of cast iron and steel water mains continues to be a problem for the water industry. This project, funded by leading members of the Water industry and with the support of the UK and the USA water industries is examining older water mains and attempting to build models for the long-term corrosion of pipes.

It will use the models developed previously within the group for the marine and fresh water corrosion of steels to build models for corrosion in-ground, allowing for the influence of varying water table and moisture conditions and the aggressive nature of some soils, including possible microbiological influences. The latter have long been recognized as important for the corrosion of cast iron pipes in water-logged soils but not studied in detail or for situations with varying soil moisture content. It also will employ the newly developed interpretation of Extreme Value theory to develop predictive tools for the likelihood of pitting in water mains. Research is also proceeding on the Linear Polarization Resistance technique used within parts of the industry to predict likely corrosion.

6. Reinforcement corrosion in hostile marine environments This project is examining why some reinforced concrete structures last many decades without much illeffect even when exposed to severe marine environments and others survive only a short time. Already it has been shown that this is not, as commonly supposed, the direct result of better workmanship or additives, or even better cement. The approach being used is archaeological in that older structures are being examined in detail. These have included the 1943-built 1.6km long, 1000 identical reinforced concrete element balustrade at Arbroath in Scotland, the 1955-built Sorell Causeway bridge in Tasmania and now the Hornibrook bridge recently demolished in Brisbane after 75 years service, without showing any serious reinforcement corrosion damage.

Tests for chloride penetration, pH and polarization resistance as well as others have been undertaken. To date it has been found that there is little difference in concrete permeability for chlorides and oxygen and that the chloride levels can be very high, even in the uncorroded elements.

Many other cases have been discussed already in the literature and possible explanations offered. Most alarming is the observation that in some cases visual inspection for bridge condition and safety may be quite misleading since it is possible also to have very severe internal corrosion without any obvious external signs. Microbiological influences are being assessed also.

In addition, laboratory-based research on the effect of reinforcement corrosion

on structural strength has been in progress for some years. Various reinforcement layouts are considered and the effect of reinforcement corrosion, accelerated by means of impressed current, is considered.

The effect of spatial variability of reinforcement corrosion and its effect on structural capacity is being considered both experimentally and theoretically.

This work is directly applicable to the assessment of the remaining life of reinforced concrete bridges.

7. Internal corrosion of reinforced concrete sewers (SCORe) The deterioration of concrete sewers in the older Australian cities such as Sydney and Melbourne is a problem of increasing concern to the Water Industry. The overall aim of this project, funded by a large Linkage grant to a consortium of Universities (Queensland, Newcastle, UNSW, Sydney) and the Water Industry is to develop more rational approaches to maintenance planning and sewer replacement. Industry needs a model to predict the likely deterioration of concrete sewers as a function of time and of (internal sewer) micro-climatic influences. Six sewers have been fitted with old and new concrete coupons and these are extracted every 12 months to build-up a profile of the changes that take place on the concrete walls and the loss of concrete due to bacterial and chemical reactions.

Microbiological analyses are being done in conjunction with the University of Queensland. The mathematical modelling work is being done at Newcastle.

8. Corrosion of mooring chain and wire rope for the offshore oil industry (SCORCH-JIP) A major research project being undertaken for an internationally funded oil-industry Joint Industry Project is investigating the corrosion of mooring chains and wire rope used to moor large vessels that are floating bases for oil production, storage and offloading in very deep waters (currently to 2km depths and deeper waters forecast).

Maintaining the FPSO vessels ‘onstation’ is critical and requires highly reliable mooring systems for which the rate of deterioration is known or can be predicted. Recent experience in the Tropics has shown that current design requirements, based on North Sea experience appear to be insufficient to predict inspection intervals and chain and wire life. The project is investigating

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

UNIVERSITY PROFILE

the corrosion of chains and wire rope with the aid of the corrosion modelling work available from earlier studies carried out in the group.

9. Corrosion of water-injection pipelines in the oil industry In conjunction with the EEC-funded research project BIOCOR and the Swedish corrosion and materials research organization Swerea-KIMAB this project is focussed on the internal corrosion of water injection pipelines used to inject a cocktail of sea and other water, including ‘produced water’, into subsea oil wells to permit greater oil extraction. The pipelines are known to suffer from severe corrosion, usually attributed to microbiological effects. Biocides are used to control this but the environmental effects can be undesirable and the costs high. Understanding of the relative contribution of bacteria to the internal corrosion is not well developed and models for predicting corrosion losses and pitting are desired by industry.

Data for the research is being provided

by Statoil (Norway). This project is attempting to develop these based on the previous Newcastle research results. Prof Rob Melchers is a visiting scientific advisor to the project, funded

by BIOCOR. The researchers Prof Rob Melchers is Professor of Civil Engineering specializing in structural engineering and with extensive specialized consulting experience. He initiated the corrosion group within the University of Newcastle’s Centre for Infrastructure Performance and Reliability. He is internationally recognized for his research and publications on probabilistic structural reliability analysis and more recently for his development of probabilistic mathematical models for marine general corrosion and for pitting, including extreme value analyses.

Currently he manages the corrosion group and leads its scientific research effort. He is a recipient of the ACA Corrosion Medal as well as a number of other awards for corrosion research.

Prof Mark Stewart is an international expert in structural reliability, risk analysis, blast loading and also in the corrosion of reinforcement and the effect of this on

p.52 CORROSION & MATERIALS

concrete structure integrity and safety.

He has gained many research grants including in the area of reinforcement corrosion particularly as it affects the safety of reinforced concrete bridges.

He has published books on engineering risk assessment and on international terrorism as well a having an extensive publication record in structural safety and in reinforcement corrosion.

Dr Robert Jeffrey has been a key member of the corrosion group for many years.

Currently a senior Research Associate, he is a Newcastle chemical engineering graduate who completed his PhD on the microbiological aspects of the marine corrosion of steel. Prior to returning to the University he gained many years industrial experience in corrosion research. He is heavily involved in marine, tidal, coastal atmospheric and inland atmospheric corrosion research, including the facility at Taylors Beach and the research on ALWC. He also manages the field studies for the SCORCH-JIP project. He has published numerous papers in the leading corrosion and corrosion science journals as well as many conference papers.

Dr ‘Tony’ Wells, a senior Research Associate, is a chemical engineer with a wide range of research experience, including the investigation of the influence of moisture on glass fibre composites, research that has received a significant citation rate. Currently he is working on the internal corrosion of reinforced concrete sewers. He manages the extensive field studies involving 6 sewers in 3 states and is developing computational models for concrete sewer wall loss prediction using also microbiological analysis results and localized internal sewer environmental inputs.

Dr Torill Pape was awarded a PhD in a civil engineering for her research on pre-stressed concrete bridge prestress strand corrosion and specializes in reinforcement corrosion.

A Research Associate in the corrosion group she is currently investigating the Hornibrook bridge recently demolished in Brisbane. She also is working on the influence of concrete mix design and aggregate material properties on longterm reinforcement corrosion durability.

Dr Robert Petersen is a civil engineering and PhD graduate from the University of Newcastle.

Prior to joining the corrosion group to work on the cast iron water pipe project he was involved in research on mathematical modelling of the behaviour of masonry structures.

Dr Mukshed Ahammed is a Research Associate and holds a PhD in engineering in structural reliability analysis and acts as principal computational advisor and programmer for the corrosion research group. He has published numerous papers in international journals, including papers on pipeline corrosion and reliability that have significant citation records.

Dr Iulian Comanescu is a post-doctoral engineer researcher based at the Corrosion in Aggressive Environment group at Swerea-KIMAB and working with Prof Rob Melchers of the Newcastle corrosion group. Iulian is investigating the relative importance of bacteria in the internal corrosion of water injection steel pipelines for the oil industry.

Dr David Nicholas (Conjoint Research Fellow), a recipient of the ACA Corrosion Medal, is very wellknown in the water industry for his corrosion expertise. He acts as scientific advisor to several of the Newcastle research projects.

Dr Kayley M Usher (Conjoint Research Fellow) has a PhD in microbiology from UWA and an impressive international journal publication record in this area.

She acts as an expert advisor to the group’s research efforts in MIC.

INDUSTRY INSIGHT

Protecting the Protection: What can Patent Filing Trends Tell us About Technology Trends in Corrosion Treatments?

Summary 20,000 global patent families (containing 60,000 patents in total) filed in the area of corrosion management in the last decade were reviewed as a guide to trends in corrosion technology. Annual patent filings grew from around 1500 to around 2,000 per year over this decade.

However this growth in patent filings hide a significant fall in patent families from Japanese applicants, and an even larger rise in patent filings from Chinese applicants. Applicants from South Korea, the US and Germany were also prolific filers, with applicants from the US and Germany most likely to file patents outside of their home countries.

This was much less likely with Chinese, South Korean or Japanese applicants.

The most active technology area for patent filings was anti-corrosion paints, followed by galvanising and multilayer coatings. Anti-corrosion paints were also the fastest growing area.

Only about 5% of these patent families had Australian family members, and only 31 families in total originated in Australia, which is a lower proportion than we have seen in some other technologies. The leading applicant filing into Australia was Henkel of Germany, followed by Nippon Steel and PPG Industries of the US. Overall, there appears to be healthy global activity in the patenting of corrosion technologies which is likely to reflect R&D of new inventions in corrosion treatments. However, very little of this patenting activity appears to be happening in Australia.

Introduction Corrosion presents a significant issue to a wide range of industries. It has been estimated that the annual global cost of corrosion is over 3% of global GDP1 or around US$2.2 trillion. Addressing corrosion problems will continue to require ongoing research to find new and innovative solutions2. Whilst these

problems are significant and varying, they can also be seen as an opportunity, as they offer appreciable commercial rewards for finding and implementing new solutions.

C09D: Paints

As in any technical field, research into finding such new and innovative solutions for managing corrosion often results in the filing of patent applications. Patents can therefore provide a source of information on what research is being conducted, information that might not be available through other means. By studying patent filing trends in a technical field, such as corrosion, an insight can be gained into the areas within that field that are being researched including who is doing this research and where the resulting outcomes are being patented.

23: Coating metals, inhibiting C corrosion, anodic and cathodic protection and surface treatment

Moreover, many patent applications contain commercially valuable solutions to common problems in an industry. Since most patent applications are only filed in one or a handful of countries, the inventions disclosed in these patent applications may be freely available to use in other countries.

In this paper we look at global patent filings in corrosion related technologies in the last decade in order to understand trends in technology development and the associated patent filings.

What we did To analyse patent trends in corrosion related technologies, we first produced a data set of relevant patents by conducting a search in the Patbase commercial patent database. The search was based on classes of the International Patent Classification (IPC)3. All patents are independently classified by various Patent Offices into relevant classes of the International Patent Classification, and patents are regularly classified in more than one class.

Classes of the International Patent Classification that we searched were:

09K: Anti-oxidant compositions C and compositions for inhibiting chemical change

We filtered the search results by combining the above classes with relevant keywords including “corrosion”, “corrode”, “rust”, “anticorrosion” and “galvanise”.

Finally, so that we were considering only recent patent trends in corrosion technologies, we limited our search results to patents having a priority date of on or after 1 January 19984.

The reason for choosing this date is that publication of a patent (except in special circumstances) does not occur until 18 months after its priority date.

Therefore, this priority date limitation will capture patents that were published from mid-1999. At the other end of the timeline for our results, this 18 month publication delay in the normal patent process means that our patent data becomes less reliable in capturing all patents that have been filed since mid-2010.

The search results contained 21,478 patent families containing approximately 60,000 patents. A patent family consists of one or more patents directed to the same invention.

Typically, a patent family consists of an initial patent application in the home country of the patent applicant and any corresponding patents filed overseas for the same invention as in the initial patent application and claiming the same priority date. Our analysis of the search results is based on patent families because, as a general principle, one patent family equals one invention.

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

INDUSTRY INSIGHT

The major Asian countries Japan, China and South Korea dominate the overall patent filings. Japanese patents have been falling from approximately 900 patent families to approximately 300 patent families, but Chinese filings have been increasing by more than enough to compensate for this. This phenomenon of Asian and in particular Chinese growth in patent filings is not contained to corrosion related technology, but is seen across many technical fields and overall patent filings5.

While there is a drop-off after 2009, it is hard to say at this stage how much of this is due to the 18 month publication delay for patents. Hence, this drop-off in very recent patent filings should be ignored, at least until for a year or two until after this very recent data can be confirmed.

The relative proportion of US patents is lower than we have seen in other technical fields we have looked at. It is not clear why this is so.

The majority of corrosion patents are only filed in the applicant’s home country, Figure 2.

Figure 2 shows that Chinese patent applicants almost entirely only file Chinese corrosion patents. Similarly, the majority of Japanese and South Korean corrosion patents are only filed

in their respective home countries.

This is also a result that is observed across many other technical fields.

In respect of Chinese patents, it has been reported6 that the Chinese government offers a range of incentives to businesses and researchers to file more patents, which may be the cause of the results shown in Figures 1 and 2.

This has led to a debate on the quality of these Chinese patents. However, any assessment of patent quality is beyond the scope of this paper.

Figure 2 suggests that Chinese patent applicants have a very inward view on corrosion technology, particularly compared to US and German companies which are more likely than not to file overseas patents.

Hence, despite the increased patenting activity, China may still be a net importer of corrosion innovation. US and German companies, on the other hand, have a much more outward facing view with respect to their corrosion technologies and seek to export those technologies overseas.

Figure 2 also suggests that China and Japan are a potential source of corrosion technology which can be used overseas, including in Australia, without patent infringement. The legal protection provided by a patent is limited to the jurisdiction in which it is filed. Accordingly, the subject matter of the Chinese and Japanese patents only filed in their respective countries may be used in other countries without infringing those patents.

The most popular IPC patent class for corrosion patents was C09D 5/08

Number of corrosion patent families filed in each year

Japan and increasingly China lead global corrosion patent family findings 2500 2000 Rest of world

1500

Germany Russia

1000

US South Korea

500

China Japan

0

2000

2002

2006

2008

2010

Priority year for patent filings

Figure 1: Overall trends in filing of corrosion patent families

p.54 CORROSION & MATERIALS

Number of corrosion patent families filed 2000 to 2011

What we found Corrosion patent filings sat at around 1500 patent families annually worldwide in the first part of the decade searched, but then grew toward the end of the decade, Figure 1.

“Anti-corrosion paints”, particularly in the last four years, Figure 3. Anticorrosion paints has also seen a strong increase in patenting activity over the past decade from around 500 patent families during 1999-2002 to nearly 1000 patent families by 2007-2010, making it the fastest growing patent class. The next most active class is zinc or cadmium based hot dipping.

As zinc hot dipping is used to produce galvanised steel for both building and automotive industries, there is probably some correlation here with the industrialisation of China.

Figures 4 and 5 set out the top 10 patent applicants for all patent families (Figure 4) and for patent families which include at least one non-home country patent (Figure 5).

Japanese companies dominate the overall leading corrosion patent family filers, Figure 4. It is also noted that the top five overall patent family filers are steel companies. However, when international corrosion patent families are considered, Figure 5, the leading companies are more widespread in their location and business interests.

An interesting aspect of Figures 4 and 5 is that there are no Chinese entities amongst the leading corrosion patent filers. This suggests that, in China, patent activity and research in corrosion is more widespread but less concentrated, whereas patent activity in Japan, the US, Germany and Korea in corrosion technology is carried out by only a relatively small number of key players.

9000 8000 7000 6000 5000 4000 3000 2000 1000 0

Outside of home country Only home country

Japan

China

South Korea

US

Russia

Germany Rest of world

First priority country of patent filing

Figure 2: Analysis of whether patents are being filed outside of the applicant’s home country

INDUSTRY INSIGHT

But the leading companies are more widespread when international patent families are considered

The majority of corrosion patents are only filed in the applicant’s home country C09D 5/08, Anti-corrosive paints JFE Steel (JP)

C23C 02/06, Zinc or cadium based hot dipping

Nippon Steel (JP)

C23C 28/00, Multi-layer coating

General Electric (US)

C09D 163/00, Epoxy resin coatings

Hitachi (JP)

B05D 07/14, Chemical binding of liquid coatings

Kansai Paint Co. (JP)

1999 – 2002

Siemens (Germany)

2003 – 2006

Nippon Paint Co. (JP)

2007 – 2010

C23F 11/00, Corrosion inhibitors 1999 – 2002

C22C 38/00, Steel alloys

POSCO (KR)

2003 – 2006

B32B 15/08, Layered products of metal and resin C23F 13/00, Anodic or cathodic protection of metals C23C 02/00, Tin or alloys based hot dipping

Nihon Parkerizing (JP)

2007 – 2010

0 20 40 60 80 Number of patent families filed with family members outside of home country, in time period

Figure 5: Top ten corrosion patent filers (international families only)

0 500 1000 1500 Number of patent families filed in 4 year blocks that list this IPC class

Figure 3: Leading IPC classes for corrosion patent filings

Shanghai University and BaoSteel led list of Chinese corrosion patent family filers Shanghai University

Japanese companies lead patent applicants (all patent families)

Baosteel

Nippon Steel (JP)

Wuxi Linlong Aluminium

JFE Steel (JP)

BYD

POSCO (KR)

Institute of Metal Research

Sumitomo (JP)

Institute of Oceanology

Kawasaki Steel (JP)

Anji Microelectronics Kunming University of Science and Technology Zhejiang University

Kansai Paint Co. (JP)

1999 – 2002

Hitachi (JP)

2003 – 2006

Nisshin Steel (JP)

2007 – 2010

1999 – 2002 2003 – 2006 2007 – 2010

Tianjin Zhendong Paints China National Petroleum Corporation

Mitsubishi (JP)

0

Nippon Paint Co. (JP) 0

100 200 300 Number of patent families filed in time period

400

20 40 60 80 Number of Chinese originating patent families, in time period

Figure 6: Top ten corrosion patent filers from China

Figure 4: Top ten corrosion patent filers (all applicants) Figure 6 shows the leading Chinese corrosion patent filers. One of those leading filers is BYD, a rechargeable battery, electric car and solar company which Warren Buffet has a 10% stake in. Another interesting aspect of Figure 6 is that the profile of Chinese corrosion patent filers includes companies from a wider variety of industries but, in particular, is dominated by universities and research institutions. This can be compared to the national steel makers in Japan and Korea and the multinational chemical and engineering firms from Germany and the US. It is still unclear how many of these university and research institute originating inventions will eventually be commercialised.

Only 31 of these patent families originate from Australia, Figure 7.

These low numbers make it difficult to reliable draw any trends from this data.

In contrast, there were a total of 1078 patent families with Australian family members. Figures 8 and 9 show what corrosion patents have been filed in Australia by applicant, whether an Australian or overseasbased applicant (Figure 8) and by area of technology (Figure 9). As shown in Figure 8, the leading filers of corrosion related patents were US, German and Japanese companies. There are no Chinese filers amongst these top ten applicants. Henkel (sealants and surface treatments) led this list, although their activity has slowed as of late.

In Figure 9 it can be seen that, as with the global situation in Figure 1, anticorrosion paints is the leading area of corrosion technology for Australian patents. Zinc or cadmium based hot dipping is of much lower importance for Australian patents than globally.

This perhaps reflects the difficulties of Australia’s local steel businesses as well as the fact that many of the leading global patent filers are Japanese and Korean steel makers who don’t file large numbers of corrosion patents in Australia.

Overall, only about 5% of global patent families had Australian family members.

Even US and German companies, who have a tendency to export their technology and file overseas patents, are

June 2012 www.corrosion.com.au p.55

INDUSTRY INSIGHT

Only small numbers of patent families come from Australia

not filing patents in Australia as much as they are filing in other countries. To an extent, this reflects the relative size of Australia’s economy and the likelihood these companies consider that they will make a return on their investment in an Australian patent, as compared to patents filed in other countries. It does present, however, a further opportunity for Australia companies to potentially use commercially useful corrosion technologies which are the subject of patent protection overseas but not in Australia (subject to a confirmation from a suitably qualified patent specialist).

7

Number of corrosion patent families with Australain priority claims

6 5 4 3 2 1 0

2000

2002

2004

Priority year

2006

2008

2010

Interestingly, for Australian corrosion patents, companies from the oil & gas industry (Exxon Mobile and Baker Hughes) and pipe manufacturers (Thyssen Krupp, Nippon Steel, JFE Steel and Sumitomo) are amongst the leading filers of corrosion patents. The Japanese companies aside, this is very different to the list of leading patent filers globally and perhaps reflects the increased commercial activity in CSG and LNG projects throughout Australia.

Figure 7: Trends for Australian originating patents Henkel was the leading filer in Australia, but has greatly slowed activity. Nippon Steel, PPG Industries (coatings) and ExxonMobil (lubricants and surface treatments) Henkel (Germany) Nippon Steel (JP) PPG Industries (US) Exxonmobil (US) ThyssenKrupp (Germany)

1999 – 2002

JFE Steel (JP) 2003 – 2006

Chemetall (US)

2007 – 2010

Baker Hughes (US) Sumitomo (JP) Nippon Paint (JP) 0

10 20 30 40 Number of patent families with Australian family member, in time period

50

Figure 8: Leader filings of corrosion patents in Australia Anti-corrosive paints most popular IPC class for corrosion patents filed in Australia C09D 5/08, Anti-corrosive paints C23C 28/00, Multi-layer coating C23F 11/00, Corrosion inhibitors C23C 02/06, Zin or cadium based hot dipping C23F 13/00, Anodic or Cathodic protection of metals B05D 07/14, Chemical binding of liquid coatings

1999 – 2002

C09D 163/00, Epoxy resin coatings

2003 – 2006

B32B 15/08, Layered products of metal and resin

2007 – 2010

C22C 38/00, Steel alloys C23C 02/00, Tin or alloys based hot dipping 0

20 40 60 80 Number of patent families with Australian family member, in time period

Figure 9: Leading IPC classes for corrosion patents filed in Australia

p.56 CORROSION & MATERIALS

Discussion Corrosion is an issue of global significance and, not surprisingly, is attracting worldwide R&D effort. This is reflected in over 1500 new patent families per year, in theory each for unique inventions (in practice there is likely to be significant overlap in these inventions). In some ways, the types of inventions filed are not overly surprising, being predominately focused on coatings and galvanising type treatments.

What is perhaps more surprising is where these patents came from.

In many other areas of technology we have reviewed, the US has been a leading source of technology. In contrast, Japan, China and South Korea lead the patent filings in this study.

This may reflect the recent growth in the economies of the last two countries, and the long standing engineering excellence of many Japanese companies. However, the majority of the patent families filed in Japan, China and South Korea are only filed in these countries, which may reflect local factors that encourage applicants to file local patents.

The number of patent families filed by Australian applicants is very low, again in comparison to other technical areas.

It is unrealistic to expect Australia to be at the forefront of every technical area, and the relatively small size of the Australian engineering sector

INDUSTRY INSIGHT

may mean that it has little natural competitive advantage in this area.

This is entirely understandable, but does raise a risk for Australia. For a country to absorb a new technology, the technology has to be easy to understand or at least use (for example new paint formulations), or there must be significant expertise within that country that is capable of understanding and applying this new technology. This in fact is a key role of researchers, not just developing new technology but also understanding and applying new technologies developed elsewhere. On the other hand, many new corrosion treatments such as new paints may be relatively easy to apply, regardless of their underlying sophisticated technologies. Also the importers of these technologies will often provide technical support to their users as part of their service. Overall, given Australia’s limited resources, the

Coating with

Confidence

results of this patent study perhaps indicate an ongoing need for corrosion research and knowledge building in this country to be focussed on problems specific to Australia and in technology fields which are not readily adopted from overseas.

Andrew Davey and Mike Lloyd Griffith Hack

invention of the subject patent and is date at which the validity of a patent is assessed. A further patent may be filed for the same invention and claim the priority date of the first filed application (within specific time limits).

Thus the priority date of a patent can be different from its filing date.

References [1] http://www.corrosion.org/images_ index/nowisthetime.pdf

[5] http://www.reuters.com/ article/2012/03/05/us-patentsidUSTRE82416120120305 and http://www.economist.com/ node/17257940?story_id=17257940

[2] http://www.corrosion.org/images_ index/whitepaper.pdf

[6] http://www.economist.com/ node/17257940?story_id=17257940

[3] http://www.wipo.int/ ipcpub/#refresh=page [4] The priority date of a patent is the date of filing of the first patent application which discloses the

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