ipcm® Protective Coatings n. 36 - December 2020 by ipcm® International Paint&Coating Magazine

ISSN 2282-1767

Protective Coatings ®

THE MAGAZINE ABOUT CORROSION CONTROL AND PREVENTION TECHNOLOGIES

ipcm_PC digital on www.myipcm.com

2020 - 9th Year | Quarterly - N.36 December

Interpon Align Two coat, one bake coating system The quickest route to outstanding performance. Interpon Align is a two coat, one bake powder coating system that provides outstanding edge corrosion protection in an efficient and cost effective manner. Comprising of two specially formulated powder coating layers, Interpon Align eliminates the need for a primer curing process. Customer benefits • Cost savings • Energy efficiency • Excellent performance • Less investment • Environmental benefits

For more information on Interpon Align, speak to your local representative or visit www.interpon.it

Azur™ pumps a nd Airless® spraying solutio ns for demanding protective coating applica tions

AZUR™ PUMPS, THE ULTIMATE ANSWER TO PEOPLE ADDICTED TO WORK 52C225 & 72C160

SFlow™ Spray gun

Airless® paint pumps

The highest paint ﬁnishing quality Constant ﬁlm build Operates in intense conditions Simple maintenance Extreme comfort of use

Apply your skills www.sames-kremlin.com

Reliability and Experience at your Service Tosca srl is a leading company for over 50 years in the design and construction of shot blasting machines and shot blasting plants for surface treatment. In a site area of 30.000mq and a reference of over 4.000 worldwide shot blasting machines installations, Tosca srl produces in accordance with Industry 4.0 ensuring extremely reliable products thanks to high engineering skills and advanced know-how where the details make a diďŹ&#x20AC;erence.

EcoQuip™ 2 EQp Vapour abrasive blasting

A cleaner and easier way of blasting for more proﬁtable and durable results. Small and portable – makes it easy to move on the deck. It can handle both horizontal and vertical surfaces Atex approved – can be used on all vessel types (even tankers) Environmental friendly – 92% less dust and less media consumption compared to dry blasting. Uses less abrasive and less water than traditional machines for slurryblasting, pressure washing or water jetting. Limited Health Risks – Limited risks due to vibrations caused by hand tools Surface preparation – the surface roughness, visible cleanliness (rust, deteriorated coats) and nonvisible cleanliness (chloride levels) combined with feathered edges in spot blasting generate quality prepared metallic surfaces for recoating jobs.

WATCH THE VIDEO! www.graco.com/marine/ecoquip

in this issue 01 EDITOR’S LETTER 02 ANALYSIS A sustainable solution to corrosion protection

04 SUCCESS STORIES BioPad: the biobased fabric for corrosion protection of multi-metals

06 BRAND NEW

20 08 INNOVATIONS: PRESENT&FUTURE © Belzona

Suﬀolk County, NY, and Dynamic Infrastructure to maintain dozens of bridges through AI

10 FOCUS ON TECHNOLOGY The importance of shot blasting in the treatment of machinery components subjected to high stress: the choice of Carantini

16 MARKET CLOSE UP

Positive post-pandemic and post-Brexit perspectives of the British coatings sector

20 INNOVATIONS: PRESENT&FUTURE Cortec launches silica-free version of MCI-309 to protect hard-to-reach metal surfaces from corrosion

22 ANALYSIS How to blast fiberglass hulls without damaging the gel coat

24 FOCUS ON TECHNOLOGY

36 BRAND NEW 40 INSPECTION LOGBOOK Coating inspections - Inspection of steel surface preparation, part 1

42 INNOVATIONS: PRESENT&FUTURE Fast cure, surface tolerant, abrasion resistant system for emergency patch repairs

Closing the Clifton Bridge

44 FOCUS ON TECHNOLOGY 32 HIGHLIGHT OF THE MONTH New Airless® Azur™ Pumps for applying anti-corrosion coatings prevent the icing phenomenon

Keeping the lights on in the middle of the pandemic

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EDITOR’S LETTER

ow is the Coronavirus pandemic aﬀecting corrosion control?

I have not found any precise data on this subject. However, we can hypothesise that the corrosion prevention and mitigation sector has also suﬀered a slowdown

due to the repeated lockdowns, the closure of construction sites, and the discontinuity of industrial operations. It is also easy to assume that the intensity of such an impact will depend on the duration of this pandemic, also considering that it is occurring with different manners and times in different countries. Corrosion control is known to be particularly important for infrastructure and production assets, which are one of the cornerstones of the economic development of countries. Be they in steel or concrete, they require inspection and maintenance interventions that guarantee their functionality over time, in order to avoid the occurrence of problems that undermine their durability and call for extraordinary maintenance operations. Maintenance must therefore become a priority for all public and private asset owners. This is why in recent times and, even more so, in this historical moment, innovation in the protective coatings sector has been developing especially in two directions: the continuous monitoring of the durability of infrastructure and production assets, aimed at switching from planned to predictive maintenance programmes, and the offer of

corrosion prevention and mitigation products that are increasingly high-performance and easy-to-apply. Digital technologies are of great help to the maintenance sector. For example, the use of artificial intelligence, for now limited to pilot projects (see p. 08 of this magazine), will guarantee huge savings by providing visual diagnostics of the state of assets and by identifying any future maintenance needs and risk evolution possibilities. The use of drones (or RPAS, remotely piloted aircraft systems) for critical operations in professional settings is another precise, highly technological, economical, and low-risk solution for monitoring critical and difficult-to-access areas (p. 32). This issue of ipcm®_Protective Coatings, which concludes our editorial activity for this year, offers numerous insights on the above-mentioned topics, including products capable of effectively mitigating corrosion on hard-to-reach metal surfaces, such as bridge tension cables and post-tensioning solutions; an in-depth case study on how closer monitoring would have prevented a bridge in the UK from closing, thus cutting a vital highway link; and another in-depth case study on the effective maintenance operation performed on a biomass power plant with the pandemic in full swing, thanks to the use of thermal spray coatings. This and much more will keep you company during the Christmas break, with the hope that 2021 bring a new upheaval – this time a positive one – in our lives.

Alessia Venturi Editor-in-chief

ipcm® Protective Coatings - 2020 DECEMBER - N.36

ANALYSIS

A Sustainable Solution to Corrosion Protection Ella Newington Hexigone Inhibitors Ltd – Port Talbot, Wales

marketing@hexigone.com

The analysis of huge implications which the corrosion has for the environment has driven the eco-friendly and ethical strategies by Hexigone for developing new anticorrosion technologies.

ACE International, the Worldwide Corrosion Authority, estimates that the global cost of corrosion is $2.5 trillion a year or 3.4% of Gross Domestic

Product (NACE International, 2016). In amongst these financial headlines is a huge cost to the environment. These range from structural failures resulting in environmental contamination, to harmful pollutants being released from iron corrosion, to the over utilisation of natural resources when repairing and replacing damaged metals (Hanson, 2011). Sustainability is a critical consideration for all businesses involved in the manufacture and maintenance of goods, and the longevity of the metal assets in question across key industries such as O&G, aerospace and architecture is

one of the largest drivers for innovation in the coatings industry. Maintenance is extremely costly for OEMs and the avoidable drain on natural resources for premature replacement and repair of metal assets is now a global concern.

A safe, effective alternative to hexavalent chromium It is evident that effective corrosion management is vital in order to protect our planet – but what happens when the world’s most effective corrosion inhibitor turns out to be toxic itself? Hexavalent chromium [Cr(VI)] can protect metal assets from premature failure but is also known to cause cancer in humans and animals (United States Department of Labour, 2020) – posing another environmental dilemma. The toxic chemical compound was brought to the public’s attention most notably in the 2000 movie “Erin Brockovich” where it was detected in groundwater samples in California and other states. The EU’s REACH legislation has now banned the use of chromium VI across almost all industries and other regions are planning to do the same, or have already followed suit. Driven by his interest in sustainability, Hexigone’s Founder and CEO embarked on a mission to develop a safe corrosion inhibitor of comparable performance to hexavalent chromate. During his EngD at Swansea University, Dr Patrick Dodds trialed hundreds of combinations of active ingredients in order to eventually develop a highly effective, safer alternative to chromium VI. The technology - known as Intelli-ion – utilises novel active ingredients which are attached onto a smart, micro-reservoir system and react ‘on demand’ to corrosive activity. Unlike zinc phosphate which causes harmful algal blooms through leaching, the Intelli-ion product range does not leach out into the environment. The technology has since been independently proven to protect metal assets for longer when compared to the current market-leading alternatives, prolonging

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

ANALYSIS

asset lifecycles across a range of markets and reducing the strain on natural resources.

Low carbon offices and manufacturing But it’s not just Hexigone’s products that are sustainable in nature, the manufacturing is also driven by environmentally-conscious ethos. The new Hexigone HQ was designed with energy efficiency in mind, achieving an A Rated Energy Performance, the most efficient rating possible. The energy reduction strategy of the office and manufacturing units involves reducing energy demand through thermally efficient building design, as well as supplying building systems with onsite renewable technology. The manufacturing units are supplied by a 20kW solar PV system which is utilised within the building to offset CO2 emissions and substantially supplement the

power requirements. Heating is supplied using a highly eﬃcient Air Source Heat Pump powering an underfloor heating and radiator system. This reduces the reliance of importing electricity from the National Grid and ensures that our manufacturing facilities run oﬀ low-carbon energy supplies where possible. Furthermore, Hexigone’s manufacturing process adheres to a circular economy, not only recycling virtually all raw materials used within production, but also utilising the waste stream from an adjacent industry comprising up to 60% of its product.

Conclusion Corrosion evidently has huge implications for the natural environment, and nowadays society and industry are much more aware of issues related to sustainability. Engineers are increasingly encouraged to design and manufacture products that can minimise negative environmental and societal impact (Industry Europe, 2019), and this directly aligns with Hexigone’s vision – to create a safer and more sustainable world through chemical intelligence. CEO and Founder, Dr. Patrick Dodds, commented: “Environmental sustainability runs through everything we do at Hexigone. Firstly, our materials are chromate-free, contain no metals or phosphates. Our manufacturing process involves recycled materials and renewable energy. And finally, by plugging the performance gap and oﬀering a highly eﬀective inhibitor, we are able to protect metal assets for longer, reducing the drain on natural resources. We’re proud of this and are always looking for ways to improve our green credentials”. ‹

References: - Hanson, C. (2011). The Impact of Corrosion on Society. Metallurgical & Materials Transactions, 16. - Industry Europe. (2019, 11 30). Time To Fight Corrosion – For The Environment’s Sake. Retrieved from Industry Europe : https://industryeurope.com/time-to-fightcorrosion-for-the-environments-sake/ - NACE International. (2016). International Measures of Prevention, Application and Economics of Corrosion Technologies Study. Retrieved from NACE: http://impact.nace. org/documents/Nace-International-Report.pdf - United States Department of Labour. (2020, 8 19). Occupational Safety and Health Administration. Retrieved from United States Department of Labour: https://www.osha. gov/SLTC/hexavalentchromium/.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

SUCCESS STORIES

BioPad: The Biobased Fabric for Corrosion Protection of Multi-metals BioPad by Cortec, powered by NANO VpCI, ensures corrosion and surface protection of both ferrous and non-ferrous metals and several other alloys.

eveloped by Cortec, BioPad® is a cost-eﬀective, flexible and easily

marine engine manufacturer that, for years, has been using Cortec®

applied corrosion inhibiting device constructed from biobased

VpCI® to protect the externals of massive ship engines and motor shafts

non-woven material, which provides a sustainable packaging option for

being stored outdoors near the sea for 12 months awaiting shipment.

ferrous and non-ferrous metals as well as various alloys: galvanized and

The company conducted a test to see if they could use BioPad® to

carbon steels, copper, brass, aluminum, zinc, etc.

protect the internals of the engines from corrosion. They hung one

It is free of nitrites and chromates, and its high VpCI® concentration, in

BioPad® inside each of three diﬀerent engine voids for six months of

combination with a thin design, results in material reduction by up to

outdoor testing.

94% in comparison to similar polyurethane foam emitting devices.

The test was successful as there were no traces of corrosion. Moreover,

BioPad provides up to two times as much corrosion inhibiting action

as BioPad® contains renewable materials derived from corn-processing

as its conventional VCI counterpart and, having recently become a

byproducts, it has a lighter smell and protects more than twice as much

USDA Certified Biobased Product, it falls within the minimum biobased

space per square meter (1.2 yd2) than the competitor’s product, making

requirements for the mandatory federal purchasing initiative of

it a more cost-eﬀective option.

the USDA BioPreferred® Program. BioPad® conforms also to NACE

The engine manufacturer ended up ordering 7,000 sheets of BioPad® in

Standards TM0208-2008 and RP0487-2000, as well as MIL-I-22110C,

order to protect 150 engines per year.

and it has been tested by a certified laboratory in accordance with ASTM D-1748 (Humidity Test) and ASTM D 1735 with excellent results.

Preservation of high voltage interrupters Another success story about the use of BioPad® is delivered by a global

Protecting ship engines and motor shafts in an outdoor storage

engineering services company, which had been using locally made VCI

A success stories of the application of BioPad comes from a major

film) for export of high voltage interrupters to India, China, the U.S.A.,

Cortec

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foam inside vacuum-packed 6-mil (150 μ) competitor VCI bags (yellow

and Europe (as well as domestic shipment inside India). The company was facing issues with rust on parts, along with the consequent rejections and rework this required, and wanted a complete dry packaging solution with zero rust. Cortec® Corrosion Solutions India Pvt. Ltd. recommended using 6-mil (150 μ) VpCI®-126 Bags and BioPad® inserts without vacuum packing. The customer began an evaluation process, performing their own modified versions of VIA and Razor Blade Testing on VpCI®-126 Film in their lab and finding it to be successful. They undertook three field trials that involved export to China with good results. This was followed by their trial order of BioPad® pads and custom-size rolls of Cortec’s VpCI®-126 Blue corrosion protection film. The customer was very satisfied and has not only implemented BioPad® for regular production and export of high voltage interrupters to all countries but has also extended the same packaging solutions to their vendors. For further information:

www.cortecvci.com/Publications/PDS/Biopad.pdf

BRAND-NEW

Jotun Launches SeaQuantum III, A New Range of Antifouling Coatings Jotun has announced the launch of the SeaQuantum III series, a new range of antifouling coatings that feature microZone technology for tailor-made fouling protection.

eaQuantum III, the new antifouling range launched by Jotun,

more than 16,000 vessels.

will succeed SeaQuantum S-line, oﬀering tailor-made fouling

“Now the SeaQuantum III series marks an evolutionary step forward

protection.

in development, thanks to a new silyl methacrylate blend and the

The SeaQuantum III series is silyl methacrylate-based and features

introduction of microZoneTM technology”, says Tan Keng Khoon, Global

products tailored for customer specific vessel operational profiles,

Marketing Manager at Jotun.

keeping biofouling under control to deliver an average speed loss performance of just 2% over a 60-month period. This entails benefits

The SeaQuantum III range

in terms of operational eﬃciency, environmental protection and

SeaQuantum III features three products, tailored to diﬀerent

fuel savings: USD 500K per year on average for a 3,000 TEU feeder

operational profiles:

container ship. The gains extend with larger vessels and fuel

• SeaQuantum Ultra III for vessels with lower activity (with up to 45

price hikes.

idle days);

Silyl-based coatings were first introduced by Jotun in 2000, through its

• SeaQuantum Classic III for medium activity (30 idle days);

SeaQuantum range, which, over the last 20 years, has been applied to

• SeaQuantum Plus III for high activity (with higher vessel speeds).

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BRAND-NEW

All the products feature microZoneTM, a new technology that prolongs

standard in fighting biofouling and ensuring minimal speed loss,

the time between the activation of coating biocides and their dispersal,

calculated in accordance with ISO 19030. This equates to more

keeping them closer to the hull longer and thus creating a protective

profitable vessel operations, increased on schedule arrivals and less

shield against fouling. The result is a cleaner hull, less friction, reduced

maintenance costs”, continues Tan Keng Khoon. “For owners looking

operational fuel costs and faster return on investment.

to achieve competitive advantage, while satisfying charterer and

In addition, the formulation of SeaQuantum III ensures a lower

stakeholder demands, we see this as real ‘low hanging fruit’. In

volatile organic compound (VOC) content and higher volume of

challenging times, it is more important than ever to make the right

solids. Therefore, the range is in compliance with the strict global and

investments where it matters most.”

regional VOC regulations (including Asia).

“Jotun is committed to tackling the toughest issues and delivering optimal solutions for our customers, and the operational

The new standard to ﬁght biofouling

and commercial challenges they face,” Tan concludes.

“In an ever more competitive world, shipowners need solutions that

“Through decades of experience and development expertise

don’t just work in principle, but rather deliver reliable performance

we have built a unique understanding of how to work with

and quick return on investment to gain real commercial edge in a cut

shipowners as partners, finetuning our innovations to meet

throat industry,” Tan notes. “SeaQuantum III can make that diﬀerence”.

their specific needs. SeaQuantum III is an embodiment of

“Biofouling creates frictional drag and that leads to ineﬃciency

that continuous drive. This range signals a step forward in eﬃciency,

and greater fuel consumption – slime alone can raise fuel

cost control and environmental performance, and we think that is

costs by 20%, while hard-fouling can increase it by a staggering

a compelling proposition for today’s forward-thinking owners and

85%. That is not beneficial for owners or the environment. But

operators.”

the SeaQuantum III range transforms the issue, using advanced chemistry and our in-house microZoneTM technology to set a new

For further information: www.jotun.com

ipcm® Protective Coatings - 2020 DECEMBER - N.36

INNOVATIONS: PRESENT&FUTURE

Suﬀolk County, NY, and Dynamic Infrastructure to Maintain Dozens of Bridges Through AI Edited by Dynamic Infrastructure New York, USA

contact@diglobal.tech

Dynamic Infrastructure is deploying its unique maintenance technology solution to assess the “health” of 74 bridges in the Long Island county.

he New York, Berlin and Tel Aviv based start-up Dynamic

in the U.S. as well as in Germany, Switzerland, Greece, and Israel with

Infrastructure is expanding its pilot project with the Public Works

private and public transportation bodies. The company’s clients operate

Department of New York’s Suﬀolk County using the world’s first deep-

a total of 30,000 assets, ranging from national, state, regional and

learning solution which allows bridge and tunnel owners and operators

municipal departments of transportation to Public-Private Partnerships

to obtain visual diagnosis of assets they manage in order to reduce

(PPPs) and private companies.

direct and indirect maintenance costs. After the successful completion

“The latest project expansion aims to use our technology to cover the

of a pilot involving one bridge, the parties have agreed to expand the

entire inventory by Q2 2021,” said Saar Dickman, Co-founder, and CEO

use of the AI-based technology to 74 bridges in the county located

of Dynamic Infrastructure. He added that Suﬀolk County is typical of

on the eastern end of Long Island. Deployment of the technology is

the situation in the US at large, where data from the Federal Highway

currently in process.

Administration deemed that approximately 30% of all bridges in the US were in fair or poor condition.

The Dynamic Infrastructure’s project

According to the American Society of Civil Engineers, which evaluates

Dynamic Infrastructure is currently conducting projects in other states

and publishes a report card on the U.S. infrastructure every four years,

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INNOVATIONS: PRESENT&FUTURE

maintenance and operating conditions—before

and more than 56,000 bridges were classified as

they develop into large-scale failures.

being “structurally deficient’’.

The platform creates a “visual medical record” for

The aim in the deployment in Suﬀolk County

each asset, based on existing images taken from

is to enable its Public Works Department to

past and current inspection reports and interim

better coordinate and make the right decisions

inspections. The visual analysis is being done to

by prioritizing maintenance of its infrastructure

any visual source, be it smartphones, drones,

assets. “The system allows any operator, inspector

and laser scanning. The images are compared

or maintenance engineer to have actionable intelligence at their fingertips in order to decide if, when and how the daily maintenance and maintenance projects should be conducted, by supplying instant alerts about anomalies,” said Kevin Reigrut, member of Dynamic Infrastructure’s

the country’s infrastructure was given a D+ grade

and serve as the basis for alerts on changes in maintenance conditions. They can be easily accessed through a simple browser and instantly Saar Dickman, CEO of Dynamic Infrastructure.

shared with peers and contractors to speed maintenance workflows and improve budget expenditure.

board of advisors and former executive director of the Maryland Transportation Authority.

About Dynamic Infrastructure Dynamic Infrastructure harnesses the power of AI to disrupt

New technology features

Operation & Maintenance of critical transportation assets. Founded

The use of the novel technology translates into a huge annual savings

by industry professionals with decades of operation and maintenance

for the owners, and Operation and Maintenance engineers, and

experience for PPPs and DOTs, Dynamic Infrastructure has

contractors. Dynamic Infrastructure’s AI-based, decision making, SaaS

become an industry leader and key driver of a data revolution in

product continuously processes past and current inspection reports and

decision-making processes related to bridge and tunnel Operations

visuals, identifying future maintenance risks and evolving defects. The

& Maintenance. Headquartered in New York, NY, with oﬃces

proprietary technology provides live, cloud-based, risk analysis of any

in Germany and Israel, Dynamic Infrastructure maintains a close

bridge or tunnel and automatically alerts when changes are detected in

relationship with its clients. ‹

ipcm® Protective Coatings - 2020 DECEMBER - N.36

One of the dump bodies shot blasted and coated by Carantini Srl.

FOCUS ON TECHNOLOGY

The Importance of Shot Blasting in the Treatment of Machinery Components Subjected to High Stress: The Choice of Carantini Marta Fumagalli ipcm

Carantini Sabbiature e Verniciature is focussing on the immediate future. It has invested in a last generation shot blasting machine to cope with the growing request for finishing large-sized products intended, also for the separate urban waste collection sector.

n Italy, the waste collection sector has experienced significant

management and transportation operations and defined guidelines for

growth following the legislative decree issued by Minister Ronchi

the separate collection of municipal solid waste. According to the data

in 1998, which gave rise to a series of rules that regulated the waste

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

included in the eighth edition of the Green Book 2020, the report on

FOCUS ON TECHNOLOGY

the national municipal waste sector issued by the Utilitatis Foundation and presented in Rome in October, “the production of urban and related waste in Italy amounts to about 30 million tonnes per year, whereas special waste amounts to 130 million tonnes. Italy has an urban waste recycling rate between 45.2% and 50.8%, in any case above the European average, equal to 47%. Landfilling accounts for 22%. The sector has a total turnover of over 10 billion Euros, largely derived from waste fees, and over 95,000 employees. Despite the critical issues arisen during the lockdown period, the waste management service continued to contribute to urban cleanliness and public health. Together with other essential services of high economic importance, this can be one of the sectors capable of positively impacting the © ipcm

relaunch of the national economy.”1 “In the last five years, the demand for the

The Tunnelblast 2530/16 tunnel shot blasting plant installed by OMSG.

coating of dump bodies and frames for waste collection vehicles has grown exponentially,” states Pierpaolo Piccinini, Administrative Manager of Carantini S.r.l. Sabbiature e Verniciature (Valdaro, Mantua, Italy), a company that has been operating in the surface treatment field for over thirty years. Its contracting coating service is specialised in medium and heavy-weight metal structures: it sandblasts and coats aerial platforms, crane arms, concrete mixing systems, frames, heads, and trailers for agricultural machinery and it finishes trash compactors. “This sector has a huge potential,” explains Riccardo Carantini, the company’s owner with his father. “The number of separate collection lorries travelling on our roads is growing exponentially and their producers’ requests are becoming increasingly stringent in terms both of coating quality, as the finishes must withstand the harsh conditions to which these vehicles are subjected, and of quantity © OMSG

https://www.confservizi.emr.it/2020/10/settore-rifiuti-in-italiafatturato-da-10-miliardi-e-oltre-95-mila-occupati/ (10/11/2020)

Some complex-shaped parts shot blasted by Carantini.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

FOCUS ON TECHNOLOGY

of products to be treated. Currently, the ‘ecological’ vehicle sector

degree. Having to guarantee high quality and performance standards,

accounts an increasingly large slice of our turnover. In fact, for years

the company carries out a pre-treatment operation on all workpieces

we have consolidated a close professional relationship with the

by shot blasting and subsequent cleaning. These eliminate any

Novarini S.r.l. company located in Vigasio (Verona, Italy), a manufacturer

calamine and impurities and make sure that the substrates reach a

of this type of equipment, which is proving to be impressive and

high surface roughness, thus promoting paint adhesion.

profitable for both companies”.

“We are currently equipped with two shot blasters supplied by OMSGOﬃcine Meccaniche San Giorgio (Villa Cortese, Milan, Italy), a firm

The importance of the pre-treatment process

specialising in the design, construction, and installation of shot blasting,

These structures are subjected to high chemical and mechanical

sandblasting and shot peening systems,” indicates Riccardo Carantini.

stresses and, therefore, their pre-treatment process is essential to

“We installed a tunnel shot blasting machine in 2003 and a double hoist

guarantee an excellent aesthetic quality and mechanical resistance

one more recently, in order to meet the new needs of the market. This

The new cluster shot blasting machine type Capri 20/35 H22.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

A component entering the new shot blasting system.

FOCUS ON TECHNOLOGY

latter system replaced another OMSG shot blasting plant that, although fully functional, was undersized compared with the growing number of small and medium-sized parts we were asked to treat.”

Technical characteristics of the shot blasting machines The Tunnelblast 2530/16 tunnel shot blasting system has a chamber section of 2500 mm in width and 3000 mm in height and it is equipped with 16 single disc, direct drive 7.5 kW-turbines. “Since Carantini also treats heavy, large-sized components, together with their staﬀ we developed a handling system that exploits the department’s overhead crane. It was a challenge because, back then, this was not common practice,” states OMSG CEO Enzo Dell’Orto. “Indeed,” adds Riccardo Carantini, “the Tunnelblast system was initially used to process heavy metal parts. Following the increase in more and more diversified requests from the market, we converted it in such a way that it could treat any type of part. However, as it requires a high amount of power, it was not convenient to employ it for smaller workpieces. Hence the need to install a new shot blasting machine.” “The new cluster shot blasting machine,” says Dell’Orto, “is a type Capri 20/35 H22. Its sandblasting chamber has a diameter of 2000 mm and a height of 3500 mm and it features two hoists lifting up to 2000 kg

Q U A EXCELLENCE I T Y

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

A detail of the sandblasting chamber.

FOCUS ON TECHNOLOGY

each. The components to be treated are

hung on a frame that automatically enters the shot blasting machine; at the same time, the operator can unload the already sandblasted workpieces and prepare the new ones to be introduced into the machine, thus reducing downtime. This system is equipped with 5 single disc, direct drive 7.5 kW-turbines type SG350 patented by OMSG. It is also Industry 4.0-ready.”

The coating process After shot blasting, it is necessary to clean the components from the impurities deposited on them in the manual sandblasting booths. This is crucial to prepare them for the subsequent coating phase. “In 90% of our coating treatments, we use thermosetting powders and we adopt a mixed system following sandblasting: this includes an epoxy primer application stage and a finishing

Powder finishing medium-sized parts.

one by powder coating,” explains Riccardo Carantini. The company has 3 powder application booths, 2 manual booths

devoted exclusively to liquid coating, and 2 static ovens. For the application of powders, it uses Gema manual units in both their conventional and dense phase versions. “As the workpieces we treat do not have standard sizes, a manual operation helps us make sure we cover their entire surfaces.”

Conclusions “Once again, an OMSG machine proved to be a winning choice. This long-standing collaboration enables us oﬀer an excellent shot blasting service in line with the highest quality and market standards,” states Riccardo Carantini. “Carantini’s plant equipment is now ready to cope with any future increase in requests from our main customers, operating also in the fast developing sectors of ecology and urban waste collection.” ‹ Novarini S.r.l., a company specializing in ecological vehicles, is among the consolidated customers of Carantini.

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MARKET CLOSE UP

Positive Post-Pandemic and Post-Brexit Perspectives of the British Coatings Sector Tom Bowtell CEO of BCF - British Coatings Federation

The United Kingdom is one of the Countries to which international political and economic attention is being directed the most. Not only because one of the Countries most aﬀected by the pandemic, but also because it is about to face one of the most significant historical steps: its exit from the European Union. Tom Bowtell, CEO of BCF-British Coatings Federation, talks about it with a broad overview and in-depth analysis of the situation.

o say 2020 has been a challenging time for the UK coatings

as a real shock. The full lockdown implemented in the UK from March

sector would be an understatement of significant proportion.

saw demand for products significantly altered, although members

And yet, as we draw to the end of the year, it is worth reflecting how

were aﬀected in diﬀerent ways. Whilst industrial coatings members

well the industry has done weathering the storms and responding to

saw a large drop in demand as, for instance, the auto and aero

the unprecedented demands thrown at it, as well as looking further

sectors halted production, retail paint manufacturers and printing

ahead at how the coatings sector will look to adapt, improve and

ink companies saw output increase as the money from cancelled

grow in future.

holidays was ploughed into DIY and money that would have been spent on restaurants was used to buy more packaged food to be

Impact of the coronavirus pandemic

cooked at home (graph 1).

Like other businesses, the impact of the coronavirus pandemic came

BCF worked hard to ensure that the UK government provided proper

Graph 1: Sales volume by major BCF sector.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

MARKET CLOSE UP

support to business over this period. We switched meetings and

in added raw material costs, which will likely impact UK members

training events to online webinars, held weekly board meetings to

harder than their EU counterparts.

stay on top of members’ needs and provided practical support and

New chemical regulations post-Brexit are of particular concern. As

materials to help companies navigate the smorgasbord of new – and

the EU will treat the UK as a third country from 1st January 2021, UK

sometimes contradictory - legislation used to underpin the lockdown.

businesses are now having to comply with EU REACH in a diﬀerent

We also launched our #essentialcoatings and #essentialinks

way, including setting up legal entities or registering addresses in

campaigns to showcase just how much our members were

the EU to comply with REACH and CLP regulations. On this side of

contributing to the COVID-19 response, for instance by supplying

the Channel, the UK will implement its own, independent chemical

key coatings and inks used in products and components for items

regulations from 1st January, setting up duplicate UK REACH, CLP,

such as ventilators, hospital beds and trollies, sneeze guards for

BPR and PIC regimes. Whilst not a day one issue we have serious

checkout counters, oxygen cylinders, hospital isolation units, and

concerns about the estimated costs of the duplicate REACH system,

also in meeting the increased demand for food and pharmaceutical

estimated at over £1 billion to industry across Europe as data will

packaging. It was a proud reminder of just how important our sector

have to be acquired and registered in the new UK REACH database.

is to the UK economy and society.

The UK Government has admitted that these changes are going to hit SMEs harder than larger companies and given our membership

The future of the coating sector outside the EU

of 250 is around 70% SME, that is of major concern. We have been

In addition to responding to the COVID pandemic the other big

lobbying for changes to the UK REACH system and, while the UK

challenge for our sector over the past year has been preparing to

Government has made some small concessions so far around the

deal with life outside the EU. The UK coatings sector is a net exporter

length of time suppliers have to register some substances, we need

and the bulk of its trade is with Europe. Changes to customs and

to see more done to mitigate the extra costs and administrative

border controls will have a big financial and administrative impact

burden this new regulatory regime will place on the UK coatings

and members have had to get their heads around how these will

industry and its supply chain.

work.

Again, the BCF has been working hard to help members prepare for

And, as I write, there is still no outcome on Free Trade Agreement

the end of the Brexit transition period. And, as noted above, we have

negotiations. Should a deal not be agreed we will see tariﬀs imposed

been lobbying the UK Government hard on key issues: from the need

on goods and raw materials moving between the EU and UK which

to agree an FTA at all to prevent tariﬀs being imposed; to supporting

we have estimated will cost the sector some €75 million in finished

a Chemicals annexe as part of that FTA; and in urging changes to the

goods alone: there will be additional tens of millions of Euros spent

structure of UK REACH. We have built a Brexit ‘hub’ on our website,

UK paint trade between 2014 and 2019.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

MARKET CLOSE UP

put on training webinars for members, provided weekly e-bulletins

direction of travel vis-à-vis the UK’s new independent chemical

flagging up key new guidance and information, hosted fortnightly

regulatory regime remains to be seen. Additional trade deals could

‘surgeries’ or ‘clinics’ where members can ask questions and share

open new doors and provide opportunities for members although

best practice, as well as handling hundreds of questions through our

we know that proximity matters, especially in our sector, and at this

helpdesk.

present time it is diﬃcult to see many potential gains to oﬀset the losses we currently anticipate leaving the EU will bring.

The EU’s inﬂuence Of course, even though the UK will not be a member of the EU

Sustainability and circular economy post-Brexit

from next year, and regardless of whether we get an FTA between

But enough of that – what else will the future bring? Well, we want

the UK and EU or not, the reality is we will continue to be aﬀected

to continue to drive our sector forward. When Brexit is finally

by EU rules and regulations. As a net exporter many, if not most of

clarified, we hope that certainty will help unlock fresh investment

our members will still need to be manufacturing to EU standards.

in the industry across the country. The use of digital technology

Decisions the EU makes on restrictions on substances will still

will continue to be taken up and new machinery and processes

therefore impact on us, as will broader policy decisions like the Green

introduced.

Deal. Actions initiated in the EU are also likely to drive decisions on

We know that the UK Government has set out plans to significantly

the same subjects in the UK. Our sector will need to continue to

improve the Environment and legislation such as the Environment

work closely with our counterparts in the EU and I am pleased to

Bill currently making its way through Parliament will have an impact

say that BCF will remain a member of CEPE, the European Coatings

on our sector. We will of course need to look to ensure business

Association, which made the decision to extend its territorial area to

is not unduly – or indeed unfairly – impacted by this legislation.

include the UK from next year. It’s also important we maintain our

However, the truth is we are keen to be proactive and do much

active participation in the World Coatings Council, as the UK looks to

more in terms of improving sustainability and the circular economy

have more global influence in the future.

on a voluntary basis. We have already taken great strides forwards: since 1996 our

Looking Across the Ocean

Coatings Care programme has been tracking the environmental

At the same time, the UK is looking to negotiate new trade deals

performance of our members manufacturing output and the

around the world, including with the US. How that might aﬀect the

table 1 shows how much progress has already been made.

ENVIRONMENTAL PERFORMANCE INDICATOR

1996

2018

Energy use per tonne of production (kWh)

640

205

Total waste per tonne of production (kg)

Percentage of waste to landfill (%)

Percentage of waste recycled (%)

Total solvents purchased per tonne of production (litres)

285

115

ENVIRONMENTAL IMPROVEMENT?

Table 1: UK Coatings Industry manufacturing environmental performance, 1996 – 2018.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

MARKET CLOSE UP

From a consumption perspective, coatings products accounted for 0.1% of the UK’s carbon footprint in 2016 and the carbon level in 2016 was 21% of that of 1990 – a near five-fold reduction. We have also been working hard to lower VOCs and the industry has moved away from higher VOC decorative solvent-based paints to water-based paints. Moving forward we are looking to increase paint recycling and remanufacturing through an enhanced Paintcare scheme. However, there is more for us to do and we will be working closely with the Department of the Environment in the UK to make these schemes to assist our members to navigate their way through the challenges faced over the final months of 2020 but we are looking forward to next year and beyond at ways we can support the coatings sector in achieving greater things in the future. ‹

and initiatives as successful as possible. So we still have work to do

Tom Bowtell, CEO of BCF - British Coatings Federation.

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Take care of business from the inside.

INNOVATIONS: PRESENT&FUTURE

Cortec Launches Silica-Free Version of MCI-309 to Protect Hard-to-Reach Metal Surfaces from Corrosion Ben Voight Cortec® Corporation - St. Paul (MN), United States

bvoight@cortecvci.com

Cortec Corporation has launched a new version without silica of its MCI-309 migrating corrosion inhibitor for protection of metals within an enclosed space, such as PT tendons.

o oﬀer an eﬀective and easy-to-apply solution to protect metal

the enclosed space), it will be automatically replenished by new vapour

surfaces from corrosion, Cortec Corporation has launched

being continuously released from the powder carrier.

MCI®-309, a powder-based Migrating Corrosion InhibitorTM, which

MCI®-309 is considered ambiodic (mixed), meaning it protects both

can protect ferrous and aluminium metals located in recessed areas,

anodic and cathodic corrosion sites of the metal. It does not contain

interior cavities, and structural voids.

silica, silicates, phosphates, nitrites, or heavy metals.

How MCI®-309 works

Fields of application and advantages of MCI®-309

MCI -309 is an eﬃcient dry method of protecting metals within an

MCI®-309 can be applied into a variety of tubular structures, pipes, and

enclosed space.

vessels where inaccessible or recessed metal surfaces are at risk for

Upon application of the MCI -309 powder in the void, it vaporizes and

corrosion but are otherwise diﬃcult to reach.

forms a molecular layer of corrosion inhibitors on the metal surface. If

This is why MCI®-309 finds wide application in the construction industry,

this layer is ever compromised (for example, by moisture or by opening

both onsite and oﬀsite, in which projects, especially large ones, may take

During the grouting phase, post-tensioned tendons installed in ducts are at risk of corrosion.

INNOVATIONS: PRESENT&FUTURE

Steel wire for concrete post tension system.

Tension bridge cables.

several years to complete.

Real life application: where MCI®-309 has been used

For example, for structures that use post-tensioning, grouting is a

Several recent bridge projects exemplify the use of MCI®-309 for PT

step that is often postponed due to cold weather, transit of precast

strand protection at various stages of construction.

segments, or other project delays. During this time, PT tendons installed

In the U.S., a new extradosed bridge crossing the St. Croix River Valley

in PT ducts are at risk of corrosion, especially in harsh environment such

from Minnesota to Wisconsin opened in 2017 to improve traﬃc flow in

as those of extreme moisture, chlorides, or high temperatures.

the area. The bridge took several years to complete and made use of

MCI®-309 by Cortec, makes it possible to protect these tendons in

MCI®-309 to protect post-tension strands that could not be immediately

such hard-to-reach areas, oﬀering an easy and cost-eﬀective corrosion

grouted after being placed in the structure. U.S. state and federal

protection method, which requires little to no surface preparation and

requirements usually call for use of a corrosion inhibitor if the delay

can be applied by dusting, fogging, or sprinkling. Removal is not required

is longer than 14 days, and MCI®-309 provided an eﬃcient means

prior to concrete or grout placement, even though it is possible to carry

to do so.

it out with air guns and water. This oﬀers an additional advantage over

MCI®-309 has also been used for important new bridges in Europe. For

oily or grease-based corrosion inhibitors that need to be cleaned oﬀ

example, a 5-mile (8 km) bridge being constructed in Denmark in 2018

before grouting.

was made of segments precast in Poland. MCI®-309 was applied at the

MCI -309 does not aﬀect physical properties of concrete and grout (set

casting site to protect the PT cables according to design requirements

time, strengths, etc.). Testing has also confirmed that the product does not

until the segments could be grouted, which was not until 30 days after

aﬀect strand pull-out strength compared to a control (Charts 1 and 2).

arriving at the final construction site. ‹

Chart 1 – Load-Displacement Curves, AET project No. 29-20452.

Chart 2 – Applied load, AET project No. 29-20452.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

ANALYSIS

How to Blast Fiberglass Hulls without Damaging the Gel Coat Stephan Rindlfeisch Graco Distribution BV – Maasmechelen, Belgium

stephan.rindﬂeisch@graco.com

Good maintenance is essential to extend the lifetime of a boat or a yacht. The hull in particular needs special care as it is continuously subjected to water, wind, and marine organisms. Frequent re-application of the protective coating guarantees the hull’s water resistance.

s well as the quality of work, eﬃciency is vital in the maintenance

organisms such as algae on the hull. This is important to decrease the

of boats. Removing the antifouling layer is a time-consuming and

water resistance and fuel consumption of the boat.

diﬃcult part of the essential maintenance operations.

• Primer: under the antifouling paint there is a primer that improves the adhesion of the antifouling layer on the gel coat. It guarantees a

The diﬀerent layers of a boat hull

strong chemical bond and avoids premature peeling and cracking of the

It is important to understand the diﬀerent layers of a hull and what their

antifouling paint.

functions are:

• Gel coat: the gel coat is the first layer on the hull and protects the fibre.

• Paint = antifouling: the outer layer of a hull is the antifouling paint.

It is crucial that the gel coat does not become damaged. For a good

This coating ensures a smooth structure and minimizes the growth of

adhesion of the primer, the gel coat should have a rugged profile.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

How to remove antifouling paint There are a number of stripping methods for removing antifouling paint. Chemical stripping, hand scraping, and wet abrasive blasting are the most commonly used. • Chemical stripping & hand scraping A traditional and time-consuming method for boat stripping includes toxic chemicals, harmful acids, and hand scraping. A caustic chemical product is applied to the hull. After impregnating, the top layer of the hull can be scraped oﬀ with a scouring pad or sander. This method can be environmentally damaging and contaminating to local water areas. It also requires long hours of hard work and can be a personal health hazard. • Wet abrasive blasting Wet blasting, like traditional dry blasting, relies on an abrasive media delivered at high speed under pressure to remove surface coatings and prepare a surface for finishing. However, wet blasting mixes water into the blast media. For the removal of antifouling paint on a fiberglass hull, dry blasting is too aggressive as it damages the gel coat. Wet blasting is gentle enough to leave the gel coat intact, while still being very eﬀective.

Why choose vapour abrasive blasting for the removal of antifouling? • Less labour-intensive = faster = cheaper Wet abrasive blasting is the fastest, most eﬃcient, and most economical way to remove antifouling paint. Using chemical stripping, the removal of antifouling from an average boat takes up to six days. With vapour abrasive blasting, the job is done in less than a day. • Safe for the environment Wet abrasive blasting keeps surrounding areas clean and allows others to continue working nearby safely. All non-toxic and silica-free media particles are encapsulated in water and grounded, leaving the surrounded area unaﬀected. Wet abrasive blasting leaves very little water on the ground since most of the water vaporizes and disappears. All that remains is a pile of damped media, making clean-up very easy. A fibre tarp to collect the media and debris would speed up the cleaning process. • Safe for the gel coat From antifouling paint, to epoxy, to heavy marine growth, wet abrasive blasting can remove it all without damaging the underlying protective gel coat. That way the hull is immediately ready for a new layer of paint. ‹

The western A52 Clifton Bridge as seen from the river bank.

FOCUS ON TECHNOLOGY

Closing the Clifton Bridge Alex Romankiw Senior Engineer – United Kingdom

atromankiw@hotmail.co.uk

This article has been published on the following blog: https://www.roads.org.uk/blog. It is republished here with kind permission of the author and the blogger.

On 6 February, the Clifton Bridge, a road bridge spanning the River Trent and carrying the A52 road to the west of the city of Nottingham (county of Nottinghamshire, England), was suddenly closed for emergency repairs, bringing Nottingham to a virtual standstill. What has gone wrong - and how can such a major problem come as such a surprise? Civil engineer Alex Romankiw explains in this article.

t’s very easy for infrastructure to be taken for granted. Railways have

was unexpectedly closed under emergency conditions, cutting a vital

been around for hundreds of years, roads for over two thousand

regional link and paralysing the city. Highways England have since

years in one form or another. Often the travelling public do not realise

announced that it’ll be undergoing repair work, and unable to reopen

how much work is required to keep infrastructure working - or how

fully, until 2021.

immense the disruption is when things go wrong.

Understandably, there was outrage on social media, frustration at

On 6 February 2020, the residents of Nottingham found out exactly

the disruption - and initially, information from Highways England was

how bad things could get when a defect was detected in the A52 Clifton

slow to appear. In this article I decided to explain why these sorts of

Bridge in south-west Nottingham. A major structural issue meant it

incidents happen, and why we can expect more incidents like this.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

Welcome to Nottingham

As the road crosses the River Trent, it forms part of a seriously

Nottingham is the largest city in the East Midlands, with excellent

impressive junction complex, for a city ring road. Two bridges carry the

transport connections. The initial city grew on the Rivers Leen and

A52 across the Trent, multiplexing with the A453. On the north bank, a

Trent, and is now served by the M1 to the west, Midland Mainline rail

three level junction serves city-bound traﬃc on the A453. To the south

connections, and East Midlands airport. The City Council is a majority

another junction includes free-flow movements to the outbound A453

stakeholder in the main bus operator, and also manages the modern

and local connections.

tram network that was resurrected in 2001. In the last decade a number of major projects have taken place

Meet the bridges

to improve transport: Highways England dualled the remainder

The junction formed in several stages. The western (northbound) bridge

of the A46 between Leicester and Newark and the A453 between

was built in 1958. The eastern bridge opened in 1972, and was wider,

Nottingham and the M1. The tram network was expanded in 2015

with four lanes southbound and one lane northbound. This means that,

with two additional lines, and the UK’s first workplace parking levy

when heading north on the A52, the two lanes split: lane 2 heads north

commenced in 2012. In short, the city is very well-connected with

over the east bridge, and lane 1 joins the weaving three-lane section of

plenty of transport options, and a growing movement within the city

the northbound bridge with the A453. In short, this bridge carries an

to discourage car use.

awful lot of traﬃc!

The A52 also serves Nottingham, running mostly as a dual carriageway

The western bridge is made of post-tensioned concrete and, due to its

east-west between Derby and Grantham. It forms the southern half of

age, was strengthened in the late 1990s when it was discovered that

Nottingham’s ring-road, following Clifton Boulevard, a 50mph three-

a quarter of its tendons were corroded. Tendons are long steel cables

lane dual carriageway with overhead gantry signage. It carries regional

fixed under tension to pull the bridge together.

east-west traﬃc as well as local Nottingham traﬃc, a combination

The eastern bridge is made from in-situ reinforced concrete forming

which rarely encourages smooth traﬃc flow.

pre-tensioned box beams. This is basically steel reinforcement bars cast

ipcm® Protective Coatings - 2020 DECEMBER - N.36

FOCUS ON TECHNOLOGY

Figure 1: Steel reinforcement bars (rebar) awaiting a coat of concrete.

into concrete (Fig. 1). This type of construction has two components:

A question of rust

• Steel reinforcing bar (or “rebar” for short): rebar is made from carbon

The steel used is usually carbon steel, which is susceptible to corrosion

steel. Steel is very good at dealing with tensile forces such as bending

– notice how the bars are a brown-orangey colour like rust. To prevent

and sliding forces (known as bending movement and shear force).

corrosion, we could use stainless steel, but this is extremely costly and

• Concrete: it is very good at dealing with compressive downwards

is sometimes weaker.

forces.

Corrosion takes two forms:

Put the two ingredients together and you get a very strong material.

• Carbonation, a reaction between cement and carbon dioxide in the

Reinforcing concrete is like baking. You build a large mould (usually out

air, or

of timber or metal), fix the steel in place, pour the concrete, wait for it

• Chloride penetration, a reaction caused by chloride ions, mainly

to set, and remove the moulds when it’s done. This means we can use

found in de-icing salts deposited on the road by gritting and winter

concrete to form bespoke shapes for the type of bridge or structure we

maintenance.

want.

The reinforcing bars are usually protected from corrosion by being

Figure 3: A blip in the ultrasound reading might indicate corroded metalwork.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

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Figure 2: Concrete spalling on a bridge over the M1, with reinforcement bars exposed to the air.

encased in concrete, but physical damage (like vehicle strikes, weathering, freeze-thaw action by water) can break away the concrete and expose the steel. When the steel is exposed, the salts deposited by gritters can get to the bars and cause corrosion.

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Corrosion also leads to rust as the air reacts with the steel, forming an oxide layer. The resulting expansion can blow the concrete out, exposing the steel: this is called spalling. Once exposed the corrosion can speed up and â&#x20AC;&#x153;chase alongâ&#x20AC;? the bar behind the concrete (Fig. 2). As the bar corrodes, its cross-sectional area is reduced. Since the

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bars deal with tensile loads in reinforced concrete, corroded bars have an impact on the ultimate load the structure is able to carry so you can see why, when corrosion is detected, it can be a major

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issue. So how do we detect corrosion?

An inspector calls The best way to detect corrosion is with a regular inspection schedule. There are two main types of inspection: â&#x20AC;˘ General inspection is carried out every 12-24 months, this is a quick check to make sure nothing has changed. â&#x20AC;˘ Principal inspection is a detailed, close-up, touching-distance, thorough examination of the structure. A principal inspection is generally every five years, although this can vary depending on the age, type and location of the structure. Other types of inspection can also be done. There is, of course, a wealth of guidance on bridge inspections as part of the Design

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FOCUS ON TECHNOLOGY

Figure 4: Gravelly Hill Interchange, better known as Spaghetti Junction: home to a rust problem.

Figure 5: Repairs to corroded rebar in progress, with new segments spliced in.

Manual for Roads and Bridges1, which sets out standards for building

To investigate and repair, the concrete must be broken out to

and maintaining highways.

expose the rebar. This involves mechanical breakers - jackhammers

Earlier, we mentioned that corrosion can continue behind the

- or hydrodemolition, where the concrete is blasted out with high-

concrete, which makes it diﬃcult to detect. One way we can “look”

pressure water jets. Both are noisy and dusty, and neither is a quick

through the concrete is using sonic logging. This sends an ultrasound

option.

signal through the concrete. Voids caused by corrosion will create a

If it’s a small area, you can break out the concrete, chop the corroded

“blip” in the signal (Fig. 3).

bars, splice and couple new bars in, re-cast the concrete (or grout)

But sonic logging provides interpretive data, and hard-to-access areas

and it’s fixed.

can be missed. It’s not usually part of an inspection unless there is

The Figure 5 shows an example of a repair in progress. The concrete

already evidence of corrosion or other structural defects. The best

has already been broken out and the damaged bars have been cut.

way to examine corrosion is to break the concrete out and have a

Couplers (with bolts on) now connect the bars back together. This

look.

work would take at least a week and relies on no further defects or corrosion being found. If the problem is worse than anticipated, we

Rubble trouble

could be in for disruption for a long time.

Concrete corrosion is a well-known issue - a lot of research is going

So what exactly has happened at Clifton Bridge?

into it and there are all sorts of clever ways to solve it. One method is called cathodic protection, which is where an electrical current is

A nasty surprise

passed through the structure to repel the chloride ions.

According to Highways England’s contractors, a crack in the concrete

Maintenance projects on the M6 Bromford Viaduct and Spaghetti

was detected during a maintenance inspection in 2018. This triggered

Junction, and the very long-running M5 Oldbury Viaduct works, have

an investigation and then a maintenance scheme, which was being

all been recent attempts to repair corrosion in bridge decks and

undertaken mainly from below the bridge decks by Balfour Beatty.

piers (Fig. 4).

Cabins and scaﬀolding were already in place below the bridge for this work.

https://standardsforhighways.co.uk/dmrb/

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

The contractors were hydrojetting within the concrete box beams

FOCUS ON TECHNOLOGY

Figure 6: Maintenance work was already under way before the problem was detected.

Figure 7: A photograph showing some of the exposed tendons.

when they uncovered some loose lumps of concrete and then - more

A52 but across the surrounding network.

worryingly - a void. Upon closer inspection, some of the reinforcing

• Free breakdown recovery was provided.

tendons were exposed and corroded (Fig. 6).

Over the weekend, the traﬃc chaos continued, and with

At approximately lunchtime on Thursday 6 February, Highways

entertainment and sporting events in the city being held, other river

England were made aware of the situation and the potential risk that

crossings such as Trent Bridge quickly ground to a halt under the

the structure was compromised. To protect the public, in case the

pressure. Police were deployed to key junctions to try to keep traﬃc

bridge was actually unsafe, it had to be closed.

moving.

At 2pm, Highways England informed that the A52 would be closed later in the afternoon, perhaps at 4.30pm. In fact, the road was

No quick ﬁx

closed at 5.30, right in the middle of rush hour, and although long

While all this was going on, engineers were hard at work. Structural

delays were reported that evening, it was only an indication of what

specialists were assessing the bridge and maintenance crews were

was to come.

working quickly to clear out the damaged area and make a repair

The road remained closed overnight, and then the Friday morning

(Fig. 8). On Monday 10 February, Highways England announced

rush hour hit. Travel times of two hours to travel half a mile were

their intention to open a single traﬃc lane by Wednesday. On

reported. The tram and bus networks were crippled as junctions

Tuesday, they announced they would try to open the single lane for

became blocked and vehicles broke down. At 9.30am, with the rush

the Tuesday evening rush-hour. Unfortunately, their optimism was

hour ending, there were two-mile queues on the approaches to the

misplaced, and it wasn’t until Wednesday that a lane was opened.

closure.

Presumably there were more nasty surprises to deal with on the

On Friday afternoon, a statement was issued, confirming that water

Tuesday afternoon.

damage had corroded steelwork within the bridge, and that HE

The lane reopening provided only minor relief, since there are still

planned to partially reopen the bridge the following week (Fig. 7).

four lanes closed to traﬃc. Normally the two Clifton Bridges provide

Other emergency measures were put into place:

a total of eight lanes across the river, but only four are presently

• All non-critical roadworks in the Nottingham area were suspended.

available. Only one lane could be reopened if the repair work was

• Highways England stepped up Traﬃc Oﬃcer patrols not just on the

going to continue.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

FOCUS ON TECHNOLOGY

The restriction is making for some interesting arrangements. The lane doesn’t follow the existing ones across the road surface; it’s been set out specially, protected with a temporary barrier, and is temporarily marked with white lines.

Eternal vigilance Unfortunately, many of the concrete and steel structures in the UK are getting to an age where they require more and more maintenance and upkeep to remain in service (Fig. 9). Some structures, like the M6 viaducts near Birmingham or the M4 Brentford Viaduct in West London, now need constant maintenance works. This problem isn’t unique to roads. Rail structures like the Severn Tunnel and Forth Bridge require similar round-the-clock interventions to keep them open for the travelling public.

Figure 8: An engineer inside one of the Clifton Bridge’s hollow concrete beams.

Equally, emergency closures like the one the Clifton Bridge is suﬀering have also happened

in the past. The closure of the A4 Hammersmith Flyover in 2011 was well reported, as were the problems aﬀecting the A90 Forth Road Bridge in 2017. The good news is that the UK is experienced in maintaining a large portfolio of highways structures. Compared with the rest of the world, our inspection regimes are particularly stringent and we have an excellent pool of engineers keeping the network running. The problem isn’t inattention; it’s that even close attention is sometimes not enough to spot an issue before it becomes serious. So if you’re stuck in the Nottingham traﬃc, or indeed a future emergency closure, I hope this gives you some idea of how and why these things happen. ‹

Editor’s note: As a consequence of the closure for maintenance work in February 2020, the Clifton Bridge has not yet been fully reopened and will not be for the whole of next year (source: www.nottinghampost.com, 5 of November 2020). Figure 9: Engineers climb to reach an access hatch underneath the Clifton Bridge.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

MEDITERRANEAN CONFERENCE & EXHIBITION 23 -25 M A RC H 2021 R A V E N N A - I TA LY

R E T H I N KI N G E N E RGY TO G E T H E R

A L L I A N C E S FO R A S U STA I N A B L E E N E RGY F U T U R E w w w. o m c . i t

B I O F U E L S - C A R B O N C A PT U R E - C C U S - C E RT I F I C A T I O N - C I RC U L A R EC O N O MY C L A S S I F I C A T I O N - C L I M A T E - C O R R O S I O N - D I G I TA L I S A T I O N - D R I L L I N G - E F F I C I E N C Y - E L E C T R I C A L - E N E R G Y - E N E R G Y S T O R A G E - E N G I N E E R I N G - E N V I R O N M E N TA L E X P L O R A T I O N - G A S - G O V E R N M E N T - H E A LT H - I N S T R U M E N TA T A T I O N - L N G - M A I N TA ANENCE - M A R I N E - P OW E R SYST E M S - P RO C E S S I N G - P RO D U CT I O N - R ECYC L E - R EG U L A TO RY - R E N E WA B L E S - S A F E T Y - S U B S E A - S U S TA I N A B I L I T Y - T E L E C O M M U N I C A T I O N S TRANSITION T R A N S P O R TA T I O N VESSELS WA S T E MANAGENT exhibition@omc.it / conference@omc.it LINKEDIN @Offshore-Mediterranean-Conference

+39 0630883030 / +39 0544219418

FACEBOOK @OffshoreMediterraneanConference

TWITTER @OmcRavenna

HIGHLIGHT OF THE MONTH

New Airless® Azur™ Pumps for Applying Anti-corrosion Coatings Prevent the Icing Phenomenon Marie-Anne Guilldou SAMES KREMLIN – Pioltello (Milan), Italy

marie-anne.guilldou@sames-kremlin.com

SAMES KREMLIN launches its brand new AIRLESS® solutions with the new AZUR™ pumps for the application of anti-corrosion coatings integrating new innovative and patented technologies.

he application of anti-corrosion coatings has many challenges.

It depends on many parameters: the preparation, the conditions of

Having to paint outdoors, applying complex or highly abrasive

intervention, the equipment for the transfer or application of the

coatings, painting very large parts or at very great distances makes this

paint, the ability of the painters to control the production tool. These

job extremely demanding.

parameters influence the quality of the finish and the life span of the

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

HIGHLIGHT OF THE MONTH

protection. Making the right investments will optimise the application of

The design of the housing allows the continuous evacuation of moisture

paint and reduce the maintenance costs of the works.

to the outside. The air circuit remains dry and therefore does not freeze.

“Our customers tell us that when they have an outdoor job site, they

The second, the heating of the air by compression at the exhaust in the

have a weather window to paint everything. They need to be sure that

foam outwards and its acceleration through the Venturi outlets keeps it

they can do all the painting in that window. Meanwhile, their airless

warm and prevents icing.

pumps must remain operational and eﬃcient without aﬀecting the

This technology integrated in the air motor of SAMES KREMLIN pumps

paint application. They must not stall, they must not freeze, they must

allows applicators to start the job and concentrate only on their work

not leak” explains Christophe Denis Bosio, Communication Manager at

as applicators. The pump will not stall and will maintain its performance

SAMES KREMLIN.

throughout the application.

“We know that frost is the most complicated parameter to control and is the number one enemy of anti-corrosion applicators. The expansion

SST technology make things easy and durable for users

of the air in the exhaust of the pump’s motor creates cold which

On the other hand, a pump must not leak at the upper lubricant cup,

causes the moisture in the motor’s air circuit to condense and frost.

as this causes the product jet to pulse at the gun, thus overconsuming

This icing accumulates in the air distributor and eventually blocks it.

paint and also polluting the environment of the workstation.

Our technological answer is VDE (Venturi Dual Exhaust) on our Airless®

The painter must in this case tighten the sealing cartridge and is

Azur™ pumps which prevents this icing phenomenon”.

constantly asking himself the question: how often should the cartridge be tightened to prevent it from leaking, did I tighten it too much, not

The VDE technology

enough, etc.? This destroys cartridges and pistons, stops the painter in

The design of 2 foam blocks (Dual Exhaust) at the exhaust of the pump’s

his work and is extremely expensive in the long run.

air motor distributor has several functions: the first one, the evacuation

Christophe Denis Bosio confirms: “The very principle of the chevron

of humidity out of the air circuit is done through integrated channels.

joints is that they must be constantly tightened (under pressure)

EMLIN

ES KR © SAM

The 72C160 Azur™ pump by SAMES KREMLIN.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

HIGHLIGHT OF THE MONTH

to guarantee their basic function: to ensure watertightness. Their

succeeded to date. In fact, when the operator works near the pump(s),

undeniable advantage is their lifespan, because even when worn they

he no longer needs earplugs, which increases safety on the site and

can still seal by tightening them. However, this must be considered, and

limits the risk of hearing loss.

the painter often notices this when the pump leaks. He must therefore tighten the cartridge until it is destroyed or even damage the piston.

A great pump with great gun

This is very expensive in spare parts. Not to mention that during this

We also worked a lot on his main tool, the gun. Notably its ergonomics

time he does not paint.

to allow the painter to be more comfortable in his application.

Our technological answer is the adoption of cartridges with self-

Furthermore, being far from the pump, when the nozzle clogs, our

tightening seal technology. Thanks to this self-tightening seal system in

reversible system is designed to allow the painter to turn his nozzle

the upper part of the pump hydraulics, customers no longer need to

and unclog it without lowering the pressure or using a tool to loosen

worry about tightening their seals, they are constantly self-adjusting.

the nozzle base. Filters are also extremely eﬃcient in preventing nozzle

Moreover, this system is not immersed in the paint, so there is no risk

clogging and thus increase the painter’s productivity.

of being badly cleaned during rinsing operations and thus degrading its

In addition to these technical advantages, special attention is paid

sealing function”.

to simplified maintenance solutions: optimisation of the number of

There is perhaps no application more demanding than anti-corrosion.

components, minimisation of the number of operations to be carried

That’s why these pumps are designed to transfer the most diﬃcult

out and easier access to the areas where work is to be carried out.

paints with very high productivity. But the job of anti-corrosion painter

SAMES KREMLIN is therefore launching on the market its brand new

is extremely diﬃcult. That is why SAMES KREMLIN has focused on the

Airless® solutions with new Azur™ pumps, robust, powerful, integrating

parameters that allow it to work better and be more productive.

innovative technologies, with very high productivity, capable of transferring and applying all types of anti-corrosion coatings. They

Silence is comfort and protection for painters

provide eﬀective answers to the problems encountered on building

SAMES KREMLIN worked on the silencer system installed on the engine.

sites and allow a reduction in the cost of ownership1 of paint application

This technology makes its pumps the quietest on the market. The

equipment. ‹

material chosen and the density of the foams muﬄe the sound allowing to respect a decibel rate at the exhaust below 80 dba, which nobody has

Among the diﬃculties for painters there are the need to coat outdoors, apply complex or highly abrasive coatings, paint very large parts or at very great distances.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

All costs related to the use of equipment: consumption of products, energy, maintenance costs, etc.

BBROADCASTING ROADCASTING IINNOVATION. NNOVATION.

stay tuned...

BRAND-NEW

The Entry into Force of the European Drone Regulation has been Postponed to January 2021 Professional inspections with drones are increasingly common in almost all sectors where visual checks are required. The new European regulation on this subject, which should have entered into force in July 2020, will be applicable from January 2021.

he use of drones (or RPAS, remotely piloted aircraft systems)

procedures for the obtainment of the certificate by professionals have

in professional settings is increasingly widespread, as it is a

been modified.

precise, highly technological, economical, and low-risk solution for monitoring critical and diﬃcult-to-access areas. In July 2020, the

The new European regulation

first European legislation was issued that regulates the piloting of

The new European regulation, which should have entered into force on

drones in both civil (non-critical operations) and professional settings

1 July 2020, has been postponed for six months due to the COVID-19

(critical operations, CRO). Whereas already in the past a licence was

health emergency that has prevented some countries from aligning

needed for the professional use of these aircraft, which in Italy is

with the new directives. One of its most innovative aspects is that it no

issued by the Italian Civil Aviation Authority (ENAC), the new European

longer distinguishes between recreational and professional use. Now,

regulation requires a certification also for civil uses. Moreover, some

drones are classified according to the risk factor of the flight operation © Adobe Stock

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

BRAND-NEW

and to aircraft classes, primarily defined based on weight: devices

• training at a flight school (in Italy, it must be approved by ENAC),

weighing less than 250 grams, for example, can be operated with

including a 10-hour theoretical course and a practical course with

a simple certification obtained through an online training course

simulations of flight missions based on real cases, each followed by a

(in Italy, ENAC will issue a Remote Pilot Certificate - Non-critical

test.

scenarios). On the other hand, professionals must obtain an RPAS

• BVLOS/EVLOS approval, only in the case an RPAS must be operated

pilot certification for critical operations by attending a course at the

out of the pilot’s sight.

flight school of an approved training centre, as was also required by

Once they have obtained their certification for critical operations,

the previous regulation.

pilots have to record the flight times of the missions they carry out with an RPAS in a special Logbook.

RPAS pilot certiﬁcation for critical operations

The certification is valid for 5 years (for both critical and non-critical

‘Critical operations’ are all those that exceed the limits of non-critical

operations), at the end of which the license must be renewed.

activity, i.e. all Visual Line of Sight (VLOS) operations performed at a

The characteristics and piloting methods of drones for professional

safe horizontal distance of at least 150 m from congested areas and

use in critical operations, such as the monitoring of bridges,

at least 50 m from people not involved in the operations themselves,

infrastructure, buildings, pipelines, and all assets at risk of corrosion,

with a ban on flying over urban areas and sensitive infrastructure.

will be described in an article to be published in the next Protective

Starting from the entry into force of the new regulation, such

Coatings issue.

certification will be obtained as follows: • online license (like drone pilots for non-critical operations)

For further information: www.enac.gov.it

ipcm® Protective Coatings - 2020 DECEMBER - N.36

BRAND-NEW

Hempel Enhances its Antifouling Coatings and Launches New Solutions Hempel launches re-formulated antifouling technology to enhance its proven range of low investment hull coatings.

eading global coatings manufacturer Hempel has enhanced its

and this ensures the best possible fouling protection in all trading

established and proven Olympic+ and Oceanic+ antifouling range

conditions.

and is, today, launching five new antifouling solutions: Oceanic Protect+,

Oceanic Flex+, Olympic Protect+, Olympic Flex+ and Olympic Protect.

The new antifouling solutions

Building on their proven eﬀectiveness, reliability and impressive value-

Olympic Protect, Olympic Protect+ (for medium to high activity levels)

for-money, these five new products deliver additional benefits and

and Olympic Flex+ (for low activity levels) are based on ion-exchange

choice within the existing product range.

technology and give protection for up to 25 idle days and up to 60-months service interval.

Proven Olympic+ and Oceanic+ antifouling range

Oceanic Protect+ (for medium to high activity levels) and Oceanic Flex+

Hempel’s Olympic+ and Oceanic+ antifouling coatings have been

(for low activity levels) are based on zinc carboxylate technology and

protecting vessels since 2009 and 2012 respectively and the

protect for up to 30 idle days and 60-months service interval. These

introduction of the new, re-formulated products delivers an even

coatings also deliver a maximum of 5.5 per cent speed loss1.

higher performance through better control of the leached layer and an

Commenting on the new products, Marianna Sioni, Marine Group

enhanced mechanical strength. Coupled with this, higher volume solids, high dry film thickness per coat and lower Volatile Organic Compounds (VOCs) reduce costs, time and emissions during application. These new antifouling solutions are designed to suit diﬀerent trading patterns,

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

Speed loss: If a vessel’s main engine is set at a certain power output, it will propel the ship through the water at a certain speed. Over time, fouling accumulation will increase drag and cause the speed of the ship to reduce even if the main engine power output remains constant. This reduction in speed is termed “speed loss”.

BRAND-NEW

Product Manager, Antifouling coatings, said: “Hempel’s antifouling

rate and biocide release. This enables the coating to achieve a smoother

product range caters for every vessel and every owner and we are

and fouling-free hull throughout the service period.

proud that our Oceanic+ and Olympic+ range has been able to deliver through the years reliable fouling control at such an eﬀective cost.

Olympic+ and Oceanic+ at a glance

Building on this success, we have invested in re-formulating these

• Dedicated versions for each trading pattern.

products to enhance their performance so that we can continue to

• Idle period up to 25 days (Olympic+) and up to 30 days (Oceanic+).

oﬀer proven solutions for a low upfront investment, supported by

• Up to 60 months service intervals.

Hempel’s world-class global service. In short, this is proven antifouling

• Maximum 5.5 per cent speed loss (Oceanic+).

performance reinvented”.

• Proven track record since 2009 (Olympic+) and 2012 (Oceanic+). • Reliable biocide package.

New coatings’ advantages

• Incorporating Smartfibre technology for reduced leached layer,

All five reformulated products take advantage of Hempel’s reinvented

controlled polishing and exceptional mechanical strength.

Smartfibre technology which delivers a stronger and smoother hull.

• Excellent colour retention.

Each coating now contains a 20 per cent higher fibre content which

• Reduced film thicknesses and high-volume solids reduce paint

significantly improves its mechanical strength and allows the increase

consumption.

of the hydrophobic characteristics of the products - leading to reduced

• High maximum DFT per coat means fewer coats required.

leached layer thickness. As water flows over the coating, enhanced

• Reduced VOC emissions.

fibres, which fit parallel to the surface, ensure a smooth and uniform removal of the leached layer which facilitates a well-controlled polishing

UCIMU-SISTEMI PER PRODURRE

For further information: www.hempel.com

065/2019

LMRX19RS1

INSPECTION LOGBOOK

Coating Inspections - Inspection of Steel Surface Preparation, Part 1 Massimo Cornago NACE International Certiﬁed Coating Inspector, NACE CIP PEER Reviewer

cornago@ipcm.it

n our previous article, “Basic Inspection Practice”1, we analysed

1. Soluble salt contamination

the responsibilities of a Certified Coating Inspector (CI) during the

The CI must check that the surface is free from contamination to

preliminary inspection phase (Preliminary Inspection Responsibilities,

the extent specified, especially in terms of chlorides, sulphates,

paragraph 1), with ample space devoted to the necessary work

iron ions, and dust. Chloride salt contamination, in particular, can

planning activities. We will now delve into the inspections to

be tied to diﬀerent sources, such as airborne industrial chemicals,

be carried out during the surface preparation phase (Surface

salt contained in a marine atmosphere (in areas near or on the

Preparation Inspection, paragraph 2), particularly those relating to

sea), direct contact with sea water, defrosting of bridges and/or

surface contamination. Although often project specifications do not

highways on which salt has been thrown to prevent freezing, or

mention this, it is good practice that, during the pre-job meeting, the

even already contaminated abrasives. The latter are often invisible

CI requires two steps to be carried out. These include contaminant

to an inexperienced eye and they are generally not removable by

removal, as contaminating agents can aﬀect the adhesion of coatings

abrasive blast cleaning.

thus leading to the system’s premature failure due to corrosion, and

Although exact standards of acceptability have not been established

the achievement of proper roughness of the metal surface to be

in terms of allowable amounts of contamination that may remain

treated, in order to guarantee good adhesion.

and not aﬀect coating performance – of course, each paint product

There are many ways to obtain proper surface preparation, including

has a specific value – there are some “conventional” parameters of

solvent cleaning, water cleaning, hand tool cleaning, power tool

reference for both new construction and maintenance works. In

cleaning, abrasive blast cleaning, and centrifugal blast cleaning;

general, research and experience show that removing any chemical

all the inspection procedures required for each of these methods

contamination helps extend the service life of coatings over time.

are governed by international standards, such as NACE, SSPC, ISO,

The standard NACE5/SSPC-SP12 is a valid help for this purpose. In

etc. Surface preparation is preceded by a control phase on the

fact, it is almost always mentioned in project specifications as the

surface itself (steel preparation). Here, the CI assesses all aspects

oﬃcial reference document. Alternatively, a specifier drawing on

of the metal surface to be prepared to coating, including welding,

personal experience and/ or the support of the paint manufacturer

cutting, grinding of welds and sharps edges, weld spatters, etc., in

can give some directions and decide which are the minimum values

compliance with the reference standard regulations. Moreover, in

of acceptability.

case chemicals are used, which are generally very alkaline and/or

With the exception of acid/basic contaminants, which can be easily

contain thickeners, before surface preparation the CI must check

identified by measuring the surface pH, all other contaminants can

that the operation is carried out in full compliance with the project

only be determined through extraction, by swabbing or deionised

specifications and, above all, with the instructions issued by the

water-based cleaning with an aqueous solution. The latter can be

paint manufacturer. Indeed, if they are not properly removed, these

then analysed with diﬀerent certified methods, such as indicator

products will remain on the surfaces long enough to alkalise and

strips (ASTM-D4262), conductivity meters, or other tools that can

attack the coatings.

determine a sample’s chloride ion content.

We will now describe in detail the tests to be carried out before the

The standard NACE5/SSPC-SP12 includes a table defining three

surface preparation phase.

levels of soluble salt contamination: 1. SC-1 – Surface free of all detectable levels of contaminants

M. Cornago, Coating Inspections – Basic Inspection Practice, in ipcm® Protective Coatings no. 35 (October 2020), pages 40-41.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

(water-soluble chlorides, iron-soluble salts, and sulphates), as determined using available field test equipment.

INSPECTION LOGBOOK

2. SC-2 – Surface with less than 7 μg/cm2 chloride contaminants,

not visible in the sun, it is necessary to use a protection (a shield or

less than 10 μg/cm2 of soluble ferrous ion levels, and less than 17

black cloth) to perform this activity outdoors during the daytime.

μg/cm2 of sulphate contaminants as verified by field or laboratory

If the surfaces present a bright yellow or lime green colour when

analysis using reliable, reproducible test equipment.

exposed to UV light, they are contaminated. In the event that the

3. SC-3 – Surface with less than 50 μg/cm2 chloride and sulphate

CI ascertains the presence of this type of contamination, they must

contaminants as verified by field or laboratory analysis using

make sure it is removed through specific procedures, such as

reliable, reproducible test equipment.

solvent cleaning.

The Bresle method is currently the most used, as included in the ISO 8502.6 standard, which we will have the opportunity to deepen

3. Dust contamination

in a dedicated chapter.

The presence of dust generated during sandblasting or other

2. Grease and oil contamination

the performance characteristics of coatings. The most common

Surfaces can also be contaminated with a thin film of grease, oil,

techniques for dust control are the pressure sensitive tape method

or water-insoluble material. Contamination from grease and oils

(ISO 8502-3) and the clean cloth method. The former is certainly

is extremely damaging to the performance of coatings. Therefore,

the most used one: it involves the application of a transparent

it is necessary that the CI assesses its presence and demands it is

adhesive cellophane tape on the metal surface, pressing it well

removed from the surfaces to be treated. Such contamination is

except for a small final part to easily tear it away. At this stage, it

generally due to the presence of grease on the hands of operators

is very important not to contaminate the surface with any grease

operations can reduce paint adhesion or otherwise adversely aﬀect

and/or the CI themselves, to the oils used to lubricate compressors

present on fingers. The tape is then removed and the amount of

and power tools, and to diesel exhausts.

dust collected is analysed. The strip of tape is examined under

Some tests are available for the detection of oils and grease on

contrasting light by comparing it with pictorial references, such as

metal surfaces, e.g. water break and UV black light tests. The

the value scale shown in Figure 1.

former visually distinguishes the water diﬀusion characteristics

The amount of powder is classified from 1 (lowest dust content)

(surface energies) of clean and contaminated surfaces, by spraying

to 5 (highest amount). The level of acceptability depends on the

deionised water on them. If water collects in drops looking like

customer’s coating specifications, but normally 2 is considered

lenses, which take about 25 seconds to show, the surface is pristine.

acceptable, whereas 3, 4, or 5 level surfaces are cleaned and

If, on the other hand, water collects in droplets and forms a water

reassessed. The standard ISO 8502-3 also classifies the size of the

break within 25 seconds, the

dust particles, although this is

surface is contaminated.

not normally a requirement in

The latter method is more

coating specifications. The size

commonly used on already

of class 1 dust is not visible at

“clean” surfaces and only

10x magnification; the size of

occasionally is it necessary

class 2 dust is visible at 10x

to use it immediately before

magnification; the size of class

cleaning, as preliminary solvent

3 dust is visible to the naked

cleaning operations aimed at

eye without magnifying glass;

removing grease and oils are

the size of class 4 dust ranges

required in almost all surface

between 0.5 mm and 2.5 mm;

preparation specifications. This

and the size of class 4 dust is

procedure is widely used on oil

greater than 2.5 mm.

tank linings. With the exception

In the next article, we will have

of synthetic oils, grease and

the opportunity to discuss the

oils absorb ultraviolet light and

various surface preparation

emit it as visible, fluorescent

techniques available, starting

light, thus becoming easily

with the water cleaning

identifiable. Since UV light is

method. ‹ Figure 1: The scale of values for detecting dust contamination according to the pressure sensitive tape method.

ipcm® Protective Coatings - 2020 DECEMBER - N.36

INNOVATIONS: PRESENT&FUTURE

Fast Cure, Surface Tolerant, Abrasion Resistant System for Emergency Patch Repairs Laura Bell Belzona Polymerics Ltd – Harrogate, United Kingdom

lbell@belzona.com

Belzona Polymerics announced the launch of a new product to add to their comprehensive portfolio of solutions for industrial maintenance.

elzona 1818, the new product designed by Belzona Polymerics, one of the world leading providers of high-performance polymeric repair

and shape. What is easily identifiable about this new product is its distinctive blue

composites and protective coatings, has been specially formulated for

colour. This vivid blue serves as a good mixing indicator and provides

emergency patch repairs in highly abrasive environments typically found

contrast where an application is carried out in poorly lit conditions or

in industries such as mining, cement, pulp & paper, biomass, amongst

against dark background surfaces where the repair area should be

others where equipment is commonly exposed to extensive erosion and

easily identifiable. These conditions can be common in typical industrial

abrasion from excavated or processed materials of varying type, size

applications where Belzona 1818 is likely to be used.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

INNOVATIONS: PRESENT&FUTURE

The blue colour serves as a good mixing indicator and provides contrast where an application is carried out in poorly lit conditions or against dark background surfaces. © Belzona

Belzona 1818 application

erosion resistance expected of the Belzona 1800 series with added

Belzona 1818 is the newest addition to the highly erosion resistant

application benefits, oﬀering ease of use and a fast return to service”.

Belzona 1800 series product range and bridges the gap between surface tolerance, fast cure and high abrasion resistance. It’s fast curing

The advantages of the new product

properties means minimal downtime for damaged equipment, so

This new product is supplied in convenient 1kg units where base and

much so that the product can experience full mechanical loading and

solidifier can be easily combined on a Belzona work surface. Belzona

heavy abrasion just two hours after application, depending on cure

1818 is easy to mix and apply and oﬀers a good working life (16 minutes

temperatures.

at 20°C/68°F) whilst still oﬀering fast cure and a rapid return to service.

In these abrasive environments, surface preparation can also be an

The product is suitable for emergency repairs where downtime must be

issue and contamination is common, therefore the equipment cannot

kept to a minimum and optimal surface preparation cannot be achieved

always be fully cleaned or ideally profiled as required for many repair

due to accessibility or environmental and application constraints.

materials. The desire to deal with adverse application conditions

As with all Belzona products, Belzona 1818 is made to the highest

creates a need for a not only fast-curing, but also a surface-tolerant

quality and safety standards and has undergone rigorous performance

material. As a result, Belzona 1818 has built in surface tolerant

testing. Belzona 1818 is user friendly and can applied without the need

technology, enabling it to bond tenaciously onto steel substrates even

for hot work or specialist tools. In addition, Belzona 1818 is formulated

when surface preparation is minimal or if the substrate is heavily

without solvents and is free from CMR classification and labelling, whilst

contaminated with oil or water. The product can even be applied and

maintaining cure speed and performance to give a durable and long-

cured underwater.

lasting repair.

Kristine Savicka, Belzona R&D Technician explains: “Belzona 1818

Based on initial research and feedback from Engineers in the field, it is

builds on our knowledge and experience of producing highly abrasion

envisaged that this product will be used on various types of equipment

resistant systems, and combines this technology with our know-how

within abrasive environments such as slurry pumps, grinding mills,

and expertise in producing fast-cure and surface-tolerant products

screw conveyors, chutes and hoppers, hydrocyclones, wear plates, dust

for application in non-ideal conditions. Belzona 1818 oﬀers the high

extraction pipe work, agitator shafts, hubs and blades. ‹

ipcm® Protective Coatings - 2020 DECEMBER - N.36

FOCUS ON TECHNOLOGY

Keeping the Lights on in the Middle of the Pandemic Marina Silva IGS Integrated Global Services, Inc. – Richmond, United States

marina.silva@integratedglobal.com

Drax power station is a large biomass and coal-fired plant in North Yorkshire, England. As well as surface protection solutions, IGS supplies it with continuous inspection systems that monitor the boiler tubes’ integrity and generate data to inform and validate the metal wastage prevention strategies.

ased in the United Kingdom, the Drax power plant has a capacity

which commercial operations come to an end in March 2021.

of 3,906 megawatts (MW) and produces around 14 terawatt-hours

The boiler units went into operation in the 1970s and require ongoing

(TWh) of power a year, 96% using compressed wood pellets, a form of

monitoring and maintenance to prevent unplanned outages from erosion

sustainably sourced biomass. The remainder is produced using coal, for

and corrosion damage. As well as surface protection solutions from

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

FOCUS ON TECHNOLOGY

IGS, the plant utilizes continuous inspection systems that monitor the

outage for Unit 3, a biomass boiler burning proprietary wood pellets, was

boiler tubes’ integrity and generate data to inform and validate the plant

initially planned for February/March 2020. Due to the Covid-19 pandemic,

engineers’ metal wastage prevention strategies.

the start of the outage was postponed to the end of August, with the IGS work on the Unit 3 boiler waterwall scheduled for October.

Boiler waterwall and superheater protection Colin Bateman, Director of Business Development EMEA, IGS,

Preparation for the outage

commented: “We started servicing this Major UK Power Plant in 2016

IGS had to adapt the mobilization of the European crew to be in

and have since been awarded a long-term contract for thermal spray

compliance with the Power plant and UK Covid regulations. Quarantine

applications within their boilers. Our capability to quickly mobilize our

was not required in accordance with the UK Government’s exemptions for

applications team and equipment, coupled with extensive experience,

specialist technical workers for the power infrastructure. All the crew were

enable us to exceed client expectations in terms of shutdown schedules

tested prior to their arrival in the UK and negative results were confirmed

and solution reliability.” IGS have been applying high velocity thermal

before entry to the site. IGS Europe was the largest team coming in from

spray alloy cladding on boiler waterwalls and ceramic coatings on the

outside of the UK.

superheater.

Specialist technical workers Boiler Unit 3 2020 outage

Workers with specialist technical skills required for essential or

The boilers at this power plant run on a four-year maintenance cycle. The

emergency works to ensure the continued safe and secure operations

In 2020 650 m2 area in Unit 3 were protected in 8 days: the photo shows the application in progress.

The large biomass and coal-fired power station in Drax, North Yorkshire (England).

ipcm® Protective Coatings - 2020 DECEMBER - N.36

FOCUS ON TECHNOLOGY

of generating stations, gas or electricity transmission or distribution

hit the new required customer schedule and completed the works with

networks, electricity interconnectors, gas terminals, or district or

the application of the IGS HVTS system to 650 m2 within the new critical

communal heat networks.

path dates.

Colin added: “In addition, we have the IGS Pandemic Plan added

The scope was completed on time with no hiccups in accordance with

to our mobilization procedures. Special actions were taken for

all requirements from the government and all companies involved in

accommodation, site activity, social distancing, and keeping the team

the outage, a large-scale project delivered on time and within budget.

in small pods. We had 30+ people on-site, working 24 hours a day in

The IGS team has been commended for their professionalism and

shifts. Bubbles were maintained throughout the IGS team, ensuring

attention to detail.

on-the-job and oﬀ-the-job social distancing.” On location, COVID tests, monitoring, and temporary accommodation modules in a local leisure

Handling issues during project delivery

centre were set up.

Even a problematic compressor didn’t knock the IGS team oﬀ schedule! An IGS technician used his expertise, initiative, and knowledge to

Project execution

maintain the third party equipment to keep the project on schedule.

The planned project start date was pushed back by two days due to

In 2020, IGS is set to complete at least 273 projects, keeping essential

delays with pressure part activities in the back end of the boiler (not

infrastructure going by preventing corrosion, erosion, and fouling within

in the furnace first pass where the IGS HVTS was applied). As a result,

power plants, refineries, chemical producers, pulp & paper, metals & mining, cement plants, and other facilities. ‹

the IGS critical path was reduced from 10 to 8 days. Despite this IGS

IGS maintenance applications timeline at the UK biomass power plant.

N.36 - 2020 DECEMBER - ipcm® Protective Coatings

AMI’s Pipeline Coating conference has gone virtual for 2021!

9-11 February 2021

The free-to-attend* global virtual summit will explore line, ﬁeld and joint pipe coatings through technical presentations and networking opportunities Five reasons to attend: 1. Participate in sessions exploring the strategies undertaken to cope with Covid-19, an exploration into coating selection and how this can lead to lower costs for pipe ownership 2. Gain an operational insight with operators and contractors sharing their challenges and needs 3. Build your own schedule during the three-day event and access presentations on-demand 4. Network with representatives from across the global supply from the comfort of your own home! 5. Browse the virtual exhibition to source new materials, products and services

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