ipcm® Protective Coatings - June 2019 by ipcm® International Paint&Coating Magazine

ISSN 2282-1767

Protective Coatings Â®

ipcm_PC digital on www.myipcm.com

THE MAGAZINE ABOUT CORROSION CONTROL AND PREVENTION TECHNOLOGIES 2019 - 8th Year | Quarterly - N.30 June

No Bubbles, No Blooming New Interpon 610 Low-E Antigassing

Find out more at www.interpon.com

Monti’s Bristle Blasting® Solutions

The Subsea is Monti’s new hydraulic underwater device. Some call it the Aquablaster due to its unique water drive. Connected with a power unit via a single, neutrally buoyant high-pressure hose, the Subsea creates a surface preparation grade comparable to SA2.5 or SA3, with roughness levels up to 50 µm Rz. Excellent for pipeline composite reinforcements and subsea welding activity on ships, port infrastructure and subsea pipelines.

• Water pressure : 100 - 300 bar (1,450 - 4,350 psi) • Water flow : 20 - 40 LPM (5.3 - 10.6 GPM)

www.montipower.com

Africa - Americas - Australasia - Brazil - China - France - Germany - Holland - India - Japan - Middle East - Russia - South East Asia - UK

BRISTLE ® BLASTER SUBSEA

PROUDLY PRESENTED BY:

CROWN PROMENADE MELBOURNE, AUSTRALIA 24–27 NOVEMBER 2019

Corrosion & Prevention 2019

The Destination – Melbourne

In 2019, the ACA Victorian Branch will host the annual ACA conference in Melbourne at Crown Promenade.

Compact and diverse, Melbourne, Victoria is a perfect playground for adventurers and wildlife lovers, foodies and road trippers. Discover remote beaches and rugged coastlines, alpine outlooks and lush forests, all within easy reach of Melbourne, Australia’s culinary and coffee capital. See kangaroos, koalas, seals and dolphins in the wild. Indulge in ﬁne dining and winery wanders, and sleep in ﬁve star luxury accommodation or under millions more. Wherever you go, you’re never far from spectacular nature and fabulous food and wine.

The annual ACA conference is a 3 day gathering of world experts on corrosion mitigation. This will be a premium networking event as well as a source for the latest information concerning corrosion mitigation. Entitled Corrosion & Prevention 2019, the conference will comprise a program of keynote speakers and presentations under a range of industry ‘streams’, integrated with an exhibition that will showcase the latest products and services of the corrosion mitigation industry. Over 500 delegates and visitors are expected to attend from industries such as; protective coatings, water, defence, building and construction, mining, oil & gas, cathodic protection, power and more.

Melbourne is a creative, exciting, ever-changing city with extraordinary surprises to be discovered in every basement, rooftop and laneway. The possibilities are endless, so forget what you think you know.

For more information and to register go to conference.corrosion.com.au

in this issue 02

EDITOR’S LETTER

ANALYSIS 04

Corrosion in concrete constructions

BRAND NEW

fabiobag©adobe

INNOVATIONS 14

Long term corrosion protection performance and activity of graphene-based epoxy coating systems for aluminium and its alloys

HIGHLIGHT OF THE MONTH 22

Hempafire Pro 315 - Fast Dry increases eﬃciency for leading UK applicators

dvoevnore©adobe

INNOVATIONS 24

Manual, flexible and cost-eﬃcient coating as never before with the new airspray gun GM 1030P from WAGNER

SUCCESS STORIES 26

Cactus Industrial has landed a contract to supply the Bristle Blaster technology to the UK Ministry of Defence

Blasting with stainless steel: high durability, lower wear, more control

Project spotlight: three-tank overcoat at Helena, Alabama

Total Materia, the most complete database of construction materials in the world

The importance of having the right approach

FOCUS ON TECHNOLOGY

HIGHLIGHT OF THE MONTH

SUSTAINABILITY

INNOVATIONS 32

Corrosion protection in hydraulic steel constructions

FOCUS ON TECHNOLOGY 34

History in the making: the San Michele Bridge and Colorificio Veneziani

Five on Five Interview: sustainability according to the industry players - Part II

INSPECTION LOGBOOK 56

Coating inspections: some general considerations

FOCUS ON TECHNOLOGY 58

Corrosion causes rail accidents

INNOVATIONS

TRADE FAIRS & CONFERENCES

Researchers develop a new class of ice-proof coatings that shed ice eﬀortlessly

ZOOM ON EVENTS

39 BRAND NEW

EDITOR’S LETTER

pcm®_Protective Coatings was the media partner of Infracorr 2019, the conference held on May, 28 at Palazzo Turati in Milan and aimed at presenting the best technologies available

for the corrosion prevention and protection of bridges and roads as well as the good practices of design, inspection, and maintenance of these structures. It was organised by EOS Mktg&Communication (the publisher of ipcm®_Protective

Coatings), InnovhubSSI (the partner for Lombardy of the Enterprise Europe Network, which is the largest European network in support of firms innovation, internationalisation, and competitiveness), and PoliLaPP (the “Pietro Pedeferri” laboratory for material corrosion of Politecnico di Milano). Specifically, it combined a conference with an exhibition and a technical consultancy session targeted to the event participants – an audience of about 100 operators in the sector. Why organise a conference on the corrosion management of infrastructure? Because corrosion is an unavoidable natural process which we are confronted every day and that entails huge costs, equal to several percentage points of each nation’s GDP, and oftenunderestimated effects on safety. Inspired by the tragic events of the summer of 2018, when a long stretch of the Morandi Bridge collapsed in Genoa also due to the corrosion of bridge stays, the Infracorr conference aimed at providing answers about the best practices for the design of steel and concrete structures and the management of their corrosion during both construction and maintenance, for the purposes of durability. Therefore, the event was divided into two sessions: the morning one was dedicated to the analysis of design technologies and the afternoon one to that of maintenance technologies. Both included the presentation of numerous case studies about the application of such technologies (or the lack thereof and its consequences). Structural failures such as those of the Morandi Bridge are a danger that unites Europe and the rest of the world. Besides the environmental aggressiveness and pollution conditions that increase the degradation of bridges and infrastructure, the problem lies in the evergreater use of heavy vehicles for road transport. Indeed, not all failures or collapses are caused by corrosion, but this remains a serious threat and an important factor, because it is a subtle and difficult-to-assess phenomenon. That is why the primary purpose of ipcm®_Protective Coatings and of the events it organises is to divulge the latest technologies and innovations for corrosion management. The technical support offered by Politecnico di Milano was crucial to the success of the Infracorr conference. The teachers and researchers of PoliLaPP, in particular professor Marco Ormellese who coordinated the project, presented four reports, about design measures and material choices in the construction of new infrastructure; corrosion of steel and reinforced concrete structures; design techniques of concrete structures to ensure maximum durability; and inspection and restoration of reinforced concrete with traditional and electrochemical technologies. The event partner companies, on the other hand, presented the various technological solutions available for preventing corrosion. These ranged from surface preparation (MEC Crios) to cathodic protection (Cescor), from protective coatings for steel (Colorificio Zetagì) and for concrete (Mapei) to passive fire protection systems (Sika Italy) and their related application technologies (SAMES KREMLIN), from migrating corrosion inhibitors (Cortec) to quality control methods (Helmut Fischer). InnovhubSSI director and ipcm®_Academy teacher

Alessia Venturi Editor-in-chief

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Gianmaria Gasperini presented an accelerated method for the analysis of the corrosion resistance behaviour of protective coatings: ACET, available at the Innovhub lab in Milan for

any company requesting it, is a fundamental technique for predicting durability and schedule maintenance. Finally, we could not but involve a coating inspector. NACE III certified inspector and ipcm®_Protective Coatings collaborator Massimo Cornago moderated the conference thanks to his thirty-year experience in corrosion management in the energy sector and even presented a report about the importance of entrusting controls to certified inspectors able to identify any failure and help asset managers plan maintenance. Cornago also highlighted the importance for inspectors to check detailed project specifications and reports of previous inspections with photographs, use inspection materials and guides, and carry out a thorough pre-job meeting with all the professionals involved. This theme is taken up in the pages of ipcm®_Protective Coatings, which, since the last issue, has included a content section precisely about inspectors. This magazine issue also contains some of the reports presented at the Infracorr conference; other reports were included in the April 2019 and October 2018 issues. That testifies to the eﬀorts made by ipcm®_Protective Coatings to constantly oﬀer accurate information aimed at fighting corrosion in all industrial sectors.

©ipcm

ipcm® Protective Coatings - 2019 JUNE - N.30

dvoevnore © adobe

ANALYSIS

Corrosion in Concrete Constructions Luiz Paulo Gomes IEC-Instalações e Engenharia de Corrosão Ltda. – Rio de Janeiro, Brazil LPgomes@iecengenharia.com.br

oncrete, while new and in good conditions, has high pH and high electrical resistivity. These features provide excellent corrosion

protection for the reinforcing steel rebars. Over time, concrete can absorb water, CO2, chlorides and other

pollutants. This contamination reduces the pH and electrical resistivity of the concrete. When this happens the concrete turns into an excellent electrolyte, allowing the operation of the corrosion cells. The absorption of water, chlorides, CO2 and other pollutants is very

common to happen, being the main cause of deterioration of concrete works (ref. Opening photo).

Water, chlorides, and pollutants generally reduce the electrical resistivity of the concrete, allowing corrosion cells to run easily. The corrosion equations in these cases are well known:

Fe  Fe++ + 2e½ O2 + H2O + 2e-  2OHFe++ + 2Cl-  FeCl2 FeCl2 + 2OH-  Fe(OH)2 + 2Cl2Fe(OH)2 + ½ O2  Fe2O3 + 2H2O

The resulting corrosion product, the rust, occupies a much larger volume than the mass of corroded steel and the concrete bursts, allowing more water, chlorides, CO2 and pollutants to enter, increasing the corrosion process.

On the other hand, the absorption of CO2 causes the carbonation of the

concrete, decreasing the pH and depolarizing the steel, according to the equation below, also well known: Opening photo: The absorption of water, chlorides, CO2 and other pollutants is very common, being the main cause of deterioration of concrete works.

Ca(OH)2 + CO2 (pH>12)  CaCO3 + H2O (pH<9)

We are all accustomed to seeing this situation in bridges, viaducts, concrete roads, concrete piles and buildings in general (Figs. 1 and 2). To protect the steel rebars against corrosion the best solution is the use of a cathodic protection system, with galvanic anodes or impressed

N.30 - 2019 JUNE - ipcm® Protective Coatings

ANALYSIS

Figures 1 and 2 - Corroded steel rebars, a common situation to be observed in bridges, concrete highways, viaducts, concrete piles and buildings in general.

current, specially designed for this purpose.

without the need to break the concrete.

With the galvanic cathodic protection we can use zinc anodes,

This happens very often in columns, beams, pillars, piles and walls,

developed by Vector-Corrosion Technologies, which uses a special

where corrosion problems are diagnosed by measuring the potential of

encapsulation with appropriate high pH mortar, to keep them

the steel reinforcement in relation to concrete, the so-called corrosion

permanently activated inside the concrete.

potential.

The core of each anode is fused with an annealed wire core to allow

In these cases holes are made in the concrete structure for the

them to be tied to the steel rebar with ease.

installation of cylindrical anodes, specially developed for these

These anodes can be manufactured in various types, shapes and sizes,

applications.

depending on the application.

The anode electric cable is electrically connected to the rebar with a special technique, without the need to expose the steel (Fig. 3).

The galvanic anodes can be installed in three diﬀerent situations:

In the case of large structures the most indicated cathodic protection

• First situation: in new structures, during construction and before

system may be the impressed current type system, where special inert

concreting.

anodes fed by one or more current rectifiers are used.

• Second situation: during the repair and reinforcement of concrete

The definition of the most suitable method of cathodic protection

structures. When the rebars are exposed.

(galvanic or impressed current) depends on a careful study where the

• Third situation: in cases where the rebars are not exposed (no need to

technical and economic advantages of each method for a given concrete

break concrete to expose the rebars).

structure are analysed. For the evaluation and corrosion study of the steel rebars of a concrete structure we always use the analysis of the

In structural recovery services, the interface between old concrete and

potentials of the steel in relation to the concrete (corrosion potentials),

new recovery concrete adds significant cells of corrosion to the steel.

measured with the aid of a high impedance voltmeter and a reference

The installation of galvanic anodes in these regions is of fundamental

electrode (Cu/CuSO4 reference cell), according to ASTM Standard

importance to avoid new and even more severe problems of corrosion

C876-15 (Standard Test Method for Corrosion Potentials Uncoated

damage.

Reinforced Steel in Concrete).

We must always take advantage of the fact that the steel is exposed and install the cathodic protection anodes, easily and at low cost, before the

In these cases, the following situations may occur:

concreting of the recovered sites.

• First situation: potential more negative than -350mV (high risk of

Therefore, we can safely say that there is no justification, neither

corrosion, active corrosion).

technical nor economic, for this procedure is not adopted during

• Second situation: potential between -350mV and -200mV (medium risk

structural recovery activities.

of corrosion, moderate corrosion).

Anodes can also be installed without the steel rebar being exposed and

• Third situation: potential less negative than -200mV (low risk of

ipcm® Protective Coatings - 2019 JUNE - N.30

ANALYSIS

Figure 3 - Examples of installation of galvanic anodes in concrete structures where the steel rebar is not exposed.

corrosion, passivated steel).

Conclusions

In addition to ASTM C 876-15, the following standards are used for the

Corrosion problems in concrete structures are quite frequent and need

application of cathodic protection in concrete structures:

to be studied very carefully and it is important that they are correctly

• ISO12696: 2016 (Cathodic Protection of Steel in Concrete)

diagnosed.

• Standard NACE SP0187-2017 (Design for Corrosion Control of

The use of cathodic protection with the use of galvanic anodes (galvanic

Reinforcing Steel in Concrete)

cathodic protection) or, in special situations, with inert anodes and

• Standard NACE SP0112-2017 (Corrosion Management of Atmospheric

current rectifiers (cathodic protection by impressed current) is an

Exposed Reinforced Concrete Structures)

important solution, allowing us to guarantee reliable results over the

• Standard NACE SP0290-2007 (Impressed Current Cathodic Protection

long term.

of Reinforcing Steel in Atmospheric and Exposed Concrete Structures)

The cathodic protection facility can always be complemented with other

• Standard NACE SP0408 (Cathodic Protection of Reinforcing Steel in

corrosion protection methods, such as the use of special concrete,

Buried or Submerged Concrete Structures).

polymer injection, painting, coating and galvanizing of the reinforcement, but it is the only solution that can be used alone and safely without the

Recommended Procedure

use of any other protective measure.

The procedure that we have used frequently and that we recommend

The installation of galvanic anodes is always recommended in all

to adopt for the study, design, supply and installation of the cathodic

structural recovery and reinforcement activities and of extreme

protection system in concrete structures is the following:

importance to avoid the continuity of corrosive processes in concrete

• First step: analysis of drawings, visual inspection, measurements of

structures in general, even before the first signs of deterioration begin

steel rebars potentials and other field measurements.

to appear.

• Second step: analysis of the field information and preparation of the

In these situations the measurements of corrosion potentials are of

cathodic protection project, with definition of the type of protection to

extreme importance for the study and elaboration of an accurate

be used (galvanic or printed current), specification of materials, drawings

diagnosis. ‹

and installation instructions. • Third step: supply of materials and installation of anodes, including Warranty Certificates.

N.30 - 2019 JUNE - ipcm® Protective Coatings

BRAND-NEW

AkzoNobel’s New Digital Tool Helps Ship Owners Improve Dry Docking Eﬀiciency Owners and operators of shipping fleets can now better control their

informed decisions about upcoming dry docking requirements,

dry docking costs with an ingenious new digital tool developed by

which in turn will help them to better control their maintenance costs.”

AkzoNobel.

Adds Massimo Rubesa, Coatings and Materials Specialist at

Stolt Tankers Shipowning: “As a company that sees the value in nown as DryDoQ Insights, it closely predicts the condition of a

exploring the latest innovations in terms of products and services

vessel’s underwater hull without the need for visual inspection.

for improving vessel eﬃciencies, we are pleased to be part of the

Using data analytics, it has a unique capacity to build a complete

conception of DryDoQ Insights. We look forward to further developing

picture of the corrosion and fouling on the surface – helping to improve

the tool, which has the potential to bring clear benefits to the industry.”

maintenance planning and increase eﬃciency.

The new tool makes its predictions based on proprietary data enriched

The technology has been launched as a minimal viable product to

with multiple external data sources. It highlights specific areas for

one of the world’s largest fleet operators, who will carry out testing

consideration, taking into account the specific vessel type, trading

and provide continuous feedback so that further developments

pattern and previous dry-docking events.

and improvements can be made. The system is simultaneously also available to the wider market.

AkzoNobel’s Marine and Protective Coatings business is a leader in

It’s the latest example of AkzoNobel’s vision on innovation, exploring

big data analysis in the marine industry, with more than 40 years of

new horizons to deliver solutions beyond the expectation and

experience. A range of digital tools has been developed for customers,

imagination of customers.

including Intertrac Vision, which projects the eﬀects that various coating

“As a premium solution and service provider for the shipping industry,

scenarios will have on the hull performance of a vessel before they

we are always looking for ways to give our customers a competitive

have been applied.

edge,” explains Michael Hindmarsh, the AkzoNobel Incubator Lead for the UK. “DryDoQ Insights enables vessel owners to make more

For further information: www.drydoqinsights.com

matthew henry © burst

DryDoQ Insights closely predicts the condition of a vessel’s underwater hull without the need for visual inspection.

N.30 - 2019 JUNE - ipcm® Protective Coatings

BRAND-NEW

Dubai’s Museum of the Future Selects Sherwin-Williams Fire Protection Technology to Safeguard Iconic Structure © Sherwin-Williams

The challenge for the Sherwin-Williams fire protection experts was the museum’s remarkable design, a joint-free assembly of 890 unique stainless steel and fibreglass fused panels.

The iconic Museum of the Future in Dubai chose Sherwin-Williams

able to leverage our world-class technical expertise and global presence

Protective & Marine Coatings to provide a fire protection coating

to oﬀer more bespoke solutions to these regions than ever before.”

solution for its breathtaking structure.

Since Sherwin-Williams acquired Phoenix Fire Protection Group a year

ago, its oﬃces in Dubai and Hong Kong have been fully integrated into

he challenge for the company’s fire protection experts was the

the organisation to oﬀer the full range of products including corrosion

museum’s remarkable design, a joint-free assembly of 890 unique

protection coatings, tank linings, resin flooring, pipeline solutions and the

stainless steel and fibreglass fused panels fabricated using methods

FIRETEX® range of passive fire protection intumescent coatings.

borrowed from the aviation industry. Sherwin-Williams technical experts

The specialist range of FIRETEX intumescent and insulation materials has

selected the Phoenix 370-120H water-based intumescent coating rated

been protecting assets worldwide for more than 15 years, with added

for 120-minutes fire protection to apply on the museum structure.

visual appeal reflected in the finished building.

Fabricator was Eversendai.

Sherwin-Williams fire protection coatings also come with the support of

“For specifiers, architects, developers and applicators, this is

software including bespoke Fire Design Estimator (FDE) 2.0 which enables

game-changing. Our comprehensive range of products and the

accurate calculations of coatings properties for complex projects.

substantial advances we have made in intumescent coating technology

Landmark projects using fire protection coatings delivered by

are delivering significant protection and operational benefits and options

Sherwin-Williams in EMEAI also include London’s The Shard, Azerbaijan’s

to our customers,” said Roger Williams, Market Director-FIRETEX,

Flame Towers and the Leadenhall Building, known as The Cheesegrater.

EMEAI & APAC at Sherwin-Williams Protective & Marine. “Having strengthened the Sherwin-Williams network across the Middle

For further information:

East and Asia Pacific through last year’s acquisition of Phoenix, we are

https://protectiveemea.sherwin-williams.com/

ipcm® Protective Coatings - 2019 JUNE - N.30

BRAND-NEW

Cortec® EcoAir® Tool & Die Rust Preventative Cuts Costs and Meets the Specialized Needs of Mould, Die, and Tooling Manufacturers Cortec® recently developed EcoAir® Tool & Die Rust Preventative to

(Fig. 2). By packaging an eﬀective vegetable-oil-based rust preventative

meet the needs of mould, tool, and die manufacturers and end users.

in an EcoAir® spray can, Cortec® was able to deliver a cost-eﬀective

This eﬀective liquid rust preventative comes in a non-flammable spray

solution while providing superior protection of this vital and expensive

can that makes it easier to use than traditional greases and shipping

customer asset.

oils employed to protect tooling assets and all tool steels during

EcoAir® Tool & Die Rust Preventative was sprayed on the internal

shipping, storage, and transport (Fig. 1). It is also relatively safer to

surfaces of the mould maker’s two-cavity automotive interior P20

store than traditional highly flammable aerosols.

plastic-injection mould prior to shipment. This provided corrosion

protection, as well as water displacement and cleaning properties for he development of EcoAir® Tool & Die Rust Preventative is another

any process-related fluids remaining on the mould.

example of Cortec’s responsiveness to specific customer and

The mould successfully reached the European client with no

market needs. Cortec® tailored the product for a large midwestern

corrosion issues at all. The client was pleased that EcoAir® Tool &

U.S. tool and die manufacturer who wanted to eliminate any possibility

Die Rust Preventative did not need to be cleaned oﬀ the mould. The

of corrosion on a 40,000 pound (18,144 kg) Class A plastic-injection

client requested that all moulds be shipped in the same manner

mould during its five- to six-week overseas boat shipment to Europe

going forward. In addition to achieving a successful delivery, the

Figure 1 - The eﬀective liquid rust preventative by Cortec® is easier to use than traditional greases and shipping oils employed to protect tooling assets and all tool steels during shipping, storage, and transport.

N.30 - 2019 JUNE - ipcm® Protective Coatings

BRAND NEW

U.S. mould maker also benefited by cutting the tooling protection costs approximately in half of what is typically incurred when using traditional greases and oils. Unlike EcoAir® Tool & Die Rust Preventative, these traditional rust preventatives must be cleaned oﬀ the mould with solvent-based removers. This increases labour and hazardous waste disposal costs, while submitting workers to additional health concerns. EcoAir® Tool & Die Rust Preventative is specifically designed for all similar tool and die applications and can also be used by anyone* that wants to: • Clean grease, oils, adhesives, and water deposits oﬀ metal surfaces • Displace moisture and protect metal surfaces from corrosion • Preserve all types of carbon or alloy-based steel tooling, moulds, fixtures, and dies long-term up to 24 months indoors. For further information: www.cortecvci.com © Cortec

* EcoAir® Tool & Die Rust Preventative is only available for sale in the United States.

Figure 2 - Cortec® tailored the product for a large midwestern U.S. tool and die manufacturer who wanted to eliminate any possibility of corrosion on a 40,000 pound (18,144 kg) Class A plastic-injection mould during its five- to six-week overseas boat shipment to Europe.

TOMORROW’S MATERIAL. TODAY

DELIVERING COST SAVINGS WITH BREAKTHROUGH GRAPHENE ANTI-CORROSION TECHNOLOGY

• •

Very low addition levels

•

C1 to CX environment performance gains

•

Formulation and production ready stable dispersions

•

Supplied in range of standard resins, solvents and water

Cost saving in coat life, ﬁlm thickness and system build optimisation

FOR MORE INFORMATION +44 (0)1642 438214 info@appliedgraphenematerials.com www.appliedgraphenematerials.com ipcm® Protective Coatings - 2019 JUNE - N.30

BRAND-NEW

Carboline Introduces Carbothane® 134 UV Ultra © Carboline

Carbothane® 134 UV Ultra was developed to oﬀer a one coat polyurethane finish that provides outstanding colour and gloss retention for the exterior of water storage tanks, piping, etc.

Carboline announced the release of Carbothane® 134 UV Ultra.

significant labour cost savings and substantially reduces the time to

Carbothane® 134 UV Ultra has unsurpassed colour and gloss retention

complete projects when compared to typical aliphatic polyurethane/

for an acrylic polyurethane.

aliphatic polyurethane clear finish coats. All of these significant savings

can be achieved without sacrificing performance. arbothane® 134 UV Ultra oﬀers a smooth, durable finish with

“Carbothane® 134 UV Ultra was developed to oﬀer a one coat

outstanding chemical resistance. It is uniquely formulated to

polyurethane finish that provides outstanding colour and gloss retention

provide enhanced UV protection. The result is a premium polyurethane

for the exterior of water storage tanks, piping, etc. Although the

finish coat that delivers colour and gloss performance levels normally

primary demand for this exceptional performance is in the water and

compared to polysiloxane or fluoropolymer coatings. This product

wastewater market, this product provides exceptional value for virtually

exceeds SSPC Coating Specification No. 36 Level 3A, by greater than 2

any customer who wants outstanding colour and gloss retention without

and a half times. The primary use for Carbothane 134 UV Ultra is in any

paying the price for an extra coat of clear polyurethane,” said Jeﬀ

market where an ultra-high performance polyurethane finish is needed.

Anderson, Vice President - Research, Development & Innovation.

“The primary advantage of Carbothane® 134 UV Ultra is its outstanding

Carbothane® 134 UV Ultra provides outstanding long-term colour and

colour and gloss retention in UV exposure. It is the ideal solution for

gloss retention in UV exposure without the need for an extra coat of

customers who want higher performance than typical aliphatic acrylic

clear aliphatic polyurethane. The result is substantially lower overall cost

polyurethane coatings provide,” said Melissa Molitor, Vice President of

and much faster return to service without sacrificing performance.

Marketing. By eliminating the requirement for clear polyurethane, it provides

N.30 - 2019 JUNE - ipcm® Protective Coatings

For further information: www.carboline.com

BRAND-NEW

New Seminar Program for The Second Half-Year 2019 Published

The second half-year program 2019 of “THE CORROSION COLLEGE” by Dörken MKS oﬀers a comprehensive seminar spectrum. Under the motto “Learning with experts” the corrosion experts of Dörken MKS provide their know-how about eﬀective corrosion protection.

or the second half of 2019, the “THE CORROSION COLLEGE” by Dörken MKS has again provided a new seminar program for

laboratory technicians, plant operators, designers and all those interested. “At THE CORROSION COLLEGE, our experts impart our knowledge of almost 40 years on the full spectrum of subjets related to corrosion and thereby create a forum for discussions or queries,” explains Dr. Martin Welp, Managing Director of Dörken MKS. The topics of the seminars oﬀer ranges from a basic level to application processes up to special focus topics. Managing Director Dr. Gerhard Reusmann explains: “Individuals from diverse enterprises along the value chain can meet at THE CORROSION COLLEGE. Brainstorming from common and opposing standpoints can generate new initiatives and better understanding.” Dörken MKS organizes its seminars and workshops in its own halls in Herdecke (Germany) and, on request, also in your company. The second half-year program 2019 is available on the Internet at www.doerken-mks.de/en/the-corrosion-college/seminars/. All seminars can be booked there, too.

For further information:

www.doerken-mks.de/en/the-corrosion-college/seminars/

ipcm® Protective Coatings - 2019 JUNE - N.30

INNOVATIONS: PRESENT&FUTURE

Long Term Corrosion Protection Performance and Activity of Graphene-Based Epoxy Coating Systems for Aluminium and its Alloys M. Sharp, G. Johnson and W. Weaver Applied Graphene Materials Ltd., Cleveland – United Kingdom matthew.sharp@appliedgraphenematerials.com, gaven.johnson@appliedgraphenematerials.com, william.weaver@appliedgraphenematerials.com

wo diﬀerent graphene nanoplatelet products, graphene and reduced

of the metallic substrate. The active constituents historically have been

graphene oxide, of diﬀering electrical conductivity, were assessed

chromates but other species such as phosphates, molybdates, nitrates,

for their corrosion protection of aluminium 5005 when incorporated

borates and silicates are also used. The selection of active constituents is

into a basic epoxy coating, through both electrochemical methods

increasingly subject to regulatory pressures due to increased concerns for

and more conventional and complementary prohesion testing. In the

the environment and health and safety.

potentiodynamic data the onset of passivation is observed at ~+18 mV

Active inhibitor pigments undergo a partial dissolution in the presence of

from the open circuit potential in some scribed graphene-containing

water when the water enters the coating. At the metal substrate surface

epoxy coatings, and this is not observed for the scribed samples

the dissolved ions react and form a reaction product which serves to

containing no GNPs during the same timescale. Neither is the onset of

passivate the surface, providing protection from corrosion. Such active

passivation observed for the GNP-containing coatings with no scribe,

pigments must possess suﬃcient solubility in water to release ions for

where the coating itself acts as a barrier and no passivation occurs. The

reaction, but too much solubility may result in blistering of the coating;

data suggests that the graphene, dependent on degree of conductivity, is

such a balance is often hard to achieve when formulating a coating.

acting to increase the rate of passivation of the metal surface, acting in a

An ideal coating pigment should be dual action. That is to say that the

catalytic manner to increase the rate of oxidation of aluminium to alumina

pigment should oﬀer a barrier against water and corrosion inducing

within the scribed region. The increased passivation layer builds up within

ions whilst also releasing a suﬃcient quantity of inhibitor ions. These two

the scribed region essentially acts to seal up the scribe in a self-healing

requirements are antagonistic in principle and the inhibitive coating again

type behaviour.

requires a diﬃcult balance between barrier properties and the solvation ability.

Introduction

It is acknowledged that GNPs, both as prepared and chemically

Applied Graphene Materials UK Ltd. produces a range of dispersions

functionalised, when incorporated into a coating system or host

of graphene nanoplatelets (GNPs), enabling property introductions/

matrix, provide a highly tortuous pathway which acts to impede the

enhancements such as electrical/thermal conductivity, mechanical e.g.

movement of aggressive species towards the metal surface [1], a passive

fracture toughness, gas permeability and barrier type to be achieved.

corrosion protection mechanism. In support of this, previous work has

GNPs are manufactured using the company’s patented proprietary

demonstrated that very small additions of GNPs decreased water vapour

“bottom up” process, yielding high specification graphene materials.

transmission rates [2], indicating a barrier type property, while some

The active constituents of inhibitive coatings are typically marginally water

authors also report an electrochemical activity provided by graphene

soluble and produce active species which inhibit the ongoing corrosion

within coatings [3].

Table 1 - Various properties of graphene products used in this work.

PRODUCT GRADE

BASIC DESCRIPTION

SURFACE AREA (m2/G)

OXYGEN CONTENT (%)

RESISTIVITY Ŷ P

RGO

Reduced graphene oxide

10-20

50,000

Graphene

350

0.0037

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

Figure 1 - SEM micrographs of (a) RGO and (b) graphene nanoplatelet products.

DEGREE OF CORROSION

% AREA

Ri0

Ri1

0.05

Ri2

0.5

Ri3

Ri4

Ri5

40 to 50

Table 2 - Degree of corrosion assessment used as part of ISO4628.

This work aims to examine both the barrier properties and any

5 (prohesion) for a period of up to 4000 hours. This consists of an hour

electrochemical influence on corrosion provided by graphene within an

cycle dry at 35°C, followed by 1 hour of salt mist spray at 23 °C. Panels

epoxy-based coating, through both salt spray and electrochemical test

were assessed at 500 hours intervals for signs of blistering, corrosion,

methods.

and corrosion creep in accordance with ISO4628. The assessment of the degree of corroded area was as shown in Table 2.

Experimental Material and sample preparation

Electrochemical measurements

Two diﬀerent graphene nanoplatelet products, reduced graphene oxide

All electrochemical measurements were recorded using a Gamry 1000E

(RGO) and graphene (Applied Graphene Materials UK Ltd.), were used

potentiostat in conjunction with a Gamry ECM8 multiplexer to permit the

in this study. The basic properties of these materials are listed below in

concurrent testing of up to 8 samples per experiment. Each individual

Table 1. SEM micrographs of these materials are presented in Figure 1.

channel was connected to a Gamry PCT-1 paint test cell, specifically designed for the electrochemical testing of coated substrate samples.

Various loadings of graphene nanoplatelets were incorporated into an

Within each paint test cell, a conventional three-electrode system, the

epoxy resin system (BPA type epoxy and an amine-based fast hardener -

bare aluminium, coated epoxy aluminium and scribed coated epoxy

5:1 mix ratio). All coatings were resin only clears and not fully formulated

aluminium samples represented the working electrode, a graphite rod

products. RGO was incorporated at 0.5%, 0.03% and 0.003% by weight,

served as a counter electrode and a saturated calomel electrode (SCE)

while graphene was incorporated at 0.1%, 0.03% and 0.003% by weight.

served as the reference electrode. The test area of the working electrode

A graphene free epoxy coating was also evaluated alongside an uncoated

was 14.6 cm2. All tests were run using a 3.5 wt.% NaCl electrolyte.

(bare metal) aluminium 5005 and blasted steel substrates.

For all samples, electrochemical testing consisted of cycle of experiments

Each of the coatings were applied to aluminium (5005 grade) panels, of

comprising of electrochemical AC impedance spectroscopy (EIS)

dimensions 150 x 100 x 2 mm, by means of a conventional gravity-fed

measurements and potentiodynamic polarisation scans. Since this work is

spray gun, equipped with a 1.2 mm tip. Prior to coating application, the

focused on the change in electrochemical properties over time, each cycle

panels were degreased using acetone. The panels were allowed to cure

of experiments was conducted at approximate intervals of 2 hours over a

for 1 week at ambient temperature before commencing testing. Dry film

period of up to 1 week for all samples.

thickness of the prepared coatings was in the range of 40-60 microns.

During all EIS experiments, an AC voltage of 10 mV was applied across the

Panels were tested in both scribed and unscribed forms (electrochemical

sample, with a zero volts DC bias, over a frequency range of 1 MHz to

tests only). Scribed samples were studied since they oﬀer an immediate

0.05 Hz. Ten measurements were recorded for every decade in

study of a bare metal surface in contact with electrolyte and functional

frequency. An integration time of 1 second per measurement was used

coating (triple phase boundary), without having to observe the prior

with a delay time of 0.2 seconds between each measurement. Equivalent

lengthy breakdown/degradation of the functional coating e.g. due to

circuit fitting to the obtained data was performed using the proprietary

water uptake.

Gamry Echem Analyst software package. Potentiodynamic polarisation scans were carried out in order to generate

Prohesion/salt spray testing

Tafel polarisation curves. These curves were produced as a result of

The panels were placed in a corrosion chamber, running ASTM G85 annex

applying a potential of ±250 mV from the open circuit potential (500 mV

ipcm® Protective Coatings - 2019 JUNE - N.30

INNOVATIONS: PRESENT&FUTURE © Applied Graphene Materials UK Ltd.

Figure 2 - Coated aluminium 5005 samples following 4000 hours prohesion testing, showing (a) blank epoxy coating and graphene-incorporated epoxy coatings of (b) 0.003 wt.% graphene, (c) 0.03 wt.% graphene, (d) 0.003 wt.% RGO and (e) 0.03 wt.% RGO.

sweep) at a scan rate of 0.5 mV/second with a sample period of 1 second.

AC Impedance Spectroscopy (EIS)

Data fitting to the Tafel region was carried out using the proprietary

Water uptake in organic coatings and polymers can be measured using

Gamry Echem Analyst software in order to extract values for the anodic

a variety of diﬀerent techniques such as the more traditional gravimetric

and cathodic Tafel constants, Ecorr, and corrosion rate.

methods [4] and capacitance methods [5]. Capacitance methods rely the creation of a capacitor over time due to water uptake in the organic

Results and discussion

coating. Water has a dielectric constant around 30 times that of most

Prohesion/salt spray testing

organic coatings, and the change of capacitance as water enters the

The images shown in Figure 2 were recorded following 4000 hours

coated substrate is related to the level of water uptake. Such dielectric

prohesion testing for all samples, including uncoated 5005 aluminium and

type capacitance information can also be derived from EIS data, although

a graphene free epoxy coating.

there are several additional advantages of using EIS.

Following 4000 hours of prohesion testing, it was observed that the blank

EIS is a non-destructive test method, applicable to a wide variety of test

epoxy coated sample had a relatively large amount of corrosion visible

cases across a spectrum of diﬀerent materials, both organic and inorganic

on the metal surface, suggesting a majority coating failure during the

[6,7]. When applied to the study of organic-based protective anticorrosive

prohesion test. This test panel was graded as Ri 5 for degree of corrosion

coatings, impedance values, in their straight form, provide an indication

(40-50%). Some signs of coating delamination were also evident in this

of corrosion protection. Such values may be used as an initial screening

sample.

for coating barrier type performance. In addition, through the appropriate

No obvious signs of corrosion were noted in any of the

equivalent circuits modelling of EIS data, additional critical information can

graphene-incorporated epoxy samples, across both graphene

be obtained such as pore resistance and coating capacitance along with

nanoplatelet types, even with graphene loadings as low as 0.003 wt.%,

interfacial properties, where a coating is breached, such as double layer

where a barrier type eﬀect from the graphene nanoplatelets would be

capacitance.

relatively low. In terms of corrosion performance, no notable diﬀerence

The main contribution of the coating towards impedance occurs within

was seen between the RGO and graphene loaded epoxy coatings.

the lower frequency region, at a frequency close to 0.1 Hz. This feature

In some cases, the presence of pin holing/fisheyes are acknowledged.

may be used as a type of screening method in the selection of suitable

Such a feature with this combination of graphene type and loading may

organic coatings. In a review paper concerning the performance of

be present and is often unavoidable since the samples were not based

fast-cure epoxies for pipe and tank linings, O’Donoghue et al. describe

on a fully formulated system, where, otherwise, such defects may be

the use of EIS as such a screening tool [8], where the coating impedance

removed. Despite such defects, no corrosion was observed at the defect

measured at a frequency of 0.1 Hz can be used for screening materials.

points. No coating delamination or blistering was found on the

O’Donoghue et al. assign impedance values of 104 Ohm.cm2 to poor

graphene-incorporated epoxy samples.

coatings and impedance values of 1010 ohm.cm2 to excellent coatings

No measurable creep was found in any of the RGO epoxy samples, where

(Fig. 3). Since the O’Donoghue paper, several others have also employed

creep was observed in all of the graphene epoxy samples. This creep

this screening method to measure coating performance [9, 10].

value was consistent across all of the diﬀerent loadings of graphene and

Figure 4 shows a selection of bode plots for both uncoated and coated

was approximately 1.2 mm during the 4000 hours duration.

metal substrates, all recorded after approximately 60 hours of testing.

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

Although not intrinsically part of this study, a sample of bare blasted

sample, giving a corrosion protection between ‘good ‘and ‘excellent’.

steel has also been included with the sample set as an example of a

This suggests that the addition of graphene to the epoxy has led to an

metal which does not display passivation. As would be expected, the low

improvement in the coating’s barrier properties.

frequency impedance of this sample is comparatively low, between 102

It is observed that the low frequency portion of the bode plot for the

and 103 Ohm.cm2, since the corrosion products of steel are not strongly

0.5 wt.% RGO in epoxy coated aluminium sample displays an impedance

bound to the metal surface and very little protection is oﬀered. The

similar to that of the epoxy coated blank at this relatively short duration.

sample of uncoated aluminium oﬀers a comparatively higher impedance,

It should be highlighted that the overall impedance of the aluminium

on the order of 105 Ohm.cm2, due to the presence of the [more strongly

coated samples will be made up of impedance contributions from

bound] formation of a passivation layer on the metal surface, although

both the natural passivation layer and the coating itself. It would be

the impedance value of this passivation layer falls in between ‘poor’ and

expected that, upon a breakdown of the coating, the impedance

‘protection begins’ categories.

would drop back to the baseline level observed in the bare aluminium

The low frequency portion of the bode plot for the epoxy coated

sample i.e. impedance contributions from the passivation layer only. It

aluminium sample displays an impedance of the order of 108 ohm.cm2,

is recognised that coating performance is not simply concerned with

which places this coating firmly within the ‘good’ category with respect to

high impedance values measured at low frequency, but it is also the

corrosion protection. Sitting an order of magnitude above the straight

ability of a coating to maintain such impedance values over extended

epoxy sample is the 0.1 wt.% graphene in epoxy coated aluminium

periods of time. It has previously been reported that the introduction of

Figure 3 - Corrosion protection of organic coatings. Redrawn from [8].

Figure 5 - Change of impedance modulus at 0.1 Hz over time for coated samples.

Figure 4 - Bode plots showing the impedance modulus for bare steel, bare aluminium, epoxy-coated aluminium, 0.1 wt.% graphene/epoxy coated aluminium and 0.5 wt.% RGO/epoxy coated aluminium, post 60 hours immersion.

Figure 6 - Change of impedance modulus at 0.1 Hz over time for uncoated aluminium samples.

ipcm® Protective Coatings - 2019 JUNE - N.30

INNOVATIONS: PRESENT&FUTURE

graphene into organic coatings

frequency impedance increases

has led to increased sustained

slightly, due the gradual build-up

levels of impedance [11]. The

of the passivation layer. It was not

authors of this work acknowledge

possible to detect a change in

that the EIS studies carried out

impedance for the scribed coated

are relatively short in length in

samples, presumably due to the

comparison to similar studies,

relatively small surface area of the

and, as a result, little change in the

scribe regions.

impedance measured at 0.1 Hz

In order to assess the performance

is observed for the experimental

of these coatings over a longer

duration. Figure 5 shows the

duration, such EIS experiments

impedance modulus at 0.1 Hz for

would need to be run for longer

various coated samples over the

periods, and may be subject of

duration of the experiment. The

future work. In order to examine the

impedance for both the epoxy

immediate exposed surface area,

and 0.1 wt.% graphene samples in unscribed form remains fairly static throughout the experiment,

equivalent circuit modelling was Figure 7 - Equivalent circuits model used in the fitting of scribed panel data (interfacial properties highlighted).

reflecting the values shown in Figure

carried out on the scribed coated samples using the equivalent circuit model shown in Figure 7.

4. Figure 5 also shows the impedance of scribed versions of epoxy and

In circumstances where an organic coating has become breached,

0.1 wt.% graphene samples. Since both of these coatings are eﬀectively

for example through water uptake or by damage to the coating, the

breached due to the scribe, a lower impedance value for both, compared

equivalent circuit model shown in Figure 5 may be used to model the

with unscribed versions, would be expected. It is observed that both the

EIS data. Through introducing a scribe into the coated sample, this

epoxy and 0.1 wt.% graphene coatings give a low frequency impedance

intentional breaching of the coating reveals the triple phase boundary

value of between 105 and 106 ohm.cm2.

area incorporating bare metal, coating edge and electrolyte (and the

The only noticeable changes in impedance came from the uncoated

model shown in Figure 5 now applies). The elements which make up

aluminium samples. Figure 6 shows the low frequency impedance

this model include Rsoln (the resistance of the electrolyte), Cc (coating

change for 4 uncoated aluminium samples (measured over a surface

capacitance), Rpo (pore resistance), Ccor (double layer capacitance) and

area of 14.6 cm ). Throughout the duration of the experiment, the low

Rcor (corrosion resistance). The coating capacitance and pore resistance

Table 3 - Circuit element values for scribed coatings after 60 hours.

Circuit element

Epoxy blank

0.003 wt.% graphene

0.03 wt.% graphene

0.1 wt.% graphene

0.003 wt.% RGO

0.03 wt.% RGO

Uncoated Al

Solution resistance,

22.97

23.62

17.27

21.35

21.13

32.10

34.67

8.97 x 10-9

7.23 x 10-11

5.48 x 10-11

3.26 x 10-12

1.70 x 10-8

3.34 x 10-9

1.77 x 10-6

6.29 x 105

4.38 x 106

7.37 x 106

3.34 x 107

7.45 x 105

4.20 x 105

1.66 x 104

Rsoln Ŷ

Double layer capacitance, Ccor (F/cm

Corrosion resistance, Rcor Ŷ FP2

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

elements are properties associated with the coating itself, whereas

values will be based on the normal passivation layer of aluminium found

the double layer capacitance and corrosion resistance are interfacial

within the scribe region.

properties and exist when electrolyte meets the metal surface. The

The addition of graphene to the epoxy appears to increase the

presence of electrolyte at the interface generates a double charge layer,

corrosion resistance value from the epoxy blank, by up to two orders

which may be measured as a capacitance, with greater capacitance

of magnitude for the 0.1 wt.% sample, and some increase in corrosion

values indicating a larger presence of electrolyte at the interface, and

resistance is noted with a loading as low as 0.003 wt.%. The double

greater levels of corrosion. Rcor is a kinetic parameter associated with

layer capacitance is seen to decrease with the addition of graphene.

the electron transfer process and is related to corrosion rate. Larger

This suggests that graphene is acting to increase the rate of passivation

values of Rcor indicate a lower rate of corrosion.

within the scribed region, and this is observed through the changes in

Since little change was noted in the coating properties for all samples

corrosion resistance and double layer capacitance from the blank epoxy

over the course of the experiments, due to the relatively short

sample. Impedance measurements have shown this material to have a

experimental run time, attention was focused on the interfacial

greater impedance than the epoxy blank which suggests that graphene

properties of the scribed samples. Values extracted from the circuit

is acting both as a barrier and also to increase the rate of passivation at

element values are shown in Table 3. The values of solution resistance

the scribe region.

are included since uniformity within these values provides an indication

The additional of RGO to the epoxy appears to make no real diﬀerence

how they should be roughly equal since the electrolyte remains

to both the corrosion resistance and double layer capacitance – both

constant, although some variation may be expected if there are any

of these values are roughly similar to those obtained for the blank

slight diﬀerences in electrode placement within the test cell. All solution

epoxy sample, regardless of loading, which suggests that RGO has no

resistance values were found to be roughly equivalent, suggesting a

real impact on the rate of passivation of the aluminium. However, early

good fit of the impedance data to the chosen equivalent circuit model.

impedance measurements and the salt spray testing suggest that RGO

The scribed blank epoxy coating shows a relatively high double layer

is acting more as a barrier type material, likely due to its lower electrical

capacitance along with a relatively low corrosion resistance, and these

conductivity.

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INNOVATIONS: PRESENT&FUTURE

Figure 8 - Potentiodynamic scan of an unscribed coating of 0.03 wt.% graphene in epoxy resin.

Figure 9 - Potentiodynamic scan of a scribed coating of 0.03 wt. graphene in epoxy resin.

Potentiodynamic polarisation scans

coatings with no scribe, where the coating itself acts as a barrier and

Potentiodynamic polarisation scans permit considerable amounts of

no passivation occurs. The data suggests that the graphene is acting to

information on electrode processes to be determined. Through this

increase the rate of passivation of the metal surface, acting in a catalytic

technique, information on corrosion rate, pitting susceptibility, passivity

manner to increase the rate of oxidation of aluminium to alumina within the

and anode/cathode behaviour of an electrochemical system may be

scribed region. The increased passivation layer builds up within the scribed

obtained. During such scans, the driving force of the anodic/cathodic

region essentially acts to seal up the scribe in a self-healing type behaviour.

reactions (potential) is varied and the net change in reaction rate (the

If we then consider costings with a relatively lower electrical conductivity,

current) is measured. Tafel plots are usually displayed with the applied

based on RGO, we observe almost identical potentiodynamic plots for

potential on the y axis and the logarithm of the measured current on

both the scribed and unscribed samples, and no passivation occurs

the x axis, where the top half above the corrosion potential represents

in either of the samples. There is also little diﬀerence in the corrosion

the anodic portion of the plot and the bottom half below the corrosion

currents for both samples, which suggests that RGO is performing as

potential represents the cathodic portion of the plot.

a physical barrier, rather than controlling corrosion by accelerated

Potentiodynamic scan experiments were conducted on an unscribed

passivation (Fig. 10).

coating of 0.03 wt.% graphene in epoxy. In this case, with no direct access to the metal surface, the potentiodynamic scan shows no

Conclusions

passivation occurring and relatively a high Tafel constant (indicating a

Of the two diﬀerent types of graphene material studied, graphene, of

low anodic reaction). This result is what we would expect to see from

crumpled sheet like morphology and of 5-15 atomic layers, possesses a

a coated sample where the coating itself acts as a barrier, and no

relatively high electrical conductivity. In contrast, RGO is composed of a

passivation occurs (Fig. 8).

mixture of more planar sheets, is of a higher oxygen content, and is of a

Adding a scribe to the coating allows direct access of the electrolyte to

comparably lower electrical conductivity than graphene.

the metal surface (without waiting for the coating to degrade), and also

Post 4000 hours of prohesion testing of coated panels, all graphene

allows graphene within the coating to contact with the metal surface.

incorporated coatings (graphene and RGO) performed significantly

Potentiodynamic experiments were conducted on a scribed coating of

better than the epoxy blank control sample, presumably either due to an

0.03 wt.% graphene in epoxy resin. In looking at the potentiodynamic

enhanced physical barrier property of the coatings, and electrochemical

scan of this sample (Fig. 9) the onset of passivation is observed at ~+18

influence from the graphene or a possible combination of both.

mV from the corrosion potential for the scribed graphene-containing

EIS measurements carried out over a relatively short term have shown

epoxy coatings, and this is not observed for the scribed samples

that graphene incorporated at 0.1 wt.% into an epoxy provides a greater

containing no GNPs during the same timescale. A relatively a low Tafel

impedance than the blank epoxy control by an order of magnitude,

constant is observed over the Tafel region, indicating a high anodic

while RGO incorporated at 0.5 wt.% shows an impedance value

reaction.

equivalent to the blank epoxy. Longer duration impedance experiments

Neither is the onset of passivation observed for the GNP-containing

would be required in order to demonstrate the maintenance of these

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

Figure 10 - Potentiodynamic scans of scribed and unscribed coatings of 0.03 wt. RGO in epoxy resin.

impedance values over time when graphene is incorporated into the

to be level with the epoxy blank in the short term, with the salt spray

coatings.

testing providing an indication that this impedance level is mentioned

Equivalent circuit modelling of the impedance data, examining the

in the RGO samples where the epoxy blank drops oﬀ towards the poor

interfacial circuit elements of scribed samples, has shown a progressive

protection region.

increase in corrosion resistance and a decrease in double layer

Additional electrochemical experimentation in the form of

capacitance for the more conductive graphene coated samples, where

potentiodynamic polarisation scans has revealed the presence of an

the epoxy blank and RGO samples have remained lower and fairly

onset of passivation in the scribed graphene samples, where no such

constant throughout. This suggests that graphene is acting to increase

region can be found within the scans for the RGO incorporated samples

the rate of metal passivation within the scribed region. The relatively

or the epoxy blank. This again suggests the graphene is acting to

high impedance measurements of graphene suggest that graphene is

increase the rate of passivation of the metal surface, acting in a catalytic

acting both as a barrier and also to increase the rate of passivation at

manner to increase the rate of oxidation of aluminium to aluminium

the scribe region. The fact that RGO appears to make little diﬀerence to

oxide, and the degree of passivation is dependent on the degree of

corrosion resistance and double layer capacitance hints towards RGO

conductivity exhibited by the GNP. ‹

providing a majority barrier type eﬀect. Impedance values were found

REFERENCES [1] R. Ding et al.: Journal of Alloys and Compounds Vol. 764 (2018), p. 1039-1055 [2] K. Choi et al.: ACS Nano Vol. 9 (2015), p. 5818 – 5824 [3] S. Aneja et al.: FlatChem Vo1. 1 (2017), p. 11-19 [4] J. Crank and G. S. Park: Diﬀusion in Polymers, Academic Press, New York, NY, (1954) [5] D. M. Brasher and A.H. Kingsbury: J. Appl. Chem, (1954), p. 62 [6] B. A. Boukamp, A. Rolle: Solid State Ionics Vol. 314 (2018), p.103-111 [7] A. Grammatikos et al.: Composites Part A: Applied Science and Manufacturing Vol. 105 (2018), p. 108-117 [8] M. O’Donoghue et al.: JPCL-PMC (1998), p. 36-51 [9] A. Hussain et al.: Engineering Failure Analysis Vol. 82 (2017), p. 765-775 [10] G. Bouvet et al.: Progress in Organic Coatings Vol. 77 (2014), p. 2045-2053 [11] T. Monetta et al.: J. Coat. Technol. Res. (2018), p. 56-65

ipcm® Protective Coatings - 2019 JUNE - N.30

Opening photo - Vale Protective Coatings, one of the leading oﬀ-site blasting and painting applicators, specialising in intumescent coatings, tested new Hempafire Pro 315 Fast Dry by Hempel.

HIGHLIGHT OF THE MONTH

Hempaﬁre Pro 315 - Fast Dry Increases Eﬀiciency for Leading UK Applicators Hempel A/S Kongens Lyngby - Denmark

hempel@hempel.com

s one of the leading oﬀ-site blasting and painting applicators,

The challenge

specialising in intumescent coatings, Vale Protective Coatings strive

To determine the application properties and eﬃciency of the new

to stay at the forefront of technological advancements. Using the latest

Hempafire Pro 315 Fast Dry in the field with expert applicators who are

coatings and techniques is integral to support their oﬀer of ‘unrivalled

specifically used to handling and applying intumescent coatings.

service’ to their customers in the steel construction industry. With a history of supporting trials for new products, Vale were the ideal

The results

partner to test new Hempafire Pro 315 Fast Dry (ref. Opening photo).

The customer was delighted during the trials, not only at the performance

The purpose of the trial was to prove that Hempafire Pro 315 Fast Dry

during application and subsequent time savings, but also with the high

applies more eﬃciently, significantly increasing productivity, without

quality, professional finish. The customer believes that working with

compromising coating quality.

Hempel and Hempafire Pro 315 Fast Dry will add to their oﬀering, making

“It actually applied better than the current market leader” said Ashley

them more competitive in the marketplace.

Lowe, Vale Protective Coatings Ltd.’s Commercial Director.

The main benefits were highlighted as faster drying times due to lower loadings, which lead to earlier overcoating and handling, as well as

N.30 - 2019 JUNE - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

increased eﬃciency that resulted in significant time savings. Hempafire Pro 315 Fast Dry covers all steel profiles, which negates the need to carry additional stock of other materials - another advantage that saves space, cost and time. All this makes Hempafire Pro 315 Fast Dry a very versatile and applicator-friendly intumescent coating. “The ease at which it applied and the finished aesthetic are just two of the features which will help make us more competitive in the market place” states Ashley Lowe.

Service and support As a customer for just over four years, Vale Protective Coatings was also keen to add, “The service is very good, we always get paint delivered when we should do, and even the Technical Services guys, they’re there to answer questions as and whenever we need them to (Fig. 1).”

At a glance Customer



Vale Protective Coatings Ltd

About



Specialist intumescent coatings applicators for the steel construction industry

Coating system



Hempafire Pro 315 Fast Dry

Application



Airless spray

Project



Field trial.

‹

Figure 1 - Vale Protective Coatings has also admired the Hempel’s technical staﬀ always ready to answer questions as and whenever they need them to.

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23 23

INNOVATIONS: PRESENT&FUTURE

Manual, Flexible and Cost-Eﬀicient Coating as Never Before with the New Airspray Gun GM 1030P from WAGNER Katja Villnow J. WAGNER, Markdorf - Germany

katja.villnow@wagner-group.com

Opening photo – The GM 1030P is equipped with a fixable needle stroke adjustment for process-safe coating with a constant material flow rate: this additionally optimises the material usage and has a positive eﬀect on the application eﬃciency.

AGNER expands its range in the liquid coating sector with a manual

the other hand, make it easy to use the gun with water- and

Airspray gun that can do more than previously available models: the

solvent-based materials. The GM 1030P can be used for a variety of

GM 1030P provides high-quality coatings with highclass components - with

applications in many industries. It is suitable for the application of primers,

eﬃcient material consumption, versatile application possibilities, easy and

fillers, clear lacquers or stains. Metal parts can be coated as well as

fatigue-free handling and unrivalled low operating costs (Fig. 1).

furniture or plastic decorative elements.

The new manual Airspray gun GM 1030P from WAGNER is not only highly precise in its application, but also extremely versatile. It is equipped with a nozzle which, with a maximum material passage of 9 mm, enables flexible

Intelligent features support constant spray pattern and reduce overspray

processing of low to high viscosity materials with a high solids content.

The new development from WAGNER is also characterised by numerous

Depending on the application, a large number of air caps and nozzle sizes

details which are new to the market and which on the one hand reduce

can be used. All components that come into direct contact with the coating

the material costs of the medium to be sprayed and on the other hand

material are made of durable stainless steel. Solvent-resistant gaskets, on

ensure a particularly uniform spray pattern. These features include

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

setting the desired spray jet width with

reduces the cost of wearing parts. The

just one rotary knob. Once set, the air

reduced maintenance costs and minimal

volume is automatically adjusted when

downtime of the gun are also due to long-

the spray pattern changes from round

life needles and the revised concept of the

to flat jet without having to readjust the

nozzle packing. This concept features an

atomizing air. “Spraying with too high

improved, highly resistant polyethylene

atomizer air pressure is prevented, which

seal. “Tests have shown that the nozzle

reduces overspray by up to 15 percent

packing of comparable guns leaks at a

and significantly lowers material costs”,

time when the new GM 1030P’s is still

explains Peter Neu, Senior Product

sealing perfectly for a long time,” reports

Manager Industrial Solutions at WAGNER.

Peter Neu. “The maintenance intervals of

The GM 1030P is equipped with a fixable

our Airspray gun are 40 percent longer,

needle stroke adjustment for

which means further cost savings.”

process-safe coating with a constant material flow rate. This additionally

Practical design, easy handling

optimises the material usage and has a positive eﬀect on the application

WAGNER has designed the Airspray gun in a particularly practical way: with the

eﬃciency (ref. Opening photo). The

GM 1030P, the nozzle and needle size

large material and air passages of

Figure 1 - The new manual Airspray gun GM 1030P from WAGNER.

the components also support perfect atomisation and at the same time permit

currently in use can be easily read from the outside. The gun does not have to be dismantled to identify a required spare

a high application speed.

part. This feature, as well as the use of durable, high-quality components, minimizes downtimes. The gun’s low weight and ergonomic design support fatigue-free work even over long periods of time. The anodised surface

Unlike comparable models, the new Airspray gun from WAGNER is

of the gun is also particularly easy to clean. In addition, the GM 1030P is

equipped with a two-part nozzle consisting of nozzle head and nozzle

available on request as a ready-to-spray spray pack together with hopper,

nut. If necessary, it is suﬃcient to replace the nozzle head, which is

suction hose and pump (TOPFINISH DD10 double diaphragm pump or Zip

considerably cheaper than replacing the complete nozzle and significantly

52 low-pressure diaphragm pump, Figs. 2 and 3). ‹

Two-part nozzle for lower spare part and maintenance costs

©W

Figure 2 - Spraypack with low-pressure double diaphragm pump TOPFINISH DD10.

Figure 3 - Spraypack with low-pressure diaphragm pump Zip 52.

ipcm® Protective Coatings - 2019 JUNE - N.30

SUCCESS STORIES

Cactus Industrial Has Landed a Contract to Supply the Bristle Blaster Technology to the UK Ministry of Defence Frits Doddema frits.doddema@monti.de

Monti Werkzeuge GmbH, Hennef – Germany

O nin Ope Op ng phot h o: ho o: Nuc Nuclea lear lea ear subm ubmari a ne HMS ari HM Va V ngu n ard a off th ar he R Roya oy l Navy oya vy arrriv rives i ess bac back a back ba att H HM M Naval aval Ba ava ase s Cl C yde de, Fasl as ane a , Scot Scot otlan land lan d foll fo oll llowi ow ng g a patr patr at ol ol. l

N.30 - 2019 JUNE - ipcm® Protective Coatings

SUCCESS STORIES

he company will supply the

surface preparation tool Bristle

Blaster technology is uniquely suited to maintaining valuable

Blaster to the MoD for use in

Royal Navy assets including ships

maintaining Royal Navy ships and

and submarines. We have now

submarines (ref. Opening photo).

trained and educated Royal Navy

Cactus Industrial has received

personnel in how to use the Cactus

an order from the UK Ministry of

Bristle Blaster for optimal surface

Defence for a number of machines

preparation for maintaining the

using the Bristle Blaster technology,

UK’s sea-going fleet (Fig. 2)”.

a hand-held surface preparation

He added: “Blasting without grit

tool that blasts without grit (Fig. 1).

technology is one of the most

The purchase order was placed

eﬀective ways of ensuring that

after the Bristle Blaster technology

Royal Navy ships and submarines

went through extensive trials

are prepared to face the harsh

at Her Majesty’s Naval Base at

marine environment with as little

Portsmouth. Cactus is the sole licensed UK and Ireland distributor

Figure 1 – The Bristle Blaster device is a hand-held surface preparation tool that blasts without grit.

for Bristle Blaster, made by the firm

downtime as possible.” Paul Waugh, Warrant Oﬃcer Class 1, Royal Navy, said: “A

Monti Werkzeuge GmbH.

classroom introduction with hands-on training showed how correct

Cactus Industrial has deployed members of staﬀ to deliver training

surface conditions are achievable so preservation eﬀorts become

to navy personnel and contractors in the eﬀective use of the Bristle

more eﬀective - thus improving the material state of the platforms

Blaster technology in preparing surfaces aﬀected by the marine

(Fig. 3). Cactus Industrial’s Bristle Blaster technology will considerably

environment.

reduce time and improve preservation eﬀorts during a base

Chief Executive of Cactus Industrial Jamie Gallagher said: “Bristle

maintenance period (BMP).” ‹

Figure 2 - Royal Navy personnel has been trained and educated in how to use Cactus Industrial’s Bristle Blaster for optimal surface preparation.

Figure 3 – Training ensures eﬀective use of the high-performance surface preparation tool.

ipcm® Protective Coatings - 2019 JUNE - N.30

Opening photo - Tilkin Powder Coatings has selected VULKAN INOX’s stainless steel grit blast media, GRITTAL® in order to improve its blasting process.

FOCUS ON TECHNOLOGY

Blasting with Stainless Steel: High Durability, Lower Wear, More Control Christian Hoﬀmann Vulkan Inox GmbH, Hattingen - Germany

christian-hoﬀmann@vulkan-inox.de

hat if your company can’t find a supplier that can meet your powder

but we had to first familiarize ourselves with the powder coating process.

coating needs? The Tilkin family provided a solution in 1998 by

At the beginning what we lacked in knowledge, we made up for with

jumping into the unknown world of powder coating specialization. Today,

courage and passion. Our name stands for quality, and this is something

after 20 years of consistent growth, this Belgian company services the

we work hard for every day.”

Benelux countries with the largest curing oven. Purchasing the oven was the result of implementing a philosophy of being able to measure each

Largest curing oven in the Benelux countries

process step in a detailed manner, in order to be able to achieve constant

In the early years, the biggest challenge was to convince customers about

improvement.

the advantages of powder coating. Today, the process is established and

This philosophy is what led Tilkin Powder Coatings to switch to VULKAN

the demand for it has grown tremendously, so has the number of powder

INOX’s stainless steel grit blast media, GRITTAL® (ref. Opening photo).

coaters. Tilkin Powder Coatings is an exception among them because they

With this decision, the desired surface quality is consistently achieved,

specialized in coating pieces of large dimensions (Fig. 1). “Last summer we

dust disposal is significantly reduced and cost eﬃciency is increased.

purchased a new curing oven which is able to handle work pieces up to 18 x 3.6 x 3.6 m (60 x 12 x 12 ft). It is the largest in the Benelux countries.

With courage and passion

If a structure won’t fit in our oven, then it won’t fit on the transport vehicle.

Powder coating specialist Tilkin began its business activity in metal

Our customers are now able to fabricate their structures in one step and

building construction and currently has 30 employees. Michel Tilkin and

have them completely powder coated, which is an enormous advantage.

his children, Jo and Rosy, have experienced continuous development

The new oven has opened up other opportunities in new markets,

since their beginning. “In the 1990s, there were very few companies in the

including neighbouring countries.”

Tongeren region of Belgium that were able to provide blasting, metalizing and powder coating support,” remembers Jo Tilkin. “From our own

Quality through process monitoring

experience, we knew exactly what metal processing companies needed

An additional strength of Tilkin Powder Coatings can be found in their

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FOCUS ON TECHNOLOGY

complete process monitoring and traceability of all production steps. “Industry 4.0 has been in use here for 10 years,” comments Jo Tilkin. “Our own ERP System has time and again driven us to achieve greater perfection. It is only possible to retrace production quality if you are able to measure everything and therefore guarantee quality for yourself and for the customer. This is very important to us, since the quality of powder coating is often displayed years after being applied.” With this approach, Tilkin Powder Coatings became the first European company to receive the EN 1090-1 certificate. “At the end of the production cycle I know exactly what happened and can take action. More than 10 years of calculations and development stand behind our process, © Ekkow Photography

from which our customers benefit. Today, they can receive quotes and submit orders online in just a few steps.”

Figure 1 - Tilkin Powder Coatings specializes in the powder coating of large dimensions pieces.

30 times less blast media use In the course of surface preparation, the blasting results would be

according to our monitoring, all process parameters, such as blast

checked continuously. As a result, the aluminium oxide blast media in

pressure, distance and angle to the object, were constant.” The cause of

use was determined to be a weak point. Jo Tilkin points out that, “Blasting

the fluctuations was the brittle-hard aluminium oxide blast media that

prior to coating is a decisive step in our surface preparation. The correct

fractured very quickly during blasting and thereby rapidly lost its grain

RA values and the cleanliness of the surface guarantee bonding of the

size. These changes to the blast media were consequently transferred to

ensuing powder coating, metalizing or galvanizing (Fig. 2). However, we

the blasted surface, resulting in the required roughness no longer being

continuously experienced fluctuations in the blasting results although

achieved. Even within one production charge of blast media deviations

A revolutionary Commercial Transport Topcoat

Call: 0161 205 7631

www.hmgpaint.com

Email: sales@hmgpaint.com

@HMGpaints

/HMGpaints

HMGpaints

ipcm® Protective Coatings - 2019 APRIL - N.29

FOCUS ON TECHNOLOGY

can occur. Jo Tilkin adds, “That is not acceptable if one demands top quality. In addition, the aluminium oxide usage was very high and there were always delivery issues.” In the search for a blast media change, Jo Tilkin came in contact with Bert Gysen from Magistor, the representative of VULKAN INOX blast media in Belgium. Bert introduced Jo to GRITTAL®, an angular and very hard stainless-steel grit blast media, manufactured from high quality raw materials and alloys. Bert saw GRITTAL® as being the solution to Jo’s requirements. That is because GRITTAL® is extremely durable and the breakdown of the individual grains, compared to mineral grit blast media, takes place very slowly. As a result, the work mix remains very stable and the blasting result, in regards to roughness and surface area output, is safely reached. In addition, GRITTAL®’s 30 times greater durability reduces the dust development when blasting and the residual dust on the blasted surface. Visibility and blasting conditions for the blast room operator are vastly improved and the blast media waste shrinks to approx. 3% of the previous amount. These were good arguments for the owner, who was listening intently. The switch to GRITTAL® began last August in a new blast room, which has the same dimensions as the curing oven.

Quality diﬀerences are a thing of the past Figure 2 - The correct RA values and the cleanliness of the surface guarantee bonding of the ensuing powder coating, metalizing or galvanizing.

The initial results have been extremely positive for Jo Tilkin, who says, “Quality diﬀerences are now completely in the past because GRITTAL® doesn’t break down very fast. GRITTAL®’s absolutely homogeneous and

stable work mix allows us to control the process better and at the same time uses less blast media. In addition, we are able to reduce the blast pressure, which reduces compressed air costs. We also have less dust, and dust is the last thing we want to have in the powder coating booth! It is also something we want to prevent in the blasting process as it accelerates wear on the blast system. Now our blast room operator has much better visibility while blasting the work pieces, and less post-blast dust to blow oﬀ (Fig. 3). A company may have the best machines, however, it is the employees that work on the product that make the diﬀerence. Because of that, it is very important that we can make their work more pleasant by using a new blast media.”

Execute each step as efficiently as possible In order to have concrete numbers regarding cost improvements, Jo Tilkin will wait for one year. Jo declares, “It is important for us to execute each step in our production process as good and as efficiently as possible, without contamination and with perfect controls. The great thing about our relationship with VULKAN is that they supported us during the optimization process, are always available for consultation and cooperate with us to carry out the necessary adjustments in order to reach our goal. The initial investment cost is high, but our cost per square meter will drop significantly. I am already convinced of that, as Figure 3 - The blast room operator has much better visibility while blasting the work pieces, and less post-blast dust to blow off.

N. 30 - 2019 JUNE - ipcm® Protective Coatings

well as of the better quality. You can compare this to switching from a bicycle to a Formula 1 race car!”. ‹

FOCUS ON TECHNOLOGY © Induron Protective Coatings

Project Spotlight: Three-Tank Overcoat at Helena, Alabama Nick Jones Induron Protective Coatings, Birmingham, AL - United States

info@induron.com

nduron partnered with Garver Engineering and Robinson and Sons to complete a 3-tank exterior overcoat project in Helena, Alabama

(United States). These three tanks are the only ground storage tanks in Helena, so providing superior corrosion protection, extending the

Figure 1- The three tanks are the only ground storage tanks in Helena, so providing superior corrosion protection, extending the exterior warranty and making them aesthetically pleasing were the goals of this project.

exterior warranty and making them aesthetically pleasing were the goals of this project (Fig. 1). Induramastic 85 was used as a primer on all three tanks. This product

was specified because it is designed to provide long-term protection to unpainted or previously painted steel without requiring sandblasting. Induramastic 85 is a high build, surface-tolerant epoxy formulated for excellent adhesion to clean steel, rusted steel, weathered galvanizing, wood, concrete and most existing cured coatings, which makes it ideal for overcoating projects like this one. Two coats of Induramastic 85 will outperform many conventional coating systems that usually require costly blast cleaning. The one-million-gallon tank near the city’s high school was the larger and more prominent tank in this project. Perma-Gloss Fluorourethane was specified as the top coat for this tank because it provides the best colour and gloss retention in the market, which was needed due to the tank’s prominent location. Perma-Gloss Fluorourethane also significantly extends colour stability, allows for easy graﬃti removal and is available in virtually any colour. A light blue colour was used for this particular tank. On the two smaller tanks, Indurethane 6600 + Polyurethane was used as the top coat. Indurethane 6600+ is a high-gloss, aliphatic polyurethane coating designed to provide corrosion protection of steel in moderate to severe environments. It provides outstanding colour and gloss retention and is available in a wide colour range. Because these two tanks are in wooded areas, green was chosen as the topcoat colour so they would blend in with their environment (Fig. 2). Overall, Induron’s products enabled the customer to save costs while providing great corrosion protection and extending the exterior warranty of the tanks. Induron was selected as a partner in the project because of its relationship with Garver Engineering and how they choose to conduct business, so it was a great win for Induron. This project enabled Induron’s business practices and values to shine just as the tanks did when the painting was completed. ‹

Figure 2 - Because the two smaller tanks are in wooded areas, green was chosen as the topcoat colour so they would blend in with their environment.

ipcm® Protective Coatings - 2019 JUNE - N.30

INNOVATIONS: PRESENT&FUTURE

Corrosion Protection in Hydraulic Steel Constructions Kornelia Liebisch Gebr. Liebisch GmbH & Co. KG – Bielefeld, Germany

sales@liebisch.com

n the hydraulic steel constructions sector, the life expectancy of

conditions are therefore used for comparative analyses. Here,

corrosion protection coatings should be particularly long. A typical

tried-and-tested products are compared with new systems.

example are steel port barriers, often requiring maintenance intervals of

Laboratory tests are described in various standards and norms. In the

20 years. These are subjected to extreme conditions due to the quality

hydraulic steel sector, the guidelines of the German Federal Institute for

of water (seawater), the presence of tidal zones, mechanical loads (shock,

Hydraulic Engineering (BAW) define diﬀerent test methods for specific

abrasion), and temperatures (ref. Opening photo). That is why protection

types of load. These complement existing test standards. In the field

systems with layer thicknesses of up to 500 μm and more are often

of corrosion protection of steel structures, the ISO 12944 standard

applied. In this framework, the use of epoxy resin or polyurethane as the

should be used, providing state-of-the-art information about the related

main binder is particularly common. Zinc dust is used for the base coat.

practices. Part 6 of this standard specifically describes laboratory tests

The exact composition of the protection system, of course, depends

and test conditions and it includes various methods to assess a protection

on the type of load, the service life and the shape of the structure, the

system. Example salt spray test: a test object with a total coating thickness

coating process in the factory or on site, etc.

less than 250 μm should show no damage after 480 hours of salt spray

In this article, we will discuss the issue of protection systems’ suitability in

exposure at 35 °C, in order to reach the category C3 “long” protection

more detail. How can designers make sure that their selected protection

period. It should also withstand a condensation water load for 240 hours

system meets all requirements? Ideally, they should be able to rely on

at 40 °C without any damage. Correspondingly good cross-hatch results

past experiences with the same system. If it is not the case, a test under

are also required.

real conditions could provide useful results; however, there is often not

Performing laboratory tests calls for high-quality equipment in order

enough time for this. Accelerated laboratory tests under reproducible

to achieve, maintain, and possibly improve high standards. The

Opening photo - The Thames Barrier prevents the floodplain of most of Greater London from being flooded by exceptionally high tides and storm surges moving up from the North Sea.

N.30 - 2019 JUNE - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

reproducibility of the test methods is particularly important: a certain protection system should always achieve the same results whenever the same procedure is applied. That is why reliable test equipment with constant performance is key. Combined test devices can be used to integrate the above-mentioned tests, e.g. with drying or controlled-humidity phases (Fig. 1). Finally, the correlation between laboratory results and practical results will have to be further improved. For this purpose, diﬀerent test parameters or completely new processes may become necessary in future. The purchase of a multifunctional test device is certainly a reasonable investment, in order to meet current quality standards and be prepared for future developments. Liebisch’s corrosion test devices enable to perform salt spray and condensation tests such as those mentioned in the standard.

the highest resistance with the greatest possible neutrality.

isc ieb ©L

test equipment constructed of solid plastic. This material oﬀers

This equipment manufacturer specialises in the production of

Indeed, the test object, not the test chamber, should be checked. Liebisch also oﬀers a variety of housing sizes and equipment configurations with diﬀerent designs. ‹

Q U A EXCELLENCE I T Y

Figure 1 - The chest-type unit is available in 1000 litres test chamber volume for combination tests with automatic ventilation, warm air and humidity.

C O R P O R AT I O N Environmentally Safe VpCI ®/MCI ® Technologies

ipcm® Protective Coatings - 2019 JUNE - N.30

fabiobag©adobe

FOCUS ON TECHNOLOGY

History in the Making: the San Michele Bridge and Coloriﬁcio Veneziani Francesco Cavinato Coloriﬁcio Zetagì Srl, Olmo di Creazzo (Vicenza) – Italy

©wikipedia

Figure 1 – Eng. Jules Rӧthlisberger was well known for his steel structures.

N.30 - 2019 JUNE - ipcm® Protective Coatings

f.cavinato@zetagi.it

hen speaking of maintenance of steel

Historical background

structures, we normally refer to objects that

The project was entrusted to Swiss engineer Jules

are almost at the end of their so-called “service

Rӧthlisberger (Fig. 1), graduated at the Polytechnic

life”. Especially for public structures, only recently

of Zurich and known as a talented designer of steel

have experts tried to define such time period: let us

Bridges (for instance, he designed the Kirchenfeld

think, for example, of the rebuilding of the Morandi

Bridge in Bern, Switzerland). Società Nazionale

Bridge in Genoa, which could have a service life

Oﬃcine di Savigliano (Turin, Italy) built the San

of over one hundred years. In this article, we will

Michele Bridge with about 500 workers and a

discuss a historical structure: the San Michele

cost of 2,000,000 Lire (the old Italian currency),

Bridge in Calusco d’Adda (Bergamo, Italy), also

completing the job in just two years in order to

called Rӧthlisberger Bridge after the Swiss engineer

connect the neighbouring towns of Calusco and

who designed it. This road and railway Bridge,

Paderno d’Adda. The structure was entirely riveted

built in just two years between 1887 and 1889,

and free of welds and it required 2500 tonnes of

remained in operation until September 2018 (ref.

iron and 110 tonnes of cast iron (Fig. 2). The bridge,

Opening photo).

which extends for a total length of 266 m at a

Opening photo – The San Michele Bridge in Calusco d’Adda (Bergamo, Italy), inaugurated in 1889, is considered a masterpiece of industrial archaeology in Italy.

height of 85 m, underwent restoration and maintenance operations in

for the boat coating market (Fig. 3) made sure that the brand Veneziani

1972 and 1992 (at least, these are the documented ones).

became popular in England (Fig. 4), Austria, and Italy. Trieste, at that

In the same years in which the San Michele Bridge was designed and

time, belonged to the Austro-Hungarian Empire, whose battleships’ hulls

built, Colorificio Veneziani, a manufacturer of anti-corrosion and marine

were all protected with Colorificio Veneziani products. Over the years,

coatings, was establishing itself in Italy and Europe. Giuseppe Moravia

Colorificio Veneziani changed hands several times, up to being acquired

founded it in Trieste (Italy) in 1863, but, after a few years, he handed

in 2011 by Colorificio Zetagì (Vicenza, Italy), also operating in the field of

over its management to his son-in-law Gioachino Veneziani, who gave

industrial coatings and specifically in the anti-corrosion sector.

his name to the new company. The resourcefulness of Gioachino

Let us now go back to the San Michele Bridge.

Veneziani and the patent of likely the first anti-fouling paint produced

Figure 2 – The construction of the bridge, made to create a rail link between the two shores of the river Adda, was entrusted to Società Nazionale Oﬃcine di Savigliano (Turin), which completed the job in just two years, from 1887 to 1889.

ipcm® Protective Coatings - 2019 JUNE - N.30

FOCUS ON TECHNOLOGY

©museosveviano

Figure 3 – Colorificio Veneziani patented likely the first anti-fouling paint produced for the boat coating market.

©museosveviano

Figure 4 – The Veneziani factory in London.

Current conditions

technical investigation, carried out with the aid of expert climbers

In September 2018, after a monitoring operation of RFI (Italian Railway

who inspected and monitored the whole bridge structure in order to

Network), which holds the responsibility of the structure, some faults

accurately assess the status of its materials and components (Fig. 6).

were found that resulted in the closing of the Bridge. In particular, there were signs of widespread oxidation and, in some areas, advanced

The maintenance operations

corrosion. Many of these problems were certainly due to the progressive

Where advanced corrosion did not allow planning a simple maintenance

erosion and consumption of the anti-corrosion coatings used for the

operation with anti-corrosion systems, the concerned structures were

protection of the structure (Fig. 5). Actually, the last documented coating

replaced completely with 200 tonnes of steel in total. Both new and

application dated back to the early 1980s. This called for an accurate

recovered structures have been painted with RFI-approved protective

Figure 5 – The single-span San Michele Bridge is 266 metres long and rises 85 metres above the level of the river Adda.

N. 30 - 2019 JUNE - ipcm® Protective Coatings

©Ferrovie dello Stato

FOCUS ON TECHNOLOGY

©Ferrovie dello Stato

Figure 6 – Expert climbers inspected and monitored the entire structure of the bridge, in order to accurately assess the status of its materials and structural components.

Figure 7 – RFI-approved protective coatings were applied on both new and recovered structures.

coatings (Fig. 7). All RFI-approved painting cycles are subjected to

RFI-approved coating systems

preventative laboratory analyses in order to certify their compliance with

In order to be approved by RFI, all coating cycles must comply with

international parameters and their corrosion resistance, in addition to

the INSTRUCTION 44/V specifications. These describe the operating

periodic performance checks (every three years) to guarantee that they

mode to be adopted depending on the substrate (new carbon steel,

continue to adequately protect the structures to which they are applied.

galvanised steel, etc.), its maintenance, and its environment (sea, plain,

They also comply with ISO 12944, the international standard that defines

industrial areas, etc.). For the new parts of the San Michele Bridge (200

the performance characteristics of coating cycles. In order to choose

tonnes), all coating operations were carried out in the factory. The 21/V

the right painting cycle, this standard suggests starting by identifying

(Veneziani) system was used, approved by RFI for steel structures in a C4

the corrosion class (environment) in which the structure is located.

environment.

The environment surrounding the San Michele Bridge belongs to the

After the sandblasting of steel, three layers were applied in sequence, as

C4 class, i.e. industrial areas and coastal areas with moderate salinity.

follows:

As the bridge area does not present particularly harsh conditions and

• inorganic zinc base coat Elettrometal 8855, 75 μm;

durability is high (H), the next major maintenance can be planned in

• epoxy intermediate coating Flexcoat OC MIC, 135 μm;

fifteen years.

• polyurethane finish Korall 1500 UR/HB, 65 μm.

ipcm® Protective Coatings - 2019 JUNE - N.30

FOCUS ON TECHNOLOGY

For the on-site application phase, still in progress (Fig. 8), the main

Conclusions

problem has been the removal of the existing material (sand blasting).

The bicycle and pedestrian path was reopened in March 2019.

Due to environmental issues, this process requires avoiding the

Reopening to car traﬃc is expected at the end of 2019 and reopening to

dispersion of removed parts, dust, and materials into the atmosphere.

rail traﬃc is expected at the end of 2020. In the last ten years, the

To this purpose, an innovative method of sandblasting, called Sponge

anti-corrosion cycles of Colorificio Zetagì-Veneziani have protected

Blasting Jet, has been used, which allows removing scarcely adherent

about 5 million m2 of public structures (railways, roads, motorways).

particles of old paints without any dispersion.

Zetagì and Veneziani have a deep knowledge of corrosion protection

After this preliminary operation, the 79/V (Zetagì) cycle, approved by

issues and oﬀer a wide range of solutions according to diﬀerent

RFI for the maintenance of steel structures in a C4 environment, was

substrates, environments, and application needs. The Veneto based

applied as follows:

company was pleased to collaborate in this project, so that the San

• surface tolerant epoxy base coat Painting Epox ST Alluminio, 50 μm;

Michele Bridge, candidate for inclusion in the UNESCO list, can still enjoy

• surface tolerant epoxy intermediate coating Epox ST Alluminio, 190 μm;

a long service life. ‹

• polyurethane enamel Retron Acrilico SL, 40 μm.

AT A GLANCE

RFI-approved coating systems INSTRUCTION 44/V in compliance with ISO 12944

C4 Corrosive Environment for - Industrial areas and coastal areas with moderate salinity - Chemical plants, swimming pools, coastal, ship and boatyards

21/V Coating system for new parts Elettrometal 8855 75μm Flexcoat OC MIC

135μm

Korall 1500 UR/HB 65μm

79/V Maintenance coating system Epox ST Aluminium 50μm Epox ST Aluminium 190μm Retron Acrylic Enamel SL 40μm

Figure 8 – An on-site processing phase.

N. 30 - 2019 JUNE - ipcm® Protective Coatings

BRAND-NEW

The Latest Innovation in Abrasion Resistance from Belzona

Figure 1 - Belzona 1814 is designed to provide protection in highly abrasive environments and is specifically formulated for application over large areas.

Belzona has released a new material, aimed at making light work

R&D Manager, Jason Horn said, “There was a need for a lasting abrasion

of big areas.

protection system, which can be easily mixed in large volumes and applied over sizeable areas. Our second objective was to create a

elzona 1814 has been formulated to resist the harshest abrasive

formulation with performance equal to our existing abrasion resistant

environments typically found in the mining, cement, pulp & paper,

materials, while keeping the costs down – the benefit of which could

biomass and other industries (Fig. 1).

then be passed onto our end users. We believe, with Belzona 1814, we

This epoxy-based material can be applied with a brush or a float to

have produced a high performance and cost-eﬀective system.”

protect assets preventing metal loss and subsequent downtime, either

A video has also been released showcasing this new material’s

on its own or as part of a system with alumina tiles (Figs. 2 and 3).

capabilities, available to view here:

Supplied in 30kg units, compatible with mechanical mixers and boasting

https://www.youtube.com/watch?v=t3oyJnyCnEI

a long working life, Belzona 1814 is most suited for application to large assets, including chutes, hoppers and screw conveyors.

For further information: www.belzona.com/1814

Figure 2 - Abrasion-resistant system with alumina tiles and Belzona 1814.

Figure 3 - The epoxy-based material can be applied with a brush or a float to protect assets preventing metal loss and subsequent downtime.

ipcm® Protective Coatings - 2019 JUNE - N.30

INNOVATIONS: PRESENT&FUTURE

Researchers Develop a New Class of Ice-Proof Coatings that Shed Ice Eﬀortlessly from a research of the University of Michigan Ann Arbour, MI, United States

ncmoore@umich.edu, gcherry@umich.edu

he University of Michigan announced the development of a new class

described how he and his colleagues turned to a property that isn’t

of spray-on coatings based on low interfacial toughness that cause

well-known in icing research. “For decades, coating research has focused on lowering adhesion

other large structures.

strength—the force per unit area required to tear a sheet of ice from a

The researchers overcame a major limitation of previous ice-repellent

surface,” Tuteja said. “The problem with this strategy is that the larger the

coatings—while they worked well on small areas, researchers found in

sheet of ice, the more force is required. We found that we were bumping

field testing that they didn’t shed ice on very large surfaces as eﬀectively

up against the limits of low adhesion strength, and our coatings became

as they had hoped. That’s an issue, since ice tends to cause the biggest

ineﬀective once the surface area got large enough.”

problems on the biggest surfaces—sapping eﬃciency, jeopardizing safety

The new coatings solve the problem by introducing a second strategy:

and necessitating costly removal.

low interfacial toughness, abbreviated LIT. Surfaces with low interfacial

They cleared this hurdle with a “beautiful demonstration of mechanics.”

toughness encourage cracks to form between ice and the surface. And

Anish Tuteja, an associate professor of materials science and engineering,

unlike breaking an ice sheet’s surface adhesion, which requires tearing the

ice to easily shed from surfaces of cargo ships, airplanes, power lines, and

Abhishek Dhyani, Macromolecular Science & Engineering PhD Student, sprays a low interfacial toughness (LIT) coating onto a surface.

N.30 - 2019 JUNE - ipcm® Protective Coatings

surface, regardless of its size. â&#x20AC;&#x153;Imagine pulling a rug across a floor,â&#x20AC;? said Michael Thouless, the Janine Johnson Weins Professor of Engineering in mechanical engineering. â&#x20AC;&#x153;The larger the rug, the harder it is to move. You are resisted by the strength

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edge. Once that crack starts, it can quickly spread across the entire iced

entire sheet free, a crack only breaks the surface free along its leading

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toughness that resists the propagation of a crack.â&#x20AC;? Thouless said the concept of interfacial toughness is well known in the field of fracture mechanics, where it underpins products like laminated surfaces and adhesive-based aircraft joints. But until now, it hadnâ&#x20AC;&#x2122;t been applied in ice mitigation. The advance came when Thouless learned of Tutejaâ&#x20AC;&#x2122;s previous work and saw an opportunity. â&#x20AC;&#x153;Traditionally, fracture mechanics researchers only care about interfacial toughness, and ice mitigation researchers often only care about interfacial strength,â&#x20AC;? Thouless said. â&#x20AC;&#x153;But both parameters are important for understanding adhesion. I pointed out to Anish that if he were to test increasing lengths of ice, he would find the failure load would rise while interfacial strength was important, but then plateau once toughness became important. Anish and his students tried the experiments and ended up with a really beautiful demonstration of the mechanics, and a

resistance to propagating the wrinkle is analogous to the interfacial

that wrinkle across the rug, regardless of how big the rug is. The

â&#x20AC;&#x153;But now imagine thereâ&#x20AC;&#x2122;s a wrinkle in that rug. Itâ&#x20AC;&#x2122;s easy to keep pushing

analogous to the interfacial strength.

of the entire interface between the rug and floor. The frictional force is

Wet chemical quality testing

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To test the idea, Tutejaâ&#x20AC;&#x2122;s team used a technique he honed during

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previous coating research. By mapping out the properties of a vast

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library of substances and adding interfacial toughness as well as adhesion strength to the equation, they were able to mathematically predict the properties of a coating without the need to physically test each one. This enabled them to concoct a wide variety of combinations,

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each with a specifically tailored balance between interfacial toughness

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sheet approximately 3 feet square, and a flexible aluminium piece approximately 1 inch wide and 3 feet long, to mimic a power line. On every surface, ice fell oďŹ&#x20AC; immediately due to its own weight. It stuck fast, however, to the control surfaces, which were identical in sizeâ&#x20AC;&#x201D;one was uncoated and another was coated with an earlier icephobic coating. The teamâ&#x20AC;&#x2122;s next step is to improve the durability of the LIT coatings. The paper is titled â&#x20AC;&#x153;Low Interfacial Toughness Materials for EďŹ&#x20AC;ective Large-Scale De-Icingâ&#x20AC;?. In addition to Tuteja and Thouless, the team included U-M macromolecular science and engineering graduate researcher Abhishek Dhyani and former U-M materials science and engineering Ph.D. student Kevin Golovin. The research was funded by the OďŹ&#x192;ce of Naval Research, the Air Force OďŹ&#x192;ce of Scientific Research,

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and the National Science Foundation and the Nanomanufacturing program (grant #1351412). â&#x20AC;š

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ipcmÂŽ Protective Coatings - 2019 JUNE - N.30

HIGHLIGHT OF THE MONTH

Total Materia, the Most Complete Database of Construction Materials in the World Infodoc Srl Mirandola (Modena) - Italy

TMsupporto@infodoc.it

otal Materia is the most complete database of construction materials

mechanical, electrical, and magnetic properties (Fig. 2), thermal treatment

now available on the market, providing immediate access to

diagrams, metallography characteristics, and designations of all included

information obtained from 74 regulations of over 35 countries and more

materials (Fig. 3). The information available is categorised according to its

than 20 million property data in 26 languages for over 450,000 metals,

sources, from the indication of the reference regulations or specialised

polymers, ceramics, and composites. Updated through a constant content

texts to the use of specially developed tools to determine matches among

evolution process, Total Materia is organised into a series of modules

materials based on their mechanical, physical, and chemical properties.

configured to oﬀer the ideal solution for all material data-related needs.

The data are also grouped and made comparable thanks to the “side by

Figure 1 shows a brief description of the included data.

side” display mode, enabling the users to make more accurate choices.

Total Metals

Problems

Total Metals is the core module of the Total Materia database, now the go-to

The problems that this kind of research normally entails include as follows:

consultation tool for structural designers to find the chemical, physical,

• research for equivalent materials and comparison among alternatives;

N.30 - 2019 JUNE - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

• research for materials throughout the world starting from their chemical composition and physical-mechanical properties; • identification of specifications and selection of the proper designation for a specific application; • research for traceable and reliable data on mechanical and physical properties with various conditions and temperatures.

The solution The solution provided by this resource, a complete database of material properties to support design activities, includes as follows:

Total Metals

The World’s Most Comprehensive Metals Database

PolyPLUS

Property data for thousands of non-metallic materials

Extended Range

Unparalleled material properties resource for advanced calculations

DataPLUS

Material welding info, lubricants, tribology, dimensions and coatings information

Enviro

Complimentary data module providing corrosion data, irradiation, weathering and aging information

Compliance

Global regulations module for materials and substances

Suppliers

Metal supplier sourcing directory and search engine

SmartComp

ΖPPHGLDWH XQNQRZQ PDWHULDO LGHQWLȴFDWLRQ

eXporter

Bridge the gap between data source and CAE software

Tracker

Providing important standard and material updates

Advantages The advantages found include as follows: • significant time savings; • higher accuracy and reliability; • a common platform for repeatable results.

PolyPLUS PolyPLUS is the module for non-metallic materials, which

Figure 1 - The Total Materia database includes diﬀerent modules that group data based on the properties of metal and non-metal alloys.

includes the mechanical and physical properties of about 100,000 polymers, ceramics, composites, fibres, and much more. The data sources used are technical regulations as well as an extensive library of exclusive data sheets, which

often include information on advanced properties and stress-strain curves.

• tables with cross-references from 74 regulations, providing an exclusive classification of correspondences and similarities;

Extended range

• data from regulations, completed with information

The Extended Range module contains a huge library of advanced and

on exclusive materials for an integrated and

non-linear properties of materials. It includes approximately 150,000 real

comprehensive solution.

or engineering stress-strain curves, fatigue data of over 35,000 materials © Infodoc

Figure 2 - Summary table for EN 1.4301 stainless steel with its mechanical properties, i.e. yield strength, tensile strength, elongation, and resilience, for diﬀerent supply states.

Figure 3 - A unique feature of Total Materia: material matching according to the information sources available, divided into categories – oﬃcial data from regulations, data based on the products’ chemical composition alone, or manufacturer-defined data.

ipcm® Protective Coatings - 2019 JUNE - N.30

HIGHLIGHT OF THE MONTH

with strain or stress-life parameters and S-N curves, formability data, fracture mechanics data, and creep data with the possibility of calculating the Larson-Miller parameter.

DataPLUS DataPLUS is the module that provides information on joints, lubricants and coolants, dimensions and tolerances, tribology, and coatings for thousands of metal and non-metal materials. It is based on material characteristics combined with data on welding, brazing, and adherence properties and with hundreds of configurations related to the surface coatings available, their characteristics, and test data useful to accurately assess the type and performance level of each paint. The properties presented include coeﬃcients of friction, maximum operating temperatures, and micro-hardness values. The tribology data include tests carried out on thousands of materials and data such as seizure threshold pressures and weight loss rates. The selection of the right lubricants and coolants is based on the tribology information provided.

Figure 4 - The specific search engines for each database allow obtaining accurate and precise results. © Infodoc

Enviro Enviro is the additional data module that provides information on corrosion, irradiation, ageing, and exposure to external agents for thousands of metal and non-metal materials. The user-friendly search interfaces of Total Materia allow obtaining accurate information by applying filters and specialised search selectors (Fig. 4). The search results include data based on test conditions, but also diagrams on the materials’ various properties according to their exposure criteria. The example shown in Figure 5 demonstrates the ease and speed with which it is possible to find information on the corrosion behaviour of an iron alloy in contact with nitric acid. It is also possible to effectively filter the list of alloys obtained by using advanced search criteria such as maximum corrosion rate, type of corrosion, and presence or absence of the “ISO-Corrosion” diagram. If the research concerns the tribological properties of a material with a known designation, on the other hand, it is possible to see data about its seizure threshold pressure, weight loss rate, and coefficient of friction with various types of materials and with different hardness values (Fig. 6).

Compliance As its name suggests, Compliance is a recently introduced module concerning the compliance of the materials and substances included in the database with the most well-known international directives and regulations, such as RoHS, REACH and many more. Compliance also enables to quickly assess to what extent a product meets the directives and whether it can be distributed in the global market.

Suppliers Suppliers, the module dedicated to producers/resellers, matches material Figure 5 - The concentration and temperature diagram for various properties of the AISI 304 material.

N. 30 - 2019 JUNE - ipcm® Protective Coatings

designations and suppliers from all over the world in synergy with the Total Metals and PolyPLUS modules.

HIGHLIGHT OF THE MONTH

SmartComp The identification of unknown materials or reverse engineering is simple and user-friendly thanks to the SmartComp module, both when directly interfaced to common spectrometers and through the manual insertion of chemical compositions. This allows quickly locating designations in Total Metals. SmartComp can also be applied to quality control tasks and defect and complaint analyses.

eXporter Finally, with the aid of the specific tool eXporter, it is always possible to transfer advanced property and other data to the most common calculation and CAE/FEM simulation software programs. There are about 20 available formats for direct export, such as for example ANSYS, SolidWorks, Nastran, or even .XLS (Excel) for particular cases.

Tracker Total Materia is also extremely secure thanks to its double certification: DAS ISO 9001 for data reliability and traceability and ISO 27001 for access security and confidentiality. Tracker has been implemented to guarantee update traceability and allow identifying any change made each month in Total Materia. ‹

Figure 6 - Tribological properties with experimental data for EN 1.4301 steel in contact with Type 410 steel.

SURFACE TREATMENT PUMPING & DOSING SYSTEMS For HARSH environment (Outdoor, Offshore..) Airless 1K or 2K equipment, Powder complete solutions Performance

Productivity Sustainability

Apply your Skills www.sames-kremlin.com

ipcm® Protective Coatings - 2019 JUNE - N.30

Opening photo – SAMES KREMLIN’s solutions are suitable for the application of several paints, liquid or powder, solvent or waterborne, and can be implemented with electrostatic eﬀect, to assist the end user for a faster, more profitable and environment-friendly application.

HIGHLIGHT OF THE MONTH

The Importance of Having the Right Approach Edoardo Danesi SAMES KREMLIN, Pioltello (Milan) - Italy

e.danesi@exel-italia.com

ith a specific eye on anticorrosion market, where the protection from the environment aggression is the first fundamental focus,

• The second focus is to analyse the characteristics of the specific coating to be applied. SAMES KREMLIN has to deal with very diﬀerent

SAMES KREMLIN applies its experience in identifying the right approach

chemical natures (solvent & waterborne, single and plural components),

to the industrial requirements in the paint shop applications:

physical properties as viscosity, solid content that have to be seriously taken into account.

• The first step in the approach to a specific solution design for the customer is to identify the needs in terms of Return on Investment (ROI),

Once these two phases are done the company can begin to propose the

daily paint consumption, daily number of colour changes, shape of the

potential diﬀerent solutions that may cope with the user’s expectations,

parts to be coated and productivity

presenting the several benefits and cost of ownership. This is the most

N.30 - 2019 JUNE - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

interesting phase in the customer relation where SAMES KREMLIN’s wide

its specific market segment: Kremlin Rexson for liquid paints and

experience will give the first image of the potential future installation, to

viscous applications and Sames Technologies for the powder and liquid

then start to perform tests in its labs or on site and hopefully soon, let

electrostatic finishing, up to highly automated solutions as automatic

the job start. This is of its daily job that is the base of service to the end

painting lines for automotive car plants. It has the vision to give the

users, that in cooperation with the sales experienced network is the key

right answer to the new challenges of the most demanding industrial

factor in designing the fastest and most profitable solution.

markets.

When the company talks to its valuable customers it get their feedback on how SAMES KREMLIN is able to provide the right balance between

Research and innovation have always been the key factor of the firm’s

reliability and endurance performances combined with easy-to-use

success. Starting from the first introduction of electrostatic application

features.

in powder market in the early 70’s. The next absolute innovation was in

SAMES KREMLIN is the global leading company in coating equipment

the 80’s with the Airmix®. An absolute solution that joins the productivity

market with more than 90 years of experience. Originated by the merging

and profitability of the airless application with the finishing result

in 2017 of two historical French brands, Sames Technologies (established

comparable to an airspray solution the transfer eﬃciency, measured in

in 1947) and Kremlin Rexson (established in 1924), already both belonging

accordance to the specific European standard can reach up to the 86%.

to the Exel Industries Group.

A commercial brand that has become the word to globally identify this

The company is focused on the customers’ needs for fluid, powder

technology. All competitors have followed, but never reached our quality

and viscous products delivery, application and control. The global

performances. It is suitable for the application of several paints, solvent

organisation counts on 17 subsidiaries, located in 4 continents, and

or waterborne, and can be implemented with electrostatic eﬀect, to

with six product ranges, it can always give the right answer to customer.

assist the end user for a faster and more profitable and

SAMES KREMLIN bases its experience on each of the two brands in

environment-friendly application (ref. Opening photo). In the

BELZONA ABRASION RESISTANT SYSTEM

FOR PROTECTING LARGE ASSETS AGAINST ABRASIVE ATTACK

COST EFFECTIVE

EXTREMELY DURABLE

EASY TO APPLY

Visit www.belzona.com/1814 for more information ipcm® Protective Coatings - 2019 JUNE - N.30

HIGHLIGHT OF THE MONTH

meanwhile

time for the application. This products range has recently taken just

SAMES KREMLIN unveiled the first packing free pump with the Flowmax®

the name of Rexson, a brand that has given its name to the application.

technology. An innovation that ensures a totally sealed pump with

This is just a simple example of what SAMES KREMLIN can provide, as

exceptional durability, and grant total performances with hard to

application of silicon, grease, sealants, PVC and whatever you may have

handle products as UV paints, abrasive coatings and moisture sensitive

in mind.

chemicals as PU hardeners.

Concerning the powder coatings market the well-known firm is ready to

Then came the launch of the 2k mixing and dosing solutions that reduce

launch a complete brand-new range of products and solutions to cope

the uncertainty of multi-component paint preparation, as well as the

with the most demanding markets, where the world ‘innovation’ has

environmental benefits such as the reduction of mixed paint waste due

been once again the mantra during the development phase.

to the real-time mixing of the paint needed to the application.

SAMES KREMLIN has an absolute excellence that is the Inobell® rotary bell for powder coatings, that will reach the 6th generation, giving

For some years now the company is almost entirely renewing its product

unsurpassed performances in smooth and wide powder distribution, on

range, and it is aiming new designs that are minimizing the number of

a ground where competitors have never been landing and this thanks to

components in its products. It is reaching untouched results, reducing

its automotive mind-set where rotary bells are an absolute excellence.

number of parts up to 75% compared to most entitled competitors. This

The acquisition of a hose manufacturer, TRICOFlex, has led to develop

is a great innovation in the direction of durability, reduction of the total

a complete and new range of air and paint hoses designed and tested

cost of ownership and simplicity in maintenance. As well as

to give great performances. The company has been testing them, firstly,

SAMES KREMLIN is applying concepts as “modularity” to almost all its

directly within agricultural division’s facilities of Exel Industries. Which

new products, allowing to provide new solutions that can be easily

best way to develop a product as to apply it directly internally, designed

upgraded following the advanced requirements of customers. This is the

for customers as for SAMES KREMLIN.

way SAMES KREMLIN can work together with the final users, minimizing

Its constant driver has been, is and will be keeping up with “the passion

the investment for new needs.

for our products and for the satisfaction of our customers”. In its web

The company is patenting new solutions for airspray guns that are

site and social media channels the company is dynamically bringing new

bringing a new fresh air in a world that hasn’t seen major innovations

experiences, new ideas and new products that will delight the finest

since fifteen years. The Vortex and Restrictor are the new solutions it

palates.

will extend to its entire low-pressure gun range. The airless range is on

Dynamicity is once again the SAMES KREMLIN goal and the evidence is

presenting new excellent guns as the ASC and ASB for automatic guns

on just far few letters on PC keyboard or smartphone.

and the SFlowTM for the manual application, as well as the Skill™ Airless

It doesn’t mind if you are working in a shipyard, in rolling equipment, in

tips that are giving new energy to solve problems with critical paint as

oil & gas equipment, or agricultural equipment, as well as renewable

UV coatings, as air trapping in film built.

energy markets. The SAMES KREMLIN team waits only to be put to the

A brand-new selection of airless pumps is on the way to be disclosed to

test. They hope having given enough good reasons to take a look. ‹

the mass market. SAMES KREMLIN completely redefined its standards to make the easiest and most reliable products on the market. It has a solution for the rolling equipment market to apply thick products as sealants and sound deadeners that will reduce consumption and

Subscribe, you will see the results.

www.myipcm.com

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Hel en lenius, Tekn Ca o ik

a, Tikkurila kul ar

Joel Sv

Elis aM

, DSM ets M

Fred er

John Fa

HMG er, ld

n, Belzona dse en

SUSTAINABILITY

Five on Five Interview:Sustainability According to the Industry Players - Part II In our previous edition of Protective Coatings we published the first of a three-part interview to senior figures from within the Coatings and Resins industry on the role of sustainability within their organisations. We wanted to give our readers some unique and diﬀerent content while at the same time embracing a noble element within our industry. If you didn’t catch the first article you can still read it online at www.myipcm.com by selecting issue n. 29 of Protective Coatings (April 2019) and scrolling onto page 46. Below you can find the second part of the first Five on Five interview, with the answers to five further questions. Once again, we would like to call out that there are no right or wrong answers as regards sustainability and indeed each company has reached diﬀerent points in their journey.

6. Why and when did your company get involved seriously with sustainability? Joel Svendsen, Belzona – I would say it was really from the very

the very beginning was that if we can begin to slow down corrosion, then we don’t need as much metal. Everybody knew it was a problem. But they struggled to come up with eﬀective solutions for it. Steel is such an

beginning. When Belzona was formed, my father (Jorgen Svendsen) would

eﬀective material. It is so integral in construction, that you want to use it

travel around the UK and see rust and corrosion everywhere! Corrosion

all over the place and in the beginning, you accepted that its lifespan was

protection was really in its infancy at this time. For example, a bridge

short. Gradually people began to find solutions for it, but it has been a

made out of metal would have a very short lifespan, rust away and large

long process. Belzona certainly has been a leader in extending the life of

sections would have to be replaced fairly quickly. So, Belzona’s vision from

steel, being one of the first companies to have eﬀective solutions for this.

N.30 - 2019 JUNE - ipcm® Protective Coatings

SUSTAINABILITY

For this second instalment we once again had the sincere pleasure of working with the following industry leaders: Joel Svendsen - President of Belzona

Helen Mets - President of DSM Resins & Functional Materials

John Falder - HMG Paints Managing Director

Fredrik Calenius - TEKNOS Chief Procurement Oﬀicer

Elisa Markula - Tikkurila CEO & Minna Avellan - Director, Communications and Investor Relations of Tikkurila

Helen Mets, DSM – DSM has been highly focused on sustainability not

sustainable, even before it became a trend. We do this because at every

only from an ethical point of view, but as a market diﬀerentiator and as

level it is the right thing to do and the right place to be. It makes business

a business driver for about more than 10 years. With the recognition

sense, personal sense and it shapes the future of the planet.

that there were truly viable, greener and safer alternatives that delivered equitable product performance, and with the advent of innovative

Fredrik Calenius, TEKNOS – We are currently updating our strategy for

technologies enabling those developments, we began what can only

2019-2025 with the ambition to grow the company to EUR 1 billion net

be described as our sustainability journey, transforming ourselves to

sales by 2025. As of this year, sustainability will be integrated as part of

a company with sustainability as part of its DNA. For example, it was a

our strategy from the boardroom down.

decade ago that DSM, along with other coating players, founded the Waterborne China Platform to reduce VOC emissions in the booming

Minna Avellan, Tikkurila – Responsibility and sustainability has been

industrial container sector by switching from solvent-based primers

part of our business already for decades. Here are some of our key

and topcoats to waterborne ones. Today, with over 3 million industrial

sustainability milestones:

container units in operation, 90% of them have waterborne coatings

• Customer cooperation: Tikkurila first started training customers in the

resulting in a reduction in VOC emissions from 160,000 tons per year to

late 1920s. A customer magazine “Tikkurilan Viesti” was founded in 1929.

just 15,000 tons.

The magazine has been published regularly ever since, except for a six-year break during World War II.

John Falder, HMG – Since our inception HMG has always aimed to be

• First waterborne products: Our first waterborne product in Finland,

ipcm® Protective Coatings - 2019 JUNE - N.30

SUSTAINABILITY

Tikkurila brand’s Joker interior paint, was introduced in 1953. In Sweden, the first waterborne product was launched in 1951 by Beckers. Today, an increasing number of paints are waterborne, low-solvent, solvent-free or high solids products. In 2017, 85% of decorative paints sold are waterborne products (2017). • Tinting is an economic and ecological way to produce thousands of colours. Tikkurila launched its Monicolor tinting system already in 1970. This changed both paint-making and distribution. Producing coloured paints by tinting has a direct impact on the ecological footprint (less waste and improved material eﬃciency, improved production eﬃciency, logistics benefits). • In 1994, Tikkurila in Finland got the ISO 14001 environmental management certification. The majority of our units have the audited and certified quality, environmental, and safety management systems. The list is available on our website at www.tikkurilagroup.com • In 1997, Tikkurila’s Eko-Joker paint received the EU’s environmental label – as the first paint product in Finland to do so. Nowadays we have some 300 eco-labelled products.

7. How are you measuring progress? Joel Svendsen, Belzona – We regularly review our product portfolio to see where we can make our products more environmentally friendly.

decisions, and ensure all environmental objectives and targets are

Are there ways that we can reformulate to use safer materials and, at

appropriate to the nature, scale and impacts of our activities, products

the same time, more environmentally friendly? Can we incorporate more

and services.

bio-based materials than petroleum-based? These issues and how we measure them are raised and discussed in our regular technical liaison

Fredrik Calenius, TEKNOS – We have defined concrete goals/targets and

meetings. From here we decide if things need to be altered and whether

KPI’s for all of the areas below:

or not to pursue new developments.

• phase out of Reach substances of very high concern; • decrease of VOC;

Helen Mets, DSM – We measure the eﬀect that every one of our

• increase secondary usage;

products has on people and the planet benchmarked against

• safe use of chemicals;

conventional, less sustainable equivalents. We call them Brighter Living

• increase our understanding of customers sustainability needs;

Solutions and they currently account for 80% of our entire portfolio. We

• increase customers’ awareness of sustainability in Teknos’ oﬀerings;

also measure our own sustainability progress through key performance

• occupational health and safety;

indicators (KPIs) we’ve set within the business. An example is the goal of

• environmental eﬃciency;

increasing our purchasing of energy from renewable sources to 70% by

• production eﬃciency;

2030, for which we’ve made significant strides, going from 8% in 2016

• business ethics;

to 21% in 2017. Allied to this, for many years DSM has been listed at, or

• supplier code of conduct implementation;

near, the top of the annual Dow Jones Sustainability Index and last year

• supplier CSR implementation;

we ranked 2nd in Fortune’s “Change the World” list based on the social

• employee satisfactory & fair treatment;

impact woven into our core business strategy.

• leadership; • sponsorships/support local communities.

John Falder, HMG – HMG uses a variety of means but the British Coatings Federation, Coatings Care statistics are one of the documented measures.

Minna Avellan, Tikkurila – The sustainability performance is measured

We also work tirelessly to comply with relevant current and future

in various ways, both on the Group-level and locally, e.g. we are following

legislation. As part of the strategic planning processes, we incorporate

sales of waterborne products, energy eﬃciency, amount of waste,

environmental objectives, where appropriate, into business

development of safety.

N.30 - 2019 JUNE - ipcm® Protective Coatings

SUSTAINABILITY

John Falder, HMG – Ironically this is something we don’t really “Promote” as we see them as key business values. We are actively engaged in promoting good causes and eﬀorts both in the local community and industry. Nevertheless, in order to achieve competitiveness through sustainability, activities need to be unique, and not imitable by competitors. In this respect HMG works alongside its stakeholders in developing tailored activities that revolve around the companies Value Chain. Fredrik Calenius, TEKNOS – Internally we have programs in place such as workgroups and training for all the KPI’s mentioned above and our employees are encouraged constantly to participate in every area. Externally we use our communication channels (web, newsletters to customer, social media, newsroom, Trade Press). We are also cooperating with the Finnish Chemical Industry association. The first Non-Financial-Information report will be released early 2019. Minna Avellan, Tikkurila – Sustainability is a key element in our communications, brand management and marketing, so it is highlighted as part of product promotion, company communications and stakeholder cooperation. Matthew Henry © Burst

8. How does your company promote the sustainability of its activities/products?

9. What sustainability initiative are you most proud of? Joel Svendsen, Belzona – That’s an interesting question. I’m tempted to

Joel Svendsen, Belzona – Throughout our Marketing literature, videos,

say our early work/early days in the company. Because we were taking

articles, we try and promote our sustainability in the industry. We also

unprotected steel and making a really big diﬀerence. In terms of what we

have a case study library, our KHIAs, which is an incredible way of

are doing lately, I would say it is from a regulatory standpoint. Working

demonstrating how we have been successful for decades in preserving

in the chemical industry, it goes without saying that over time there will

and prolonging the lifespan of equipment and structures.

be something that is eventually found to be hazardous. The realisation

Aside from that, we do push energy eﬃciency. We have our coating,

of these previously unknown concerns then leaves you with a choice to

Belzona 1341, which is particularly useful for improving pump eﬃciency.

make. As a company there are two roads to go down. Road one - you can

This diﬀers from our usual push, saying that we will extend the life of

pop a label on it and say this chemical is nasty, be careful. Road two - you

your equipment – whereas in this instance, we are saying we can improve

can try and reformulate and replace it with something safer. Belzona has

eﬃciency. Which appeals to our customer base from an economic stand-

tried very hard to not just “label it”, but to be proactive in researching and

point even more and of course, as an environmental benefit.

developing ways to make the products safer and better. Whereas I think a lot of other companies label it and consider their work done. I feel much

Helen Mets, DSM – The industry we work within is quite a small world.

happier about the way we do it.

We are finding that DSM is starting to be recognised by our diﬀerentiation brought about by our approach to sustainability. But beyond the

Helen Mets, DSM – We are proud of so many genuinely pioneering

immediate borders of the industry we operate within, it is important for

innovations, but a particular one that comes to mind is our family of

DSM to advocate on sustainability issues with legislators, partners and

eco-friendly paint resins – that is, Decovery® for building, construction,

customers. We need to continue to be not only outspoken, but to play a

interior decorating and furniture applications. Our Decovery range

proactive guiding role to enable long term sustainable change. At DSM

is nearly 50% plant-based, but with equitable or better performance

Resins, sustainability is addressed in all of our product communications.

characteristics than VOC-embedded crude oil-based versions – from

Recently, we have launched what we think are the boldest sustainability

coverage and applicability, to durability and colour finish (no yellowing). It’s

targets in our industry with the aim to change the industry into a more

one of our flagship brands and is testament to how sustainable product

sustainable one.

stewardship can be a successful business driver. Above and beyond

ipcm® Protective Coatings - 2019 JUNE - N.30

SUSTAINABILITY

specific product innovations, we are also immensely proud of our vision and ability to dare to take on the sustainability journey in the way that we have. We are not involved in occasional or half-hearted sustainable activity but rather have absorbed the philosophy and tenets sustainability into our very DNA. John Falder, HMG – The huge water saving initiatives we have undertaken as a business overall. The River Irk was the heartbeat of the Industrial Revolution in Manchester and flows through our site so we’re extremely conscious of maximising its resources. Fredrik Calenius, TEKNOS – Currently we are really proud that we have succeeded to integrate sustainability as part of our strategy. To know more about our recent success cases, you can visit our website: http://www.teknos.com/about-us/sustainability/ Minna Avellan, Tikkurila – Within the latest product launches, our new biobased product, Alcro A1, in Sweden. A third of the raw materials that usually are fossil-based have been replaced with bio-based ingredients in this interior wall paint. Another interesting product launch is our new product family for facades, Tikkurila’s Finngard Clean. It is one solution for challenges posed by climate change to building facades. Due to its special technical properties (the superhydrophobic surface), Finngard Clean products repel water and dirt from the surface but allow any structural humidity to evaporate through it. Facades are under increasing stress, and surfaces remain wet for longer periods. This is a favourable growth medium for microbes and fungi, causing exterior surfaces to suﬀer damage more quickly. Regarding our social contribution: in Sweden, Tikkurila has established a Paint Fund, which gives the general public the opportunity to realize socially beneficial painting projects. In practice, anyone in Sweden can apply with his or her painting project for a project within the Paint Fund. A jury of Tikkurila Sverige’s representatives decides which projects to support and donates the needed safe and durable paints. The repainting projects can include a worn asylum-seekers’ homes, forgotten club venues or dark pedestrian tunnels. In 2018, within all applicants some 10 projects have been realized.

10. Almost 40 years ago everybody rushed to go green, but the results were scarce. Do you feel like this is truly a time of change or is it just another marketing strategy? Joel Svendsen, Belzona – As with everything, it goes in fits and starts – fast progress, followed by a plateau. But I don’t think it died. Living in the US for most of my life, I find it interesting to compare the US and the UK in terms of environmental regulation. Starting in the early 1970s, the US were pioneers in this field. But as result, they suﬀered a lot. For example, they were among the first to put emission

N.30 - 2019 JUNE - ipcm® Protective Coatings

SUSTAINABILITY

standards on cars and automobile manufacturers really struggled to make the technology work. Whereas, when you compare to the UK, environmentalism came a little later. And because it came later, the big challenges that previously had been stumbling blocks were now overcome. That meant they were able to push it further forward more quickly. In the US, because they had this bad experience, there was a bit of an aftertaste that the environmental legislation was a nightmare. So now, there is more resistance in the US to improving regulations. But time heals old wounds and as things continue to change, environmental issues will become universally accepted rather than be a debate. Helen Mets, DSM â&#x20AC;&#x201C; While we can see that there are undoubtedly cases of greenwashing, I absolutely believe we are at the cusp of real change. Although, as Iâ&#x20AC;&#x2122;ve commented previously, as pioneers in sustainability, we still feel the need to pull the market along. We are nevertheless seeing more drive from within industry and certainly big shifts from the outside world. There is an increase in consciousness which gives me optimism. Sustainability used to be part of the â&#x20AC;&#x153;softerâ&#x20AC;? stuďŹ&#x20AC; that companies adopted into their strategies, but now the softer stuďŹ&#x20AC; is becoming harder and more tangible â&#x20AC;&#x201C; so much so that quite robust measurement and reporting is being implemented. John Falder, HMG â&#x20AC;&#x201C; For many companies, Sustainability is seen as short-term public palliative actions that are expected of it by the public as obligations move from stockholders to stakeholders, and companies become more accountable for their impacts on stakeholder communities. For many companies, it is still merely a â&#x20AC;&#x153;cosmetic public relationsâ&#x20AC;? activity, that generates no long-term value to society or to the business itself. As mentioned, since our inception in 1930, this has been a key part of the HMG Paints ethics and values, exemplified by its Coatings Care Award wins and awardwinning CSR initiatives that have had real impact on us as a company and our local community. Fredrik Calenius, TEKNOS â&#x20AC;&#x201C; We truly believe that the successful companies in the future will integrate sustainability into their strategies. We see a good possibility to build a competitive edge on sustainability. It is not a green washing. Elisa Markula, Tikkurila â&#x20AC;&#x201C; In 2030, the human population will be 8 billion and we will consume 50% more food, 50% more energy and 40% more fresh water. There is an urgent need for all companies, governments, countries and individuals to start behaving so that we have something to leave for the next generations. Every company needs to do its part and we believe that our sustainable actions have a meaning to the bigger picture. To help save this planet for the next generations.

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INSPECTION LOGBOOK

Coating Inspections: Some General Considerations Massimo Cornago NACE International Certiﬁed Coating Inspector, NACE CIP PEER Reviewer

cornago@ipcm.it

“The best coating available is of little value if it is not carefully and

its useful life several times over by initiating coating maintenance and

properly applied, so the coating inspections are specified to ensure the

repair before major coating failure result. Comparison of the results

proper application”.

obtained during the coating application has shown that also the life

expectancy of the finished coating can be increased by two-three n order to produce an optimum coating life and the relative

times.

economical advantage, a coating specification must be complied

Unfortunately, the inspection of the coating application is overlooked

with if it is to serve any useful purpose and then include a precise

by the owner of the structure, in spite of the fact that inspection is the

inspection requirement to ensure a quality coating application that will

area of the job where he is most likely to receive less than he specified.

give a very long coating life, even under severely corrosive conditions.

In fact the protective coatings application is very often considered an

Proper and accurate inspection is a primary key to eﬀective coating

indefinite and rather haphazard operation, where quality control is

performance and therefore should be a requirement of every good

more the exception than the rule.

specification, as well as a periodic requirement over the lifetime of the

Failure to provide inspection is also common in contracts for

coating. Eﬀective inspection, during the life of the coating, can extend

maintenance coating work, although it is no more excusable in this

“The best coating available is of little value if it is not carefully and properly applied, so the coating inspections are specified to insure the proper application”.

N.30 - 2019 JUNE - ipcm® Protective Coatings

INSPECTION LOGBOOK

case than it is for new works.

the inspection (Oil & Gas Industry, Oﬀ Shore plants, Nuclear Facilities,

In conclusion we can take into consideration two diﬀerent inspections

etc.). Extensive documentation requirements will also increase the

activities: during the construction (new materials) and during

inspection cost, sometimes unnecessarily.

maintenance (old material); in addition we have another type of inspection named survey, in which is required the state of the art of

The value of inspection

the coated structure.

The value of coating inspection is much more diﬃcult to quantify2. Inspection is a form of insurance for the owner because it greatly

The need for quality inspection

decreases the risk of early or catastrophic failure. This topic will be

Most coating contracts involve the investment of very significant

addressed with detailed examples in the next articles. Inspection also

amounts of time and money and the inspector plays a critical role in

increases the likelihood that the coatings will provide “the full intended

ensuring that the owner receives a return on this investment. With a

service life” and attributes (e.g. appearance, coloration, gloss) of the

well-written job specification in hand, the owner requires a thorough

coating system over a long period of time. A large number of specifiers

inspection to establish that all the requirements of the specification

have come to recognize the value of inspection when it comes to the

are met and that work is completed in a timely and satisfactory

success of a coatings project. Unfortunately, it may take an expansive

manner.

failure, on a program where inspection was ignored or under-evaluated, to demonstrate the true value of inspection.

Inadequate or improper inspections can result in: • Costly delays in completion of the work

Inspection personnel

• Less quality or quantity of work than specified

The Coating Inspector’s figure is very important before and during an

• Contractual disputes and litigation (years)

inspection activity. Just to introduce the topic, it is however necessary

• Costly replacement of inadequately protected structures and/or

to answer the classic question: “Who is the Coating Inspector?”.

equipment

The Coating Inspector is a highly qualified technician who has the basic

• Costly maintenance of inadequate coatings

skills and qualifications required for a coating inspection, such as:

• Environmental contamination (air, water, soil, etc)

• Physical requirements

• Accidents.

• Training • Communication skills

The cost of inspection

• Ethics and judgement.

Inspection should be considered an essential feature of a coating project and of its cost. Its costs may be direct or indirect and will

The Coating Inspector has several pre-job responsibilities, such as

reflect on factors such as training and the Company overheads. We

familiarizing with the job specification and the facilities and equipment

have to take into consideration direct and indirect costs.

to be coated, attending the pre-job conference, becoming aware of safety hazards and responsibilities and inspecting the jobsite. The

Directs costs include mainly the inspector’s time, travel (including

inspector should also inspect the equipment that will be used for

food, drink, hotel, etc.) and materials. Other costs are due to the

surface preparation, mixing, and coating application; inspect all the

applicator to provide access to the structure and for the applicator’s

material to be used for the job and monitor ambient conditions.

time for meetings and discussions regarding the inspection procedure

Typical capability levels of inspectors (based on education, training

and results. Pre-job meeting with the applicator, inspector, and owner,

and experience) must be clear and recognised by a qualified Society.

must be taken into account as a direct cost.

The Certified Coating Inspector may be employed by the owner, the applicator, or an independent inspection firm, but in any case he/she

Indirect costs for the owner include additional time that may be

must have certain basic skills and international qualifications: NACE,

required to perform the inspection. In addition, we have to take into

FROSIO, SSPC, etc.

consideration the period of time the facility or process will be shut

The complex figure of a Qualified Coating Inspector will be addressed

down or inaccessible. If rework is required, it will increase the time

in depth, in the article that will be published in the next issue of

before the job is complete and will require additional inspection time

ipcm®_Protective Coatings. ‹

on the job. Depending on the size of the job, the cost of coatings inspection is typically in the range of 5-18% the cost of the “coating portion” of

1 - SS. G G. Pinney Pinney, “Coating Inspection: Is It Worth It?” It?”, in The Economics of Protective Coatings Coatings,

the project . Generally, the more stringent the quality control and

SSPC Proceedings, Baltimore, November 1988.

inspection requirements, the higher the percentage of the cost of

2 - W. W. Kaminski and J.R. Allen, “What is Inspection Worth?” JPCL, August 1984.

ipcm® Protective Coatings - 2019 JUNE - N.30

FOCUS ON TECHNOLOGY

Corrosion Causes Rail Accident Intertek UK Brentwood, United Kingdom

production.assurance@intertek.com

railway signal post corroded at the base, collapsed and fell,

corrosion, the susceptibility of the post to corrosion and whether any

obstructing one rail track and partially obstructing another (Fig. 1).

coatings had been applied to it in the past.

A train travelling at 110mph (177 km/h) struck the top of the collapsed signal on the partially obstructed track (Fig. 2). The train car sustained

The Solution

exterior damage and did not derail. No human injuries were reported.

Intertek performed laboratory analyses on the relevant sections of the

Intertek was commissioned to evaluate the cause of corrosion with the

damaged post and submitted a report of its findings. Visual analysis,

findings published in a report by the Rail Accident Investigation Branch

hardness testing, optical and scanning electron microscopy, energy

(RAIB, ref. Opening photo).

dispersive analysis of X-rays and chemical analysis were all performed on the corroded post section.

The Challenge Intertek’s corrosion services were sought by the RAIB to ascertain

The Result

which failure mechanism caused damage to the signal post, the rate of

The findings consisted of several key points, which are included in the

Opening photo: A train travelling at 110 mph (177 km/h) struck the top of a signal which had collapsed and fallen across the railway line.

N.30 - 2019 JUNE - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

Figure 1 – Signal post along the British Network Rail.

Figure 2 – The fallen signal post after the accident.

oﬃcial RAIB report on page 18 to 21, paragraphs 43 to 51 (see text

and the evaluation of the circumstances that occurred in the run-up to

box).

the incident. The RAIB concluded that the signal collapsed because the

• Both internal and external corrosion had occurred around the base

base of the post had corroded.

of the post, resulting in severe metal wastage.

It also found that the corrosion was not detected by the routine

• Traces of a coating system were detected, most likely to have been

examination regime, by additional inspections carried out during a re-

originally applied to prevent atmospheric corrosion. Very little of this

signalling project or during maintenance.

was found remaining on the corroded section of the post.

The RAIB made several recommendations in its report to prevent a

• Corrosion was focused at ground-level. Ballast and holding water

similar incident happening again in the future.

concentrated around this area were likely to have aﬀected the integrity of the coating system originally applied and increased the posts’

• The asset management strategy should be reviewed in order to

susceptibility to corrosion.

improve examination and maintenance processes.

• Rainwater was able to seep through the open top of the post. As no

• A risk assessment process should be developed and implemented

drainage system was implemented, it was able to pool internally at the

that specifically addresses partially buried hollow ancillary structures

bottom.

and their susceptibility to corrosion.

• The bottom section of the post critically aﬀected by corrosion was

• Examination maintenance regimes for ancillary structures should

buried in ballast and the visible section (above ground level) remained

be reviewed and an additional five key steps added. These were

relatively unaﬀected. This may explain why the damage was not

developed following this signal post collapse incident and were

detected by routine visual examinations.

designed to consider aspects that may have been overlooked previously and enabled the corrosion of the hollow post to go

RAIB’s Report Conclusions

undetected.

Intertek’s analyses were taken into account by RAIB and contributed

• Competence management processes for personnel involved in

to the conclusions made by the body as to the cause of the corrosion

structure examinations should be reviewed and revised.

ipcm® Protective Coatings - 2019 JUNE - N.30

FOCUS ON TECHNOLOGY

The Actions/Progress Intertek was commissioned to understand the failure mechanism, the

• Commissioned a retrofit design to strengthen weakened assets

progression of corrosion in the signal post and the nature of the post

• New examination methodology and report form aﬀecting ancillary

material. Since the incident, several actions have been taken to carry

assets with visual exams developed.

out structure examinations including:

Changes were also made to examining and reporting methods that

• Ensure damage to signal posts is noticed during the inspection

require examiners to provide more detailed information in their

processes

reports, such as a greater number of images. They are also required

• 1,700+ signal posts installed ballast boards to mitigate similar issues

to examine parts of the structures that were previously omitted from

where necessary

report forms. ‹

Corrosion at the Base of the Signal Post Excerpt of report edited by RAIB – Rail Accident Inves ga on Branch, pages 18 to 21, paragraphs 41 to 51. 41. The signal collapsed because the base of the post had corroded. 42. The RAIB commissioned specialist laboratory analysis of the corrosion in order to understand the failure mechanism, the progression of corrosion in the post, and the nature of the post material including any coatings it may have had. The analysis consisted of a visual examination and sectioning of the post, optical microscopy and hardness testing, scanning electron microscopy (SEM) and energy dispersive analysis of X-rays (EDX), and chemical analysis. The material in paragraphs 43 to 51 is based on the specialists’ analysis. 43. Corrosion around the base of the post and the ladder had caused severe metal wastage and an almost complete loss of wall thickness at and around the ballast in which the base of the post was buried (Figs. A, B and C). It is likely that localised sites were perforated (rusted through) before the post collapsed. 44. Corrosion had occurred on both the external and internal surfaces of the post, especially within 250 mm of the rupture site. Remaining wall thickness at the thinnest point measured was around 0.1 mm, as compared with 6 mm when new. The post is of hollow round tubular construction made of carbon steel, with an outside diameter of approximately 168 mm, while the manufactured wall thickness was approximately 6 mm. As a structure, the post is welded into a baseplate assembly which, in turn, is bolted to a concrete foundation (Fig. D). The signal structure also includes an access ladder which is similarly fixed into the ground. 45. The external surface had a five-layer organic coating system, although no zinc galvanised coating was detected. The coating was almost certainly designed to prevent atmospheric corrosion. There was little evidence of any remaining coating on the external surface of the affected region. 46. Away from the rupture site, the rest of the external surface (the visible section of post above ground level) was relatively unaffected on a cursory visual inspection. Since the corrosion was particularly focused at ground level, this suggests that the corrosion was not simply due to atmospheric exposure (which the coating was designed to protect against), but was particularly affected by the post being buried in ballast. 47. The ballast would have affected the integrity of the external coating (through abrasion) as well as holding water around the base of the post. Once the corrosion activity was established, it would progressively undermine the surrounding coating. 48. There was no evidence of any coating on the internal surface, although there was nothing to prevent water getting in (there are several holes in the sides of the post for cable access and there is no cap at the top of the post where the signal head is attached).

N. 30 - 2019 JUNE - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

Corrosion scales (ie. rust flakes) were unevenly distributed around the interior of the post, varying from 70 mm to 400 mm above the failure, while metal loss on the internal surface tapered up to around the same point. 49. By design, there is no drainage at the bottom of the post where it interfaces with the concrete foundation. It is therefore likely that the internal corrosion occurred due to continual exposure to stagnant rainwater which had entered through the cable holes and the top of the post, and had pooled inside the base. Upon inspection after the accident, the base was full of rust flakes, which would have further impaired the ability of the water to escape. 50. Typical corrosion rates for carbon steel in fresh water are between 0.02 mm and 0.1 mm per year. Over the 40 year lifetime of the post, it is therefore plausible that almost complete wastage of its 6 mm section could occur if the both internal and external surfaces were corroding simultaneously. The analysis revealed that the corrosion appeared to be worse on the external surface; internal corrosion scale built up may have had the eﬀect of slowing down the corrosion process, while the external surface was more exposed to weather and ballast movement which could have removed corrosion scales, exposing fresh metal and thereby accelerating corrosion. 51. There was no significant evidence of any potentially corrosive chemicals in the samples analysed. There was also no evidence of any

latent defect with the manufacture of the post.

Figure A - Corrosion at the base of the signal post.

Figure D - Schematic of post and baseplate assembly (holding-down bolts and concrete foundation not shown).

Figures B and C - Corrosion at the baseplate in situ after the accident (note level of ballast, above image) and after removal from site (below image).

ipcm® Protective Coatings - 2019 JUNE - N.30

TRADE FAIRS & CONFERENCES

MP : MEDIA PARTNERSHIP - ipcm _Protective Coatings is present with own booth or press corner ®

JULY 2019 MP

giornate nazionali sulla corrosione e protezione

Palermo, Italy

corrosion and protection

July 3-5, 2019

www.aimnet.it/gncorrosione

AUGUST 2019 marintec south america

Rio de Janeiro, Brazil

shipbuilding, platform and maintenance

August 13-15, 2019

www.marintecsa.com.br

SEPTEMBER 2019 the big 5 construct egypt spe oﬀshore europe asia paciﬁc coatings show the big 5 construct nigeria eurocorr cape construction expo corrosion technology week

N.30 - 2019 JUNE - ipcm® Protective Coatings

Cairo, Egypt

building, construction, architecture

September 2-4, 2019

www.thebig5constructegypt.com

Aberdeen, UK September 3-6, 2019

Bangkok, Thailand September 4-6, 2019

Lagos, Nigeria September 9-11, 2019

Seville, Spain September 9-13, 2019

oﬀshore industry www.oﬀshore-europe.co.uk raw materials suppliers and equipment manufacturers for the coatings industry www.coatings-group.com/apcs/bangkok building, construction, architecture www.thebig5constructnigeria.com

corrosion prevention technologies www.eurocorr.org

Cape Town, South Africa

building and envelope technologies

September 11-12, 2019

www.cape-construction.co.za

St. Louis, USA September 15-19, 2019

corrosion prevention and control technologies ctw.nace.org

TRADE FAIRS & CONFERENCES

: SPECIALIZED EVENT FOR SURFACE TREATMENTS INDUSTRY

neva

for arch

tube southeast asia

aog expo

St. Petersburg, Russia

shipbuilding, oﬀshore energy, ports, inland waterways

September 17-20, 2019

https://transtec-neva.com/

Prague, Czech Republic

building and construction

September, 17-21 2019

www.forarch.cz

Bangkok, Thailand September 18-20, 2019

tube, pipe, pumps and valves industries www.tube-southeastasia.com

Buenos Aires, Argentina

oil & gas industry

September 23-26, 2019

www.aogexpo.com.ar

OCTOBER 2019 expo ferroviaria

isk-sodex

inmex smm india

Rho, Italy October 1-3, 2019

Istanbul, Turkey October 2-5, 2019

Mumbai, India October 3-5, 2019

railway industry www.expoferroviaria.com

HVACR, pumps, valves, water treatment and insulation www.sodex.com.tr

shipbuilding, machinery and marine technology www.inmex-smm-india.com

canwea annual conference

October 8-10, 2019

mediterranean oﬀshore conference

October 15-17, 2019

www.moc-egypt.com

Düsseldorf , Germany

plastic and rubber

October 16 -23, 2019

www.k-online.de

expo coating

Calgary, Canada

Alexandria, Egypt

Moscow, Russia October 22-24, 2019

wind energy industry https://windenergyevent.ca/2019

oﬀshore industry

technologies, equipment and materials for surface treatment and coatings application www.expocoating-moscow.ru

ipcm® Protective Coatings - 2019 JUNE - N.30

ZOOM ON EVENTS

Melbourne, Australia to Host Corrosion and Prevention 2019 Conference & Exhibition The Australasian Corrosion Association (ACA) will host the industry

lecture marks Percival Faraday Thompson’s contribution by emulating the

leading, Corrosion and Prevention 2019 (C&P 2019) conference on

academic and technical qualities for which he was known.

24-27 November 2019 at the Crown Promenade in Melbourne, Australia.

In addition the following key note speakers have been confirmed:

This annual conference and trade exhibition will bring together leading

• Carmen Andrade, President - Alconpat

researchers and industry practitioners who combat corrosion on a daily

• Dudley Primeaux, Owner – Primeaux Associates LLC, USA

basis.

• Srdjan Nesic, Russ Professor of Chemical Engineering at Ohio University, USA • Stuart Lyons, AkzoNobel Professor of Corrosion Control, School of

he destination for 2019 is Melbourne, Victoria - compact and diverse,

Materials (Corrosion & Protection), UK.

it is a perfect playground for adventurers and wildlife lovers, foodies

and road trippers. Discover remote beaches and rugged coastlines,

In addition to the technical program, the conference 60 booth exhibition

alpine outlooks and lush forests, all within easy reach of Melbourne,

will be an integral part of the activities. It provides an opportunity for

Australia’s culinary and coﬀee

delegates to experience the

capital. See kangaroos, koalas,