Corrosion & Materials December 2012

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Vol 37 No 6, December 2012 ISSN 1326-1932

Inside this Issue: Corrosion & Prevention 2013: Call for Papers ACA 2013 Training Calendar Technical Introduction: Designing For Corrosion Protection – Part 2 Project Profile: Restoring the Pride of an Australian Icon Project Profile: Neptune champions ACFM in Australia University Profile: The University of Queensland Professional Practice Paper: Cathodic Protection – it Never Sleeps

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CORROSION & PREVENTION 2013 C O N F E R E N C E

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Major Sponsor:

ANTICORROSION TECHNOLOGY

Proudly Presented by:

E X H I B I T I O N

Where Theory Meets Practice Brisbane Convention & Exhibition Centre

10–13 November 2013 www.acaconference.com.au

First Announcement & Call for Papers Call for Papers

Brisbane

Submissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2013. Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are:

Located on the east coast of Australia in the heart of one of the country’s fastest growing regions, Brisbane is the capital of Queensland – a state well known for its natural beauty and world-class tourism attractions.

Close of Abstracts: 29th March 2013 Acceptance of Abstracts: 12th April 2013 Receipt of Papers: 28th June 2013

Submit an Abstract Please refer to www.acaconference.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (29th March 2013).

Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process for Corrosion & Prevention 2013.

Guide to Submission Papers submitted to the Corrosion & Prevention 2013 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/permission from their organisation.

Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary. All authors whose papers are accepted are required to attend the conference to present.

p.2 CORROSION & MATERIALS

Boasting a great outdoors lifestyle and the greatest variety of native wildlife (dugongs, wild dolphins and koalas just to name a few) of any capital city in Australia, Brisbane offers an impressively diverse menu of leisure and recreational activities. From art lover to outdoor adventurer, Australia’s third largest city caters to all tastes.

Along with the cosmopolitan and urbane offer of world-class shopping, restaurants, nightlife, culture and entertainment, Brisbane lives and breathes outdoor experiences. From kayaking on the river, to cuddling a koala, to hand-feeding wild dolphins at sunset, visitors can enjoy a range of unique and memorable Australian experiences.

Best known as the home of iconic tourism destinations like the Great Barrier Reef, the Daintree Rainforest and Fraser Island, Queensland is a state blessed by both beauty and bounty. Held fast in the hearts of many Australians as their favourite holiday destination, Queensland is also a state rich in resources, talent and innovation. From white sandy beaches to red desert reaches, Queensland is a state of contrasts. City, coast or country it’s got something for everyone. www.visitbrisbane.com.au

CORROSION & PREVENTION 2013

Technical Topics

Conference Convenor

Corrosion and Prevention 2013 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion on a daily basis.

Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application.

Submissions may include research papers, posters, review papers and case studies related to the technical streams listed below.

Geoffrey Will

• Corrosion mechanisms, modelling and prediction • Protective coatings • Cathodic protection • Concrete corrosion and repair • Materials selection and design • Asset and integrity management • Corrosion prevention implementation • Failure analysis

Technical Chair Francis Carroll

Committee Arthur Austin Allan Sterling

Sponsorship and Exhibition Sponsorship will enable your company to make a significant contribution towards the success of Corrosion & Prevention 2013. In return, the conference offers strong branding and exposure in a focussed and professional environment. As with every Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services.

• Contractor perspectives

For further information, please contact the Australasian Corrosion Association on +61 (0)3 9890 4833 or conference@corrosion.com.au

• Education and training

Your Hosts

• Corrosion in biomedical applications

Industry Sectors This conference will have material of value to those working within the following industries, or related areas: • Transport and marine infrastructure • Energy, oil and gas • Mining and resources • Water and wastewater • Defence, aviation, maritime • Buildings and construction • Cultural and historical materials preservation • Consulting engineering and technical services • Education and research

The Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, industry association, established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion.

The mission of the ACA is to disseminate knowledge to enable best practice in corrosion control thereby ensuring all impacts of corrosion are responsibly managed, the environment is protected, public safety is enhanced and the performance of economies improved.

ACA Centre PO Box 112 Kerrimuir, Victoria, Australia, 3129 Ph: +61 3 9890 4833 Fax: +61 3 9890 7866 Email: conference@corrosion.com.au Website: www.acaconference.com.au

CORROSION & PREVENTION 2013 December 2012 www.corrosion.com.au p.3

CONTENTS

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

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

The ACA is a founder member of the World Corrosion Organization

6

President’s Message

8

Chief Executive Officer’s Message

9

Letters to the Editor

10

ACA 2013 Training Calendar

12

News

19

Event Report: Gerald Frankel ACA Foundation Funded Tour

20

ACA Branch News

22

ACA Standards Update

30

Coating Inspection Certificate

32

ACRA Award Winners 2012

Front Cover Photo: Non slip Safety Walkway on the roof of Bulk Storage Tanks in Brisbane. Photo supplied

by Industrial Protective Coatings Queensland.

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

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

Advertising Sales Wesley Fawaz – The Australasian Corrosion Association Inc, wesley.fawaz@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscriptions Print Version: ISSN 1326-1932 Subscription rates: Within Australia: AU$72.60, incl GST Outside Australia: AU$77, excl GST posted airmail The views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.

The Australasian Corrosion Association Inc PO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: aca@corrosion.com.au Internet: www.corrosion.com.au

CONTENTS

34

Technical Introduction: Designing For Corrosion Protection – Part 2

37

Coatings Group Member Profile

38

ACA Corporate Members

42

Member Tales from Abroad: Qatar: A Small Land of Great Opportunities for the Australian Corrosion Industry

44

Project Profile: Restoring the Pride of an Australian Icon

46

Project Profile: Neptune champions ACFM in Australia

48

University Profile: The University of Queensland

50

Professional Practice Paper: Cathodic Protection – it Never Sleeps

57

Suppliers and Consultants

ACA Operations Board President: Allan Sterling

Corrosion & Materials Corrosion & Materials is the official publication of The Australasian Corrosion Association Inc (ACA).

Published bi-monthly, Corrosion & Materials has a distribution of 2,500 to ACA members and other interested parties. Each issue features a range of news, information, articles, profiles and peer reviewed technical papers. Corrosion & Materials publishes original, previously unpublished papers under the categories “Research” and “Professional Practice”. All papers are peer reviewed by at least two anonymous referees prior to publication and qualify for inclusion in the list which an author and his or her institution can submit for the ARC “Excellence in Research Australia” list of recognised research publications. Please refer to the Author Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au with a copy to bruce.hinton@monash.edu ACA also welcomes short articles (technical notes, practical pieces, project profiles, etc) between 500 – 1,500 words with high resolution photos for editorial review. Please refer to the Article Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au

ACA Branches & Divisions Auckland Division: Sean Ryder

64 9 261 1400

ACA Technical Groups Cathodic Protection: Bruce Ackland

61 3 9890 3096

Coatings: Matthew O'Keeffe

61 437 935 969

Chief Executive Officer: Ian Booth

Newcastle: Karen Swain

Operations Chairman: Paul Vince

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

Senior Vice President: Andrew Hargrave

Queensland: Cathy Sterling

Junior Vice President: Mohammad Ali

South Australia: Erwin Gamboa

Immediate Past President: Peter Dove

Tasmania: Grant Weatherburn

61 0 418 120 550

Directors: Graham Carlisle Matthew Dafter Brad Dockrill John Duncan Fred Salome Graham Sussex Dean Wall Geoffrey Will

Taranaki Division: Ron Berry

64 27 671 2278

Research: Nick Birbilis

61 3 9905 4919

Victoria: John Tanti

61 3 9885 5305

Research: David Young

61 2 9385 4322

Water & Water Teatment: David Mavros

61 419 816 783

Wellington Division: Monika Ko Western Australia: Gary Bennett

61 0 418 854 902

61 7 3821 0202 61 8 8303 5473

64 4 978 6630 61 0 408 413 811

Concrete Structures & Buildings: Frédéric Blin

61 3 9653 8406

Mining Industry: Peter Farinha

61 8 9456 0344

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

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

61 8 8303 5473

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

PRESIDENT’S MESSAGE

At the recent Melbourne conference, I took over as President of the Association from Peter Dove. I thank Peter for handing over an Association in very good shape.

The Melbourne conference was an outstanding success which set the bar very high in terms of technical content and catering for the needs of all members. Thank you to Ian Godson (Conference Convenor) and the Victorian Branch for hosting such a wonderful event. The conference surpassed all records for conferences hosted solely by the Association.

With the bar set so high, the 2013 Conference will need to be flawless.

Keep an eye out for details including the call for papers (in this issue of C&M) in the coming months. The Queensland Branch in conjunction with Head Office is up to the challenge of trying to surpass the efforts of Victoria with respect to the conference.

Allan Sterling President Hi All 2013 is set to be the 58th year of The Australasian Corrosion Association Inc. That’s right; our humble Association started in 1955. In human years, our Association should be looking forward to putting up its feet and easing back to a comfortable retirement. Due to the hard work and efforts of Ian Booth and the staff in Head Office and volunteers across the region, the Association is currently in a very strong position.

Back on the human analogy, we are just coming into the prime of our life and ready to surge ahead. With the right guidance and good fortune, the Association should be able to achieve whatever it is that we decide to set our minds to.

At the Melbourne conference I also had the pleasure of dining with 26 past Association Presidents, including Bill Denholm (AM) 1964 Australasian President. The experience and history residing in the minds of those 26 gentlemen was unbelievable. It is hoped that this event will become an annual fixture at our conferences.

With the Association in such a strong position, it is important we plan for the future. The Association has a set a Strategic Plan 2012 – 2014 which is available in short form for members to review. The Association will be embarking on the next round of

members’ surveys and I encourage all Association members to put in their two cents’ worth. Now is the time to voice your opinions on the direction of the Association and where we think we need to be in the coming years. If you don’t speak up, we don’t know what your thoughts are.

Despite the strong position of the Association, we still remain somewhat insular. The progress and development of the Young Corrosion Group (YCG) is aimed at breaking out of the mould to boost our profile to the outside world.

Any ideas or thoughts on developing the public profile of the Association would be appreciated. The Association’s profile is further developed through our annual Seminar Series. It is important for us to encourage as many nonmembers as possible to attend the valuable information sessions.

On a personal note, it is an honour and a privilege to the serve the members of this Association as President.

The President’s role is to represent members’ best interests. I look forward to representing members in dealings with Head Office and the operations committee to further strengthen the position of the Association during 2013 and into the future.

Finally, remember to eat your crusts if you want your hair to grow curly.

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p.6 CORROSION & MATERIALS

Impressed Current CP for Concrete

Sacrificial Anode CP for Concrete

Fully controllable and easily monitored either locally or remotely the Zebra systems has a coating replacement interval of 20 years and Cassette a design life of 50 years.

No wires or control systems. Ideal for almost any item where a quick, no fuss fix is required. Typically designed to meet CP protection criteria for 20 years and has 10 year proven performance.

Zebra™

ZLA™

Conductive Paint System for Buildings For building facades with decorative top coat.

No weight penalty.

Surface Applied Zinc Sheet

For industrial slabs with high build wear resistant coating.

No thickness penalty.

The simplest CP system ever.

Peel off protective tape, press zinc with adhesive/ activation paste backing onto concrete surface, connect to reinforcement.

No wires or control systems.

Roll Anode™

Rolled Zinc in Drilled Holes Anode string up to 1m long embedded in 30mm drill hole for CP of existing structures. Protect columns, beams, pile caps. Can be used in wet/seawater areas.

Cassette™

Surface Mounted Ribbon Anode for Aggressive Environments

GSC Super Anode™

Specifically designed for rapid, easy application and developed to withstand wet/splash exposures. Install to: • underside of wharf decks in splash zones • leaking basements, pools and tunnels • confined space or limited access areas

Embedded Zinc Anodes

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

STAINLESS STEEL CLAMP PRESSURE PLATE GFR PANEL CONTACT FELT TITANIUM RIBBON

Active Corrosion Protection For Any Steel Element

T: +61 8 6102 0303 E: info@SRCP.com.au

Monitoring & Control of CP Systems

ZincTape™

Camur II™

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

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

Pre-assembled as a complete system or for use with client transformer/rectifiers.

Interface can be via web site or LAN. Web hosting can be provided.

Pipelines

Tanks

Applied rapidly insitu on pipes of any diameter using the Metawrapper. Double wrap (50% overlap) for 20 year warranty.

Quickly installed in long strips and pressed down using a Metapress (strong magnetic roller).

Structural Sections

Sheet Piles

Applied in appropriate widths over complex shapes such as steel sections. Applied in conjunction with GSC Super Anodes for elements founded in concrete. Simple method to repair column bases.

Laid up on sheet piles.

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

ERE 20™ ½ Cell

Continuity Tester

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

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

Test under load is essential.

CP Logger

Current Limiters

corrPRE’s 4 channel half cell potential data logger is ideal for monitoring potentials and undertaking 24hr potential decays on simple CP systems.

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

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

CEO’S MESSAGE

Conference success signals need for change More than 600 members and industry participants from around the world took part in ACA’s Corrosion and Prevention 2012 conference and exhibition in Melbourne during November. This is the highest participation ACA has experienced for a stand-alone Australasian conference.

The 2012 success follows from the record number achieved at the combined ACA and ICC conference in Perth in 2011.

In 2009 ACA commenced the implementation of a new approach to the management and delivery of conferences. This new approach more appropriately divided the substantial amount of work required to successfully stage an ACA conference between the members of the local organising committee and senior staff. In earlier years organising committees and host Branches were responsible for assessing and managing all risks and the majority of financial impacts. Much better results have been achieved in recent years as the risk elements have been rightly managed by senior staff and members through organising committees and Branches have been able to concentrate on content – technical, networking and social.

So, if the model which has been employed since 2009 has proven to be successful, why change it?

Attendance at ACA conferences has steadily climbed to the point where it is not unreasonable to speculate that by 2020 total attendance at ACA conferences will be around or above 1000.

Events of this size take the whole management consideration to a new level.

With size comes complexity. It is unreasonable to expect volunteer member based organising committees to continue to “reinvent” the approach to conferences every year. Under existing and past models, the expertise developed by organising committee members is by and large lost to the organising committee for the following year’s conference. Certainly, there are some members of organising committees who reappear every 8 years or so to lend a hand. A lot can change in 8 years.

ACA’s Council and Board have been examining a new method which will maximise the important contribution of members whilst improving the stability of the organising committee, especially so that the knowledge and experience from recent years is not lost.

The proposed structure will allow for host Branches to positively impact the event when held in their territory and will also allow for stability in the management of conferences on a rolling basis. The proposed participation structure for the standing committee includes important elements which will see participants, particularly those involved with technical content gradually increase their participation in the management of a conference and then pass on that experience to those that follow in a much more structures manner. Limits will be set to how much time any individual can serve. This will ensure ACA is regularly exposed to new ideas and new talent. ***** With Christmas, New year and the summer holidays rapidly approaching I would like to take this opportunity on behalf of all of ACA’s staff to thank everyone, members and non-members alike who have helped to make 2012 one of the busiest on record. To you and your families — please be safe and enjoy the festive season.

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

A move to a standing committee structure is proposed and the Board will resolve its position in February 2013.

The ACA Centre will be closed from midday Friday 21st December 2012 and will re-open on Wednesday 2nd January 2013

p.8 CORROSION & MATERIALS

LETTERS TO THE EDITOR

Bill Woodbury The word brilliant is often misused, but it definitely applies to Bill Woodberry whose Vale was published in the August issue of Corrosion & Materials.

On completing university in 1967, I was offered a position in the Technical Research Department of AGL. Bill or WKW as he was affectionately known was the Corrosion Engineer in that department. Natural gas had not come to Sydney, but was expected. Natural gas has to be distributed at a higher pressure than coal gas and the cast iron pipes used for distribution were increasingly being replaced with welded steel, which had to be provided with cathodic protection.

AGL had a property department and constructed a new housing estate in Mt Druitt. The gas service was a welded steel system including the service pipe to the meter. The union connection to the meter incorporated an insulating fitting, and the whole system was protected with an impressed current system. Unfortunately the pipe manufacturer had left steel turnings in the pipes. These were blown along by the gas until they lodged in the insulating fitting, shorting it out. In an estate of some 1000 houses, finding the shorted out insulating joints was a frustrating and time consuming exercise. In particular the turnings didn’t lodge in the joints all at once, but over a period extending some years.

the shorted insulating fittings. Some discussion took place with the pipe manufacturer regarding compensation.

WKW’s resigned from AGL and accepted a position as Chairman of the Electrolysis Committee and I took his position of Corrosion Engineer at AGL. AGL decided they needed a Woodberry type detector and hired a first class honours Science/Electrical Engineering graduate to develop an identical piece of equipment. At this time integrated circuits had just come on the market, and even though they were outrageously priced at $70, no expense was spared. After 18 months of work, the new Engineer had not been able to duplicate WKW’s work, and he abandoned AGL and last time I heard, he had started a robotics company. The equipment was left as a pile of junk.

WKW went on to complete a Masters Degree based on the detector.

In his position as Chairman of the Electrolysis Committee WKW investigated the corrosive consequences of “DC from AC appliances”. Brian Martin outlined his success in the banning of coloured TV sets based on the PAL system, and similar devices with variable speed drives which also generated DC. WKW considered there should be regulations to control the operation of impressed current CP systems in NSW, and was instrumental in the development of the “Cathodic Protection Regulations of 1973”. Similar legislation has since been introduced in most states in Australia.

• COMFORT

identification and mitigation of these hazards. The mitigation measures were to connect the structure suffering the corrosion to the rail, via a bond consisting of a diode to prevent current reversal and a resistance to control current flow. WKW came up with the concept of using 32 volt light globes as controlling resistors.

The filament of the globe gets hotter as the applied voltage increases, and its resistance increases. The resistance characteristic is a square root function.

A combination of globes acts as a variable resistance.

Before WKW put his mind to it, design and testing of railway drainage bonds was done by using a 2 pen recorder, separately recording structure to earth and structure to rail. The trace was then examined to identify similar points which were then plotted on X-Y graph paper. This was laborious and subjective. WKW introduced use of an X-Y recorder to plot the information in real time. A problem was that the sampling speed of the available recorders at the time was slow, and the trace often ended in a page of ink. WKW developed a bank of capacitors which could be switched in progressively to smooth the inputs.

WKW then developed a formula to calculate the correct combination of series/parallel globes to control the potential on structures within set parameters.

WKW introduced me to the ACA. WKW devised a technique for imposing He was an ultimate professional and a signal on the pipework which although a private person, was very could be tracked by an above ground hospitable inviting me to enjoy many detector. The device the “Woodberry Detector” could identify the strongest • FUNCTION meals with himself and his wife Lorna in their Rushcutters Bay home.

Stray traction current is a major current which could be tracked to the • SAFETY cause of corrosion in cities which short, and additionally could identify • CE CERTIFIED Bill McCaffrey have DC traction systems. In the the depth of cover. The detector was PROTECTIVE CLOTHING – WITH THE STRONGEST FIBER IN THE WORLD! 1930’s, Australia was a pioneer in the completely successful in identifying

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2012-10-31 15.59 December 2012 www.corrosion.com.au p.9

ACA 2013 TRAINING CALENDAR

ACA 2013 Training Calendar Corrosion Technology Certificate

Introduction to Cathodic Protection

Mbr Status

Fee

GST

Total Fee

Mbr Status

Fee

GST

Total Fee

AU Mbr

$1922.73

$192.27

$2115.00

AU Mbr

$500.00

$50.00

$550.00

AU Non Mbr

$2254.55

$225.45

$2480.00

AU Non Mbr

$618.18

$61.82

$680.00

NZ Mbr*

$1925.00

NZ Non Mbr

$2255.00

NZ Mbr*

$455.00

NZ Non Mbr

$620.00

Melbourne

January

21st - 25th

Brisbane

February

12th

Brisbane

April/May

29th - 03rd

Adelaide

June

24th

Sydney

October

14th - 18th

Perth

December

09th

Introduction to Protective Coatings

Cathodic Protection Monitoring

Mbr Status

Fee

GST

Total Fee

Mbr Status

Fee

GST

Total Fee

AU Mbr

$500.00

$50.00

$550.00

AU Mbr

$1286.36

$128.64

$1415.00

AU Non Mbr

$618.18

$61.82

$680.00

AU Non Mbr

$1568.18

$156.82

$1725.00

NZ Mbr*

$455.00

NZ Non Mbr

$620.00

NZ Mbr*

$1285.00

NZ Non Mbr

$1570.00

Melbourne

March

25th

Brisbane

February

13th - 15th

Sydney

June

11th

Sydney

May

13th - 15th

Brisbane

September

02nd

Adelaide

June

25th - 27th

Melbourne

August

12th - 14th

Perth

December

10th - 12th

Protective Coatings Quality Control Mbr Status

Fee

GST

Total Fee

AU Mbr

$1286.36

$128.64

$1415.00

Cathodic Protection Advanced

AU Non Mbr

$1568.18

$156.82

$1725.00

Mbr Status

Fee

GST

Total Fee

NZ Mbr*

$1285.00

NZ Non Mbr

$1570.00

AU Mbr

$1922.73

$192.27

$2115.00

Melbourne

March

26th - 28th

AU Non Mbr

$2254.55

$225.45

$2480.00

Sydney

June

12th - 14th

NZ Mbr*

$1925.00

NZ Non Mbr

$2255.00

Auckland

August

06th - 08th

Brisbane

February

04th - 08th

Brisbane

September

03rd - 05th

Sydney

May

06th - 10th

Adelaide

June

17th - 21st

Melbourne

August

05th - 09th

Perth

December

02nd - 06th

Coatings Selection and Specifications Mbr Status

Fee

GST

Total Fee

AU Mbr

$1286.36

$128.64

$1415.00

AU Non Mbr

$1568.18

$156.82

$1725.00

Corrosion & CP of Concrete Structures

NZ Mbr*

$1285.00

NZ Non Mbr

$1570.00

Mbr Status

Fee

GST

Total Fee

Adelaide

April/May

30th - 02nd

AU Mbr

$918.18

$91.82

$1010.00

Perth

July

16th - 18th

AU Non Mbr

$1150.00

$115.00

$1265.00

Melbourne

October

01st - 03rd

NZ Mbr*

$920.00

NZ Non Mbr

$1150.00

Sydney

February

25th - 26th

Brisbane

July

16th - 17th

Tasmania

November

25th - 26th

Coatings Inspection Refresher Mbr Status

Fee

GST

Total Fee

AU Mbr

$500.00

$50.00

$550.00

AU Non Mbr

$618.18

$61.82

$680.00

ACA/ACRA Corrosion & Protection of Concrete Structures

NZ Mbr*

$455.00

NZ Non Mbr

$620.00

Mbr Status

Fee

GST

Total Fee

Brisbane

November

10th

AU Mbr

$918.18

$91.82

$1010.00

New Zealand

December

12th

AU Non Mbr

$1150.00

$115.00

$1265.00

NZ Mbr*

$920.00

NZ Non Mbr

$1150.00

Brisbane

May

27th - 28th

Sydney

August

13th - 14th

Perth

September

19th - 20th

p.10  CORROSION & MATERIALS

ACA 2013 TRAINING CALENDAR

NACE - Coatings Inspection Program CIP Level 1

Resits NACE – Coating Inspector Program Level 1 & 2

Mbr Status

Fee

GST

Total Fee

Mbr Status

Fee

GST

Total Fee

AU Mbr

$3236.36

$323.64

$3560.00

AU Mbr

$863.64

$86.36

$950.00

AU Non Mbr

$3700.00

$370.00

$4070.00

AU Non Mbr

$1090.91

$109.09

$1200.00

NZ Mbr*

$3235.00

NZ Non Mbr

$3715.00

NZ Mbr*

$865.00

NZ Non Mbr

$1110.00

Melbourne

February

04th - 09th

Adelaide

February

18th - 23rd

Examination Tests will be conducted to coincide with scheduled programs – contact ACA for details

Brisbane

March

11th - 16th

Perth

March

18th – 23rd

SSPC – C7 Abrasive Blasting Certification Program

Sydney

April

08th - 13th

Mbr Status

Fee

GST

Total Fee

Melbourne

April

15th - 20th

AU Mbr

$1181.80

$118.20

$1300.00

AU Non Mbr

$1354.55

$135.45

$1490.00

NZ Mbr*

$1180.00

NZ Non Mbr

$1355.00

Melbourne

January

15th – 16th

Melbourne

February

04th – 05th

Melbourne

February

25th – 26th

Melbourne

March

12th – 13th

Melbourne

March

25th – 26th

Melbourne

April

15th – 16th

Melbourne

May

07th – 08th

Melbourne

May

20th – 21st

Melbourne

June

11th – 12th

Melbourne

June

25th – 26th

Adelaide

May

06th - 11th

Brisbane

May

13th - 18th

Perth

June

17th - 22nd

Tasmania

June

03rd - 08th

New Zealand

July/August

29th - 03rd

Sydney

August

19th - 24th

Adelaide

October

14th - 19th

Brisbane

October/November

28th - 02nd

Melbourne

November

25th - 30th

NACE – Peer Review CIP Level 3 Mbr Status

Fee

GST

Total Fee

AU Mbr

$1271.82

$127.18

$1399.00

AU Non Mbr

$1493.64

$149.36

$1643.00

SSPC – C12 Airless Spray Basics

NZ Mbr*

$1272.00

NZ Non Mbr

$1494.00

Mbr Status

Fee

GST

Total Fee

Brisbane

November

08th - 12th

AU Mbr

$1181.80

$118.20

$1300.00

AU Non Mbr

$1354.55

$135.45

$1490.00

NZ Non Mbr

$1355.00

Electrolysis Testers Course

NZ Mbr*

$1180.00

Mbr Status

Fee

GST

Total Fee

Melbourne

January

17th – 18th

AU Mbr

$618.18

$61.82

$680.00

Melbourne

February

06th – 07th

AU Non Mbr

$677.27

$67.73

$745.00

Melbourne

February

27th – 28th

NZ Mbr*

$550.00

NZ Non Mbr

$620.00

Melbourne

March

14th – 15th

Sydney

October

TBA

Melbourne

March

27th – 28th

Melbourne

April

17th – 18th

Melbourne

May

09th – 10th

NACE - Coatings Inspection Program CIP Level 2 Mbr Status

Fee

GST

Total Fee

Melbourne

May

22nd – 23rd

AU Mbr

$3236.36

$323.64

$3560.00

Melbourne

June

13th – 14th

AU Non Mbr

$3700.00

$370.00

$4070.00

Melbourne

June

27th – 28th

NZ Mbr*

$3235.00

NZ Non Mbr

$3715.00

Melbourne

February

11th - 16th

Brisbane

March

18th - 23rd

Sydney

April

15th - 20th

Adelaide

May

13th - 18th

Perth

June

24th - 29th

Sydney

August

26th - 31st

Adelaide

October

21st - 26th

Brisbane

November

04th - 09th

Melbourne

December

02nd - 07th

All registration fees are payable in Australian Dollars.

All registrations are subject to ACA’s published terms, conditions and policies which can be found at www.corrosion.com.au 2013 Calendar accurate as of 22/11/2012.

Refer to www.corrosion.com.au for an updated version. * All NZ courses are GST free

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

NEWS

C&P2012 Melbourne The ACA’s annual conference took place recently on the 11-14 November 2012 in Melbourne at the Crown Conference Centre. 2012 was the largest ACA stand-alone conference ever conducted attracting 573 delegates including a large international delegation from the USA, UK, Libya, Kuwait, Sweden, China, UAE, India, Germany and more.

The conference brought together international, regional and national experts to discuss, explore strategies, approaches and options for mitigating corrosion. In addition to hearing the latest research and business concepts

through conference presentations, meeting participants also participated in technical group fora to exchange ideas as well as a 60 booth exhibition of the industries product and service providers.

Many of the conference’s volunteers, committee members and conference office staff tirelessly worked together much of the year in preparations to fully utilise all four days of Annual Conference including the usual social functions as a continuous celebration and commemoration of the ACA and the corrosion industry.

The ACA thank all of the speakers for their excellent, informative presentations and contributions. A CD Rom with all the conference papers are available to purchase from the ACA office for $90 including postage.

A CD Rom booking form can be downloaded at www.corrosion.com.au or by requesting a copy via email to aca@corrosion.com.au A full review and compilation of photos from the 2012 conference will appear in the 2013 February issue of Corrosion & Materials.

Anti Corrosion Technology – major sponsor 2013 conference During the closing session of Corrosion & Prevention 2012 in Melbourne, the ACA announced that Anti Corrosion Technology is the exclusive major sponsor for next year’s 2013 ACA conference in Brisbane.

Anti Corrosion Technology (ACT) is an established Australian-based engineering company that was founded in 1993. ACT specializes in providing sustainable solutions in materials engineering and corrosion control for Oil & Gas, Water, Power Generation and Mining industries.

ACT is the sole Australian partner of STOPAQ B.V. who is the pioneer and manufacturer of the visco elastic corrosion protective coatings and sealants. ACT is the exclusive

p.12 CORROSION & MATERIALS

distributor of STOPAQ products in Australia offering solutions for external pipeline corrosion protection of field joints, HDD, steel pipe casing, road crossings and complete pipeline rehabilitation including valves and flanges as well as external corrosion protection of tank bottoms.

“For the last three decades I personally consider ACA as the leader in providing our industries with the most professional support in materials engineering & corrosion control through its annual events, technical groups and dynamic website. Anti Corrosion Technology is a 100% Australian-owned company and is honoured to be 2013’s Major Sponsor of the ACA’s annual conference held in Brisbane. We plan on optimising this

event as the technical platform for us to share with all the ACA’s professional members our 40 years experience and continual effort in contributing and enhancing safe, sustainable and cost effective anti corrosion solutions for the corrosion industry from the conceptual design through to the decommissioning phase,” said Dr Fikry Barouky – Founder & Chairman of Anti Corrosion Technology Pty Ltd. The ACA looks forward to hosting the conference and working with ACT and the local organising committee. For further details on Corrosion & Prevention 2013, please visit www.acaconference.com.au

NEWS

457 visas may be cause for concern ACA has been contacted by a number of members who have expressed concern over the use of 457 visas and the possible adverse consequences associated with their use. The enquiries are all related to resource projects and coatings inspectors from overseas who have been sponsored under the 457 visa scheme.

The Department of Immigration and Citizenship has strict guidelines and audit programs in place to monitor adherence to the requirements associated with this class of visa.

Issues raised with ACA include possible forged qualifications, inappropriate

qualifications, inadequate assessment of qualifications, market undercutting conditions of employment and possibly inappropriate observance of inspection requirements and Australian Standards.

ACA has contacted senior departmental officials and has started a dialogue which will enable ACA and its members to raise any specific instances of concern with the Department.

Any ACA member who is concerned about possible inappropriate behaviour by anyone involved with the employment of coatings inspectors under 457 visa arrangements should

first check with the Department. The conditions and guidelines associated with the 457 program can be viewed on the Department’s web site. Making enquiries and talking with a real person at the Department can be a challenge.

ACA members who have valid causes for concern which can be directly related to possible breaches of the scheme’s conditions and guidelines are invited to contact Ian Booth at ACA on +61 3 9890 4833 or by email to ibooth@corrosion.com.au.

SSPC courses underway ACA has commenced the roll out of SSPC courses. The arrangement between ACA and SSPC allows for the C7 and C12 programs to be conducted

by ACA throughout Australia and New Zealand.

The C7 Abrasive Blasting Program is designed for contractor personnel who wish to obtain certification or others who wish to learn about dry abrasive blast cleaning of steel. It covers principles of surface preparation, surface cleanliness, surface profile, dust and debris control, and abrasives.

The C12 Airless Spray Basics Program assesses the skills of sprayers who have

a minimum of 800 hours applying protective coatings with airless spray in an industrial or marine environment.

Candidates are certified through a certification written exam and a practical hands-on skill assessment.

This course is designed to train and certify marine/industrial applicators to operate airless spray equipment.

The first of the programs were recently conducted in Melbourne. These offerings were principally conducted to assess suitable candidates to be lecturers and assessors for the programs.

C7 and C12 will also be offered to TAFE Institutes conducting

Certificate III programs as suitable assessment tools in their recognition of prior learning for the purposes of establishing advanced standing.

ACA has also received considerable interest from asset owners who are likely to insist that at least supervisory staff engaged on their projects are certified under the C7 and C12 programs.

The schedule of C7 and C12 programs for 2013 is now available for download from ACA’s web site at www.corrosion.com.au. Further enquiries can be directed to Barry Hodder on +61 3 9890 4833 or to bhodder@corrosion.com.au.

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

December 2012 www.corrosion.com.au p.13

NEWS

ACA LinkedIn group achieves steady growth Membership of ACA’s LinkedIn group page has grown to more than 300 in a relatively short period of time.

The group allows members and other industry participants to exchange information, contribute to discussions and share resources which are of

general use to those interested in corrosion related matters.

Not all applicants for membership of the group page are approved. ACA has established guidelines to limit overtly commercial spam.

Jacquie Martin at ACA’s Melbourne office administers ACA’s LinkedIn group page and Corrosion Matters e-newsletter. Enquiries can be directed to Jacquie on +61 3 9890 4833 or jmartin@corrosion.com.au.

UQ research leads to smarter sewage management Scientists from UQ’s Advanced Water Management Centre have found a way to curb the cost – and smell – of sewage transportation.

Professor Zhiguo Yuan said bad smells were only one cost of transporting sewage.

“Bad pipes caused by hydrogen sulfide corrosion are another more noxious side-effect that costs the Australian water industry around $100 million a year,” Professor Yuan said.

“Our plan is to change all that by applying to the pipes a once-a-week dose of environmentally friendly free nitrous acid (FNA).

“This will be good for both the environment and our senses.”

p.14 CORROSION & MATERIALS

Currently, expensive chemicals are used to deal with the inevitable smells and corrosion caused by unwanted biofilms that grow on the surfaces of wastewater infrastructure.

“The pipes won’t rot, nor will they smell, and should actually last the 100 years they were designed for, instead of the sometimes only 10 years they currently do,” Professor Yuan said.

Apart from the cost of the chemicals, the existing “solutions” create further problems in the sewage treatment and reclaiming process, as it becomes yet another chemical to be neutralised.

Building on work conducted over the past decade, Professor Yuan and his team of engineers and microbiologists recently made the ground-breaking discovery that, at parts per million level, FNA is a strong biocidal agent, causing cell-death and biofilm disintegration.

“Our challenge was to find an affordable chemical that didn’t harm the environment,” Professor Yuan said.

The FNA kills the organisms that create the smells and corrosion, and is then removed itself by the microbial community living within the sewage pipes.

“This was a very exciting breakthrough and allows us to turn our technology into a valuable business,” he said.

NEWS

ACA welcomes new members Corporate Gold AKRON GROUP NT AKRON GROUP NT is a progressive and innovative company that constantly seeks to expand in Civil, Building Construction & Asset Maintenance.

AKRON GROUP NT is a Territory owned and operated family business.

Their Headquarters are in Darwin and they have been operating solely within the Northern Territory since 1997.

Hunter Galvanizing www.huntergalvanzing.com.au Hunter Galvanizing is proudly Australian owned and operates two galvanizing plants in Tomago, NSW. Commissioned in 2002 to meet the needs of fabrication, structural and mining industries in the Newcastle and the surrounding region, Hunter Galvanizing has grown to incorporate handling facilities in Sydney and a transport fleet servicing clients throughout the state.

Hunter Galvanizing plant facilities are operational 24 hours, 7 days a week catering for a diverse range of fabricated steel items in processing

business and homes. We produce more than 90% renewable generation, from low fuel-cost hydro and geothermal sources. We have a unique generation portfolio in New Zealand – it’s the only large, renewable-dominated portfolio with a major geothermal component.

baths - Plant 1: 10m long x 2.4m deep x 1.5m wide and Plant 2: 7m long x 3m deep x 1.8m wide.

Corporate Bronze Asset Team Consulting http://asset-team.biz/ Asset Team Consulting is an engineering consulting organisation with experience in Reliability Engineering and Maintenance Management. Services include asset audits, training, project management, maintenance task development & sales, maintenance analysis, work instruction development, technical writing, procedure development, asset spares & maintenance database management and more.

Pacific Remedial Solutions Pacific Remedial Solutions provide remedial building services to the residential, commercial, industrial, and public sectors. They offer high standards of service in concrete repair, waterproofing, structural strengthening, epoxy flooring, protective coating systems, facade and asset refurbishment.

Southern Cross Building Products www.scbp.com.au Southern Cross Building Products (SCBP) was formed in 2007 as a re-seller of Denso tapes. SCBP specialises in anticorrosion and building products carrying product in all capital cities.

They have manufacturing capabilities including plastic injection moulding; plastic extrusion; film coating and converting roll stock.

Mighty River Power www.mightyriver.co.nz Mighty River Power is a major competitor in the New Zealand electricity market, and was named ‘Overall Energy Company of the Year’ in 2012. We operate a flexible, multi-fuel generation portfolio, complemented by electricity sales to

Individual/Student/Retired Members Name

Company/Institution

Dean Aquilina

Location

Name

Company/Institution

Location

Queensland

James Leitch

Leitch Supervision & Inspection Services

Queensland

Jessica Lyndon

Monash University

Victoria

Daniel Atkins

Australian Maritime Safety Authority

Tasmania

Jamie Baker

Camberwell Painting

Victoria

Chris Beasley

Western Australia

The University of Melbourne

Victoria

Douglas Montgomerie

Independent Building Inspections

Queensland

Richard Osborne

McConnell Dowell

Victoria

Trefor Owen

BP Refinery Kwinana

Western Australia

Western Australia

Jeffrey Patterson

Remedial Building Works

Queensland

Queensland

Ramon Salazar

Stork Technical Services

Western Australia

The University of Newcastle

Newcastle

Steve Buckland

Tasmanian Ports Corporation

Tasmania

Courtney Campbell

Vector Gas

Taranaki

Brian Curtin

Deljay Holdings

Michael Eddy

The University of Adelaide

South Australia

Michael Searston

Philip Ferguson

Pipeline Condition Assessment

New South Wales

Nestor Sequera

Joel Fudali

South Australia

William (Bill) Sherwood

Robert Goedhart

Queensland

Facundo Varela

Tristan Graham

RMIT University

Victoria

Adrian Vinnell

Matthew Hales

Queensland University of Technology

Queensland

Mark Ward

Douglas Herd

GHD

Queensland

Peter Hirst

Monadelphous Engineering

Western Australia

John Holdsworth

SGA Property Consultancy

New South Wales

Patrick Hunter

South Australia

Danielle Measday

Subhankar Biswas

Robert Dale

Darren McDonald

Western Australia

Queensland PTTEP Australasia

Western Australia Queensland

Deakin University

Victoria Victoria

JMG

Tasmania

Tony Weber

Western Australia

Kevin Woodland

SMEC Australia

New South Wales

Ken Wright

Independent Maintenance Services

Victoria

Michael Wright

Total Custom Restorations

Queensland

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

NEWS

CDU opens research, training facility for oil and gas industry The $7 million North Australian Centre for Oil and Gas (NACOG), which is at the vanguard of research and training for the Northern Territory’s burgeoning oil and gas industry, has begun operations at Charles Darwin University.

NACOG was officially opened on the 20th November by the Northern Territory Chief Minister Mr Terry Mills.

The cutting edge facility was built with support from the NT Government and the oil and gas industry through a INPEX, Total and other participants in the Ichthys LNG Project Joint Venture.

CDU Vice-Chancellor Professor Barney Glover said “the state-of-the-art building has teaching and training facilities for both Vocational Education and Training

(VET) and Higher Education, which will not only encourage more students to consider careers in the resources sector but it will also help to expand the locally based workforce”.

He said the centre also boosted the university’s research capabilities with two new laboratories that were equipped to conduct solution-oriented research and consultancy for the oil and gas industry.

“The Multiphase Flow Laboratory houses a state-of-the-art PVT cell, putting CDU at the forefront of research into CO2 mitigation during oil and gas production and power generation,” Professor Glover said.

The second laboratory will house material and testing equipment that will be used to undertake research with industry partners Incospec and Associates into prevention and control issues facing the oil and gas industry in Northern Australia.

As well as university teaching and research, the building incorporates an 80-seat seminar space.

“We look forward to making the facility available for industry, local business and community relations activities,” Professor Glover said.

YCG NSW Site Tours The ACA’s NSW Young Corrosion Group (YCG) recently organised a site tour with the NSW Young Pipeliner Forum (YPF) to Wollongong to visit manufacturing facilities.

The first tour was at BlueScope Steel plant. Here the young professionals were exposed to the entire process for the manufacture of steel from the raw materials to rolling the steel that are made into coils. Once the BlueScope Steel tour was completed the YCG/ YPFers went to the Kemblawarra Portuguese Sports & Social Club for a lunch supplied by YCG which was a

p.16 CORROSION & MATERIALS

great opportunity for everyone to get to know one another a bit more.

Once lunch was completed, the group visited the second facility on the tour – Industrial Galvanizers. Here Matthew Cole from Industrial Galvanizers gave a brief introduction into the world of galvanizing, how the process works and how to design for structures to be galvanized. The talk was then followed by questions and a safety induction for the YCG/YPFers to attend their site.

When at the Industrial Galvanizers yard the YCG/YPFers were given all the required safety gear and was given

a tour of the site. The tour started off where they prepared the metal prior to galvanising which includes removing any coatings, oils etc and hooked onto structures ready to be galvanised. Once the metal is hooked up it goes into acid bath (flux) to clean the metal, it is then dried, placed in the galvanizing bath for a period of time and then quenched.

The galvanised metal is then stored appropriately until it is required for use.

The day finished with a relaxed drink and discussion back at the sports club before the Sydney based members began their drive home.

NEWS

BlueScope Steel Develops Longer Lasting ZINCALUME® steel BlueScope Steel is preparing to rollout a third generation of its iconic ZINCALUME® steel. It features a patented new coating that increases its durability.

Next Generation ZINCALUME® steel featuring Activate™ technology will enter production in the second quarter of 2013, bringing to fruition almost 20 years of efforts by BlueScope Steel to develop a longer-lasting metalliccoated building product.

BlueScope Steel market manager – commercial and industrial – Manu Siitonen, said BlueScope Steel has invested over $100 million in perfecting a better ZINCLAUME® steel product.

He said the breakthrough metal coating formulation of Next Generation ZINCALUME® steel improves the already high corrosion performance of the current product.

“ZINCALUME® steel is renowned in Australian building and architectural circles for the galvanic action of the zinc in its coating, which gives it a self-sealing property and increases its lifespan,” said Mr Siitonen.

“With Next Generation ZINCALUME® steel, we have perfected a new formula that improves the galvanic action of the zinc. With the addition of a new magnesium compound, it activates the aluminium in the coating composition to provide even more effective corrosion resistance.

The result is a product that is more resilient when drilled, cut or scratched.

“Ultimately, the chemistry of Next Generation ZINCALUME® steel metal coating formulation makes it stronger in harsh construction environments and opens up the possibility of new applications for builders and specifiers.”

Next Generation ZINCALUME® steel metal coating formulation has undergone 10 years of accelerated laboratory testing and 17 years of environmental field testing to ensure it exceeds the durability of the current ZINCALUME® steel product.

“The improved coating also enables a more efficient use of natural resources through the reduced use of zinc and aluminium, lessening Next Generation ZINCALUME® steel’s environmental impact.”

Since its launch in 1976, ZINCALUME® steel has been a standard-setter amongst steel roofing, cladding and construction products.

In 1994, second generation ZINCALUME® steel was launched, featuring the addition of a resin coating that improved mark resistance, and made the steel easier to handle and roll-form.

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Free Phone AU 1800 309 734 Free Phone NZ 0800 646 372

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

A lifetime of practical knowledge and skills in just 6 days.

NACE Coating Inspection Program (CIP) The NACE Coating Inspector Program (CIP) program sets the standard for inspections in the protective coatings industry and is the world’s most recognised coating inspector certification program.

CIP Level 1 Course Highlights: • Coating types and curing mechanisms • Coating specifications • Surface preparation • Coating application • Inspection procedures • Environmental testing • Nondestructive test instruments Recognition: NACE Coating Inspector Level 1 – Certified

The Australasian Corrosion Association Inc has held the license to conduct the CIP program in Australasia since 2002 and has certified over 1,000 inspectors.

The three level program utilises classroom lecture and hands-on practice labs to teach inspection concepts to a variety of coatings professionals including applicators, blasters, contractors, and manufacturers.

CIP Level 2 Course Highlights: • Blast cleaning and waterjetting • Linings and non-liquid coatings • Concrete, mainline, pipeline, and field joint coatings • Destructive test instruments • Specialised application equipment • Coating survey techniques • Common coating failure modes Recognition: NACE Coating Inspector Level 2 – Certified

CIP Level 3 Peer Review: A detailed, oral examination in front of a three-member review board where candidates must demonstrate that they can apply the practical and technical knowledge they have learned on-the-job from the CIP program.

Recognition: NACE Certified Coating Inspector Level 3

p.18 CORROSION & MATERIALS

Register today at www.corrosion.com.au and change your career forever!

EVENT REPORT

Gerald Frankel ACA Foundation Funded Tour On sabbatical at Monash University, Gerald Frankel from Ohio State University recently presented at various ACA Branch technical meetings. Supported by the ACA Foundation, Gerald presented in Newcastle, Brisbane, Sydney and Melbourne on ‘Prevention of Corrosion and Cracking of Steel Tanks for Liquid High Level Radioactive Waste’. Gerald is a member of the USA Nuclear Waste Technical Review Board. A summary of his presentation is found below.

Presentation Summary: At the United Sates Department of Energy’s Hanford tank reservation, approximately 200 million liters of liquid radioactive waste from cold war weapons production is stored in 177 underground storage tanks. Prior to permanent disposal in a geologic site, the waste will be vitrified into glass logs. However, the double shelled carbon steel storage tanks now used for storage will continue in operation until the vitrification plant construction is finalized and waste processing operations completed, which could be still several decades.

It is essential that tank leak integrity be assured through control of corrosion and cracking.

The wastes are generally highly alkaline, from pH 10 to hydroxide concentrations in excess of 6 M. The steel is passive in these environments, but is susceptible to localized corrosion and stress corrosion cracking because of the generally high nitrate concentrations and elevated temperatures. Maintaining the pH above the specification of 13 requires addition of considerable amounts of hydroxide to balance the neutralizing effects of CO2 from the atmosphere.

These additions have deleterious influences on the vitrification process.

On the other hand, nitrite ion, which is present to varying extents in the wastes, is known to be a potent inhibitor for corrosion and cracking in nitrate environments.

In this work, an experimental study was performed to investigate the ranges of susceptibility to localized corrosion and stress corrosion cracking as a function of potential and tank chemistry. Potential

The ACA Foundation Proudly Presents:

and nitrite ion concentration were shown to have a dominant influence, with pH in the range of 10-14 being less important. These results have led to the development of new approaches to control corrosion through tank chemistry. Two other issues must be addressed when considering a change in the tank chemistry specifications: atmospheric corrosion of the tank above the liquid and attack at the liquid/ air interface (waterline attack). Both phenomena have been observed and result from local differences in chemistry relative to the bulk liquid composition.

rrosion Prevention of Co eel St of and Cracking High id qu Li Tanks for Waste e iv ct oa di Level Ra with International Guest Speaker Gerald

Venue: Quality Hotel, Apollo International, 290 Pacific Highway, Charlestown, NSW, 2290 Date: Tuesday October 16th 2012 Times: 6.30pm til 10.00pm Cost: $35.00 for members and guests and $20.00 for students. Cost includes a three course meal and drinks.

RSVP: Booking is essential and close Sunday 14th October at 5pm.

Attendees must prepay via the Event Link: www.stickytickets.com.au/9270

Presentation Summary: At the United Sates Department of Energy’s Hanford tank reservation, approximately 200 million liters of liquid radioactive waste from cold in war weapons production is stored Prior 177 underground storage tanks. to permanent disposal in a geologic site, the waste will be vitrified into glass logs. However, the double shelled carbon steel storage tanks in now used for storage will continue operation until the vitrification plant construction is finalized and waste processing operations completed, which could be still several decades.

It is essential that tank leak integrity be assured through control of corrosion and cracking.

The wastes are generally highly alkaline, from pH 10 to hydroxide concentrations in excess of 6 M. The steel is passive in these environments,

S Frankel

International Guest Speaker: Corrosion Gerald S. Frankel of the Fontana USA Center, The Ohio State University, Professor Gerald S. Frankel is the DNV Chair, and of Materials Science and Engineering, Center at Director of the Fontana Corrosion research the Ohio State University. His primary localized interests are in the passivation and corrosion of metals and alloys, corrosion He is a inhibition, and protective coatings. in visiting professor at Monash University appointed to Melbourne in 2012. In 2012 he was Board by the Nuclear Waste Technical Review President Barack Obama.

but is susceptible to localized corrosion and stress corrosion high cracking because of the generally nitrate concentrations and elevated temperatures. Maintaining the pH above the specification of 13 requires of addition of considerable amounts neutralizing the balance hydroxide to effects of CO2 from the atmosphere.

These additions have deleterious influences on the vitrification process.

On the other hand, nitrite ion, which is present to varying extents in the wastes, is known to be a potent in inhibitor for corrosion and cracking nitrate environments.

In this work, an experimental study was performed to investigate the ranges of susceptibility to localized corrosion and stress corrosion cracking as a function of potential and tank chemistry. Potential and nitrite ion concentration were shown

to have a dominant influence, with pH in the range of 10-14 being less to important. These results have led the development of new approaches to control corrosion through tank chemistry. Two other issues must be addressed when considering a change in the tank chemistry specifications: atmospheric corrosion of the tank above the liquid and attack at the liquid/air interface (waterline attack). Both phenomena have been observed and result from local to differences in chemistry relative the bulk liquid composition.

Proudly Presented by:

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

BRANCH NEWS

Victoria Branch October Technical Meeting Review The October 2012 Victoria Branch Technical Meeting on the 10th October was entitled ‘Unconventional Reinforcing for Concrete’. The first speaker of the evening was Brad Birch of Durinox, a Division of Lyttons.

His presentation ‘Stainless Steel Reinforcement’ gave an excellent overview of the available grades of stainless steel reinforcing. He focused on the practical aspects of handling and fabrication of stainless steel reinforcing.

It was excellent to have such a knowledgeable speaker provide an insight into the practicalities of stainless steel reinforcing. All of the attendees

would have left with the impression that stainless steel is a viable option for many applications were additional durability would bring improvement to the service life of a concrete element.

Also that handling and detailing are important aspects of its deployment into structures.

The second speaker was Dr Marcin Wieloch of Halcrow who presented on ‘Durability of Concrete Containing Alternative Bar and Fibre Reinforcement – Comparison of Concrete Performance in Severe Exposure Conditions’. Marcin gave a very interesting talk which first

examined all of the available choices for reinforcing concrete with a rough comparison of their performance.

These included both conventional carbon steel, stainless steel and fibre reinforcing. He then went onto to provide a durability model to compare some specific scenarios, so as to quantify the comparative life of the different options. Marcin’s assumptions and use of deterministic modelling promoted a very robust discussion from all of the attendees and it was great to hear everyone’s thoughts on the matter.

ACA Auckland Division October Meeting Report

The Auckland meeting held on 24th October in the boardroom of the Engineering School at Auckland University was addressed by David Addison, Principal Consultant of Thermal Chemistry Ltd, Hamilton. Thermal Chemistry works with organisations helping to resolve chemistry and engineering problems in thermal, cogeneration and geothermal power plants. The title of the presentation was Water and Steam Cycle Corrosion Issues in Thermal, Combined Cycle and Cogeneration Power Plants.

INDUSTRIAL

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David commenced his presentation with an introduction to the operation of heat recovery steam generators (HRSG) in power plants, encompassing combined-cycle plants, thermal power plants and cogeneration plants. He then described some corrosion case studies arising in gas turbine and steam turbine generators. In steam turbines corrosion problems may arise due to pitting corrosion on turbine blades during shutdown which can lead to stress corrosion cracking in service. Operators must also guard against the possibility of corrosion fatigue during cyclical service of a steam turbine. David outlined further corrosion issues arising in steam turbine and air-cooled condensers in power plants. Problems experienced in HRSG include thermal fatigue, flow-assisted corrosion (FAC) and under-deposit corrosion in condenser tubes.

He outlined the complex mechanisms that drive FAC, which is a serious issue if it develops in boiler systems.

He also outlined some back-end corrosion problems that can occasionally occur in boilers, such as acid dew point corrosion. The presentation concluded with a discussion on the importance of boiler water chemistry.

p.20 CORROSION & MATERIALS

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BRANCH NEWS

WA Branch – Fresh Water Corrosion on Historic Shipwrecks On the 8th October, Ian MacLeod presented an interesting excursion into a little known realm in WA and that is of giant fresh water lakes. Parks Canada set up the world’s first underwater national park at Tobermory, Ontario on the shores of Lake Huron and MacLeod was invited to conduct a series of measurements on historic wooden and composite wood-iron wrecks. Analysis of the data showed up a complex physical chemistry, in terms of thermal gradients, which could however be rationalised in terms of the location of the wrecks, through exposure or shelter from prevailing winds provided by islands that abound in the Lake.

Water temperatures on the sites also played a major role in the deposition of a protective calcium carbonate layer.

Depending on the degree of water movement it was possible to see that the primary corrosion products were Fe(OH)2, and Fe3O4 with some iron (III)

a useful indicator of the amount of dissolved oxygen present on the wreck sites and the corrosion potentials of the non-ferrous metal fastenings showed up good examples of galvanic coupling as well as proximity corrosion.

oxy-hydroxides such as goethite. The fresh water leads to higher dissolved oxygen levels than found in sea water but the absence of salt greatly improved the corrosion performance of the metals.

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23/01/2012 2:00:05 PM December 2012 www.corrosion.com.au p.21

ACA STANDARDS UPDATE

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

published from 12th September 2012 to 21st November 2012 was conducted using the following key words and key word groups:

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

durability c orrosion or corrosivity or corrosive; but not anodizing or anodize(d) aint or coating; but not anodizing p or anodize(d) galvanize or galvanized or galvanizing e lectrochemical or electrolysis or electroplated cathode or cathodic

anode or anodic. c orrosion and concrete or concrete and coatings.

Results of the general search can be found in Table 2, showing 51 new Standards, Drafts and Amendments.

There was 1 new amendment for AS or AS/NZS Standards or Draft publications - AS; AS 1397-2011/Amdt 1-2012 Continuous hot-dip metallic coated steel sheet and strip - Coatings of zinc and zinc alloyed with aluminium and magnesium.

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

Table 1a For Titles search on https://infostore.saiglobal.com/store on 21 November 2012 for Water & Corrosion there were 277 citations, a sample of which is shown below, with none from Australian Standards.

Table 1a. Title search by publisher with keywords ‘Water & Corrosion’ – 277 publications found, 0 from AS/ASNZS. Results by Publisher German Institute for Standardisation (Deutsches Institut für Normung)

29

Association Francaise de Normalisation

19

US Military Specs/Standards/Handbooks

18

Osterreichisches Normungsinstitut

16

Nederlands Normalisatie Instituut

15

British Standards Institution

14

Polish Committee for Standardization

14

Standardiserings-Kommissionen I Sverige

14

Belgian Standards

13

National Standards Authority of Ireland

12

Norwegian Standards (Norges Standardiseringsforbund)

12

Asociacion Espanola de Normalizacion

11

Comite Europeen de Normalisation

11

Italian Standards

11

Swiss Standards

11

Ford Motor Company

10

American Society for Testing and Materials

8

Interstandard (Russia)

7

NACE International

6

International Organization for Standardization

5

Korean Standards Association

5

Standardization Administration of China

3

Japanese Standards Association

2

Verlag des Vereins Deutscher Ingenieure

2

American Water Works Association

1

Brazilian Standards

1

p.22 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Bureau of Indian Standard

1

Det Norsk Veritas

1

DVS-VERLAG GmbH, Verlag für Schweissen und verwandte Verfahren

1

Schiffbautechnische Gesellschaft E.V.

1

Society of Automotive Engineers

1

UK Ministry of Defence standards

1

Verlag Stahleisen GmbH

1

Results by Subject – Metallurgy – 135 results Corrosion of metals

133

Ferrous metals

1

Non-ferrous metals

1

Results by Subject – Fluid systems and components for general use – 68 results Pipeline components and pipelines

67

Valves

1

Results by Subject – Construction materials and building – 67 results Installations in buildings

64

Elements of buildings

1

Protection of and in buildings

1

Structures of buildings

1

Results by Subject – Manufacturing engineering – 26 results Surface treatment and coating

26

Results by Subject – Petroleum and related technologies – 26 results Hydraulic fluids

20

Lubricants, industrial oils and related products

4

Fuels

1

Petroleum products in general

1

Results by Subject – Shipbuilding and marine structures – 7 results Shipbuilding and marine structures in general

7

Results by Subject – Civil engineering – 5 results External water conveyance systems

5

Results by Subject – Energy and heat transfer engineering – 5 result Solar energy engineering

3

Nuclear energy engineering

2

Results by Subject – Environment. Health protection. Safety – 4 results Water quality

3

Protection against fire

1

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

3

Results by Subject – Domestic and commercial equipment. Entertainment. Sports – 3 results Domestic, commercial and industrial heating appliances

3

Results by Subject – Paint and colour industries – 3 result Paints and varnishes

2

Paint coating processes

1

Results by Subject - Clothing industry – 1 result Headgear. Clothing accessories. Fastening of clothing

1

Results by Subject - Generalities. Terminology. Standardization. Documentation – 1 result Vocabularies

1

Results by Subject – Health care technology – 1 result

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

ACA STANDARDS UPDATE

Medical equipment

1

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

1

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

1

Results by Subject – Testing – 1 result Test conditions and procedures in general

1

Table 1b For Titles search on https://infostore.saiglobal.com/store on 21 November 2012 for “Waste Water” or “Wastewater & Corrosion” there were 9 citations, as shown below, 3 from Australian Standards.

Table 1b. Title search by publisher with keywords ‘Water & Corrosion’ – 9 publications found, 3 from AS/ASNZS. Results by Publisher Standards Australia

4

German Association for water, wastewater and waste

1

Osterreichisches Normungsinstitut

3

NACE International

1

Results by Subject – Construction materials and building – 2 results Installations in buildings

2

Results by Subject – Fluid systems and components for general use – 2 results Pipeline components and pipelines

1

Valves

1

Results by Subject – Fluid systems and components for general use – 4 results Pipeline components and pipelines

4

Results by Subject – Manufacturing engineering – 3 results Surface treatment and coating

3

Results by Subject – Construction materials and building – 1 results Installations in buildings

1

Results by Subject – Rubber and plastic industries – 1 result Reinforced plastics

1

Results by Publication AS 3688-2005/Amdt 1-2006

Water supply - Metallic fittings and end connectors

ATS 5200.037.1-2006

Technical Specification for plumbing and drainage products - Flow controllers - For controlling flows in cold or heated water systems

AS 3572.1-2002

Plastics - Glass filament reinforced plastics (GRP) - Methods of test - Preparation of glass filament reinforced plastics test specimens

Table 1c For Titles search on 21 November 2012 against “Welding & Corrosion” there were 131 citations, a sample of which is shown below; one from AS. To see all titles, log on to https://infostore.saiglobal.com/store and enter search phrase “Welding Corrosion”.

Table 1c. Title search by publisher with keywords ‘Water & Corrosion’ – 131 publications found, 1 from AS/ASNZS. Results by Publisher Society of Automotive Engineers

87

US Military Specs/Standards/Handbooks

21

Japanese Standards Association

3

Korean Standards Association

3

Manufacturers Standardisation Society

3

p.24 CORROSION & MATERIALS

ACA STANDARDS UPDATE

American Petroleum Institute

2

Italian Standards

2

American Society for Testing and Materials

1

American Welding Society

1

British Standards Institution

1

Bureau of Indian Standard

1

DVS-VERLAG GmbH, Verlag für Schweissen und verwandte Verfahren

1

Interstandard (Russia)

1

National Aeronautics and Space Administration

1

Nederlands Normalisatie Instituut

1

Standards Australia

1

UK Ministry of Defence standards

1

Results by Subject – Aircraft and space vehicle engineering – 83 results Materials for aerospace construction

81

Aerospace fluid systems and components

2

Results by Subject – Manufacturing engineering – 9 results Welding, brazing and soldering

9

Results by Subject – Fluid systems and components for general use – 5 results Pipeline components and pipelines

3

Valves

2

Results by Subject – Metallurgy – 3 results Iron and steel products

3

Results by Publication AS 2205.10.1-2003

Methods for destructive testing of welds in metal - - Corrosion test for welded austenitic stainless steel

Table 2 Standards for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards and Amendments for ISO & IEC PUBLISHED from 12 September to 21 November 2012 for: Table 2. New standards, Amendments or Drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards or Amendments for ISO & IEC PUBLISHED between 12 September to 21 November 2012 Key word search on ‘durability’ - 11 citations found; all related to wood and furniture; None from AS AS/NZS SR CEN/TR 15003:2012

Durability of Wood and Wood-based Products - Criteria for hot air Processes for Curative Uses Against Wood Destroying Organisms

SR CEN/TS 15119-2:2012

Durability of Wood and Wood-based Products - Determination of Emissions From Preservative Treated Wood to the Environment - Part 2: Wooden Commodities Exposed in use Class 4 or 5 (in Contact With the Ground, Fresh Water or sea Water) - Laboratory Method

I.S. EN 1730:2012

Furniture - Tables - Test Methods for the Determination of Stability, Strength and Durability

PD CEN/TR 15003:2012

Durability of wood and wood-based products. Criteria for hot air processes for curative uses against wood destroying organisms

PD CEN/TS 15119-2:2012

Durability of wood and wood-based products. Determination of emissions from preservative treated wood to the environment. Wooden commodities exposed in Use Class 4 or 5 (in contact with the ground, fresh water or sea water). Laboratory method

BS EN 16122:2012

Domestic and non-domestic storage furniture. Test methods for the determination of strength, durability and stability

BS EN 1728:2012

Furniture. Seating. Test methods for the determination of strength and durability

BS EN 1730:2012

Furniture. Tables. Test methods for the determination of stability, strength and durability

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

ACA STANDARDS UPDATE

DIN EN 16122 (2012-10)

Domestic and non-domestic storage furniture - Test methods for the determination of strength, durability and stability; Not available

DIN EN 1728 (2012-10)

Furniture - Seating - Test methods for the determination of strength and durability Not available

UNE CEN/TS 15912:2012

Durability Of Reaction To Fire Performance - Classes Of Fire-Retardant Treated Wood-Based Product In Interior And Exterior End Use Applications

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 2 citations found; none from AS or AS/ASNZ BS 7211:2012

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

BS 8573:2012

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

Key word search on ‘paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 30 Publications found; 1 AS Amendment ISO 12013-1:2012

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

ISO 12013-2:2012

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

ISO 13129:2012

Paints and varnishes - Electrochemical measurement of the protection provided to steel by paint coatings - Current interrupter (CI) technique, relaxation voltammetry (RV) technique and DC transient (DCT) measurements

ISO 15184:2012

Paints and varnishes - Determination of film hardness by pencil test

ISO 4628-8:2012

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

ISO/DIS 13803

Paints and varnishes - Determination of reflection haze on paint films at 20 degrees

ISO/DIS 2813

Paints and varnishes - Determination of specular gloss of non-metallic paint films at 20 degrees, 60 degrees and 85 degrees

I.S. EN ISO 15184:2012

Paints and Varnishes - Determination of Film Hardness by Pencil Test (iso 15184:2012)

12/30229685 DC BS EN ISO 13803

Paints and varnishes. Determination of reflection haze on paint films at 20 degrees

12/30229691 DC BS EN ISO 2813

Paints and varnishes. Determination of specular gloss of non-metallic paint films at 20 degrees, 60 degrees and 85 degrees

12/30260937 DC BS EN 71-7.

Safety of toys. Part 7. Finger paints. Requirements and test methods

12/30266553 DC BS EN 16477-2

Glass in building. Painted glass for internal use. Evaluation of conformity

12/30266874 DC BS EN 1871

Road marking materials. Paint, thermoplastic and cold plastic materials. Specifications

12/30268985 DC BS EN 16492

Paints and varnishes. Evaluation of the surface disfigurement caused by fungi and algae on coatings

BS EN ISO 9117-4:2012

Paints and varnishes. Drying tests. Test using a mechanical recorder

BS EN ISO 9117-5:2012

Paints and varnishes. Drying tests. Modified Bandow-Wolff test

DIN EN ISO 13076 (2012-10)

Paints and varnishes - Lighting and procedure for visual assessments of coatings (ISO 13076:2012)

DIN EN ISO 2812-3 (2012-10)

Paints and varnishes - Determination of resistance to liquids - Part 3: Method using an absorbent medium (ISO 2812-3:2012)

p.26 CORROSION & MATERIALS

ACA STANDARDS UPDATE

DIN EN ISO 9117-6 (2012-10)

Paints and varnishes - Drying tests - Part 6: Print-free test (ISO 9117-6:2012)

DIN EN 927-3 (2012-10)

Paints and varnishes - Coating materials and coating systems for exterior wood - Part 3: Natural weathering test

FORD WSS M4D873 B2:2012

Engineering Material Specification - Thermoplastic Polyolefin Elastomer (Tpo) 15% Mineral Filled, Molding Compound, Paintable Over Grain, Exterior

AS 1397-2011/Amdt 1-2012

Continuous hot-dip metallic coated steel sheet and strip - Coatings of zinc and zinc alloyed with aluminium and magnesium

ISO 14188:2012

Metallic and other inorganic coatings - Test methods for measuring thermal cycle resistance and thermal shock resistance for thermal barrier coatings

ISO 16145-1:2012

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

ISO 16145-2:2012

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

ISO 16145-3:2012

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

ISO/FDIS 14604

Fine ceramics (advanced ceramics, advanced technical ceramics) - Methods of test for ceramic coatings - Determination of fracture strain

ISO/FDIS 28340

Combined coatings on aluminium - General specifications for combined coatings of electrophoretic organic coatings and anodic oxidation coatings on aluminium

BS ISO 14188:2012

Metallic and other inorganic coatings. Test methods for measuring thermal cycle resistance and thermal shock resistance for thermal barrier coatings

BS EN ISO 4628-6:2011

Paints and varnishes. Evaluation of degradation of coatings. Designation of quantity and size of defects, and of intensity of uniform changes in appearance. Assessment of degree of chalking by tape method

Key word search on ‘galvanize’ or ‘galvanized’ or galvanizing’ – 0 Standard Publications found.

Key word search on ‘corrosion’ and ‘concrete’ or ‘concrete’ and ‘coatings’ – 0 Standard Publications found Key word search on ‘cathode’ or ‘cathodic’ -2 publications found; none from AS of AS/NZS I.S. EN 16222:2012

Cathodic Protection of Ship Hulls

BS EN 16222:2012

Cathodic protection of ship hulls

Key word search on ‘anode’ or ‘anodes’ or ‘anodic’ – 1 Standard Publications found – None from AS/ANZS ISO/FDIS 28340

Combined coatings on aluminium - General specifications for combined coatings of electrophoretic organic coatings and anodic oxidation coatings on aluminium

Keyword Search on ‘electrochemical’ or ‘electrolysis’ or ‘electroplated’ - 5 Standard Publications found; None from As or AS/NZS UNE ISO 22734-1:2012

Hydrogen Generators Using Water Electrolysis Process - Part 1: Industrial And Commercial Applications

ISO 13129:2012

Paints and varnishes - Electrochemical measurement of the protection provided to steel by paint coatings - Current interrupter (CI) technique, relaxation voltammetry (RV) technique and DC transient (DCT) measurements

ISO 5814:2012

Water quality - Determination of dissolved oxygen - Electrochemical probe method

I.S. EN ISO 5814:2012

Water Quality - Determination of Dissolved Oxygen - Electrochemical Probe Method (iso 5814:2012)

BS EN ISO 5814:2012

Water quality. Determination of dissolved oxygen. Electrochemical probe method

Keyword Search on ‘anodize’ or ‘anodized’ - 0 Publications found

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

Future Leaders Forum Introduction: The ACA Future Leaders Forum is a 2 day personal and professional development program aimed to draw together young professionals from across the spectrum of the corrosion industry. It will focus on developing competencies in how to present technical papers, chair technical sessions, conduct group discussions and develop the art of expression and communication in a professional and friendly environment. The skills developed during this forum can easily be applied to work and other professional environments.

21-22 February 2013 Adelaide, SA, Australia Venue: The Sebel Playford, 120 North Terrace, Adelaide SA 5000 This forum is the first event in 2013 for The Australasian Corrosion Association’s Young Corrosion Group (YCG) which serves the purpose of organising and implementing events of value to younger members and those new to the corrosion industry and to provide a platform of access to information and networks which are of benefit to personal, professional and business development.

The Future Leaders Forum is made possible with financial support from ACA Foundation Ltd.

Facilitator: Geoffrey Witherow – Changing Organisations Geoff has extensive experience in the design and facilitation of professional development programs for leaders managing a range of issues in competitive market environments. Geoff focuses on providing people with skills to coach, influence and lead their employees. He also provides individuals with the space to explore the impact of their performance and behaviour, as well as techniques and motivation to enable them to implement change at a personal, team and business level.

Guest Speakers: Dean Ferguson, GHD – YCG VIC Branch Representative Kingsley Brown, AECOM – SA Branch President p.28 CORROSION & MATERIALS

Proposed Programme: Presentation Skills Chairing Technical Sessions Dealing with different Personalities in the workplace The Art of Leadership Maximising Associations – the benefits of Association Membership Importance of Networking & how to do it Using Conferences/Seminars for Personal Development

Applicants must be either Members of The Australasian Corrosion Association Inc. or be currently employed by one of the Association’s Corporate Members.

This Application must be supported by your employer (please provide a letter from your supervisor) Applicants must be currently working full time in the industry (full time students not accepted)

Mentoring

Costs:

Participant Presentations

Return flights to Adelaide, 2 nights’ accommodation, ground transfers and day catering for delegates will be organised and covered by the ACA. Dinner will also be provided on Thursday 22nd February. Any other costs incurred will be the applicant’s responsibility.

Future Activities- where to from here?

Application Requirements & Eligibility: There are 20 delegate places available for applicants aged 30 years or under; older applicants (who are new to the industry) are still welcome to apply, however preference will be given to those up to 30 years of age.

Applicants will be drawn from all areas of the corrosion industry. There is a maximum age limit of 35.

Applications will be accepted based on the information provided in the application form.

Applications Open: Monday 19th November 2012



Successful Applicants Announced: Thursday 20th December 2012

Applications Close: Monday 17th December 2012

Preparation: Delegates may be required to prepare certain tasks in advance of the Forum for group presentations. Up to 5 hours preparation may be required. Details will be provided to successful applicants.

For further information please contact: Katherine Webber +61 3 9890 4833 kwebber@corrosion.com.au



APPLICATION FORM Given Name

Surname

Organisation/Company

Position

Business Address Daytime Phone

Mobile

Email DOB Please describe your current position at your place of employment:

Please tell us how you would benefit from attending such a forum:

What is your current level of involvement with ACA and the Young Corrosion Group?

Applicants Signature Please ensure your statement of support from your supervisor is attached.

Submit completed application to: Katherine Webber | The Australasian Corrosion Association Inc. PO Box 112 Kerrimuir 3129 VIC kwebber@corrosion.com.au | Fax: +61 3 9890 7866

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

COATING INSPECTION CERTIFICATE

Coating Inspection Certificate Up until 2005 The Australasian Corrosion Association Incorporated conducted a 5 day Coatings Inspection Certificate Course. It was designed to provide the requisite skills and knowledge to inspect protective coatings following the requirements of Australian/New Zealand Standards.

The list below contains the names of qualified ACA Coatings Inspectors who have satisfied the requirements to be issued with an ACA Coatings Inspection Certificate and who have ‘refreshed’ their certificate within the 5 year time frame required by the ACA Council.

ACA Coating Inspectors Name

Cert.

No.

Expiry Date

Gary Abbott

4080

30/11/2013

Richard Adams

1230

19/04/2015

Andrew Aidulis

1404

30/06/2013

Dennis Ashman Travis Baensch Trevor Baensch Stuart Bayliss

390 4209 2211 247

30/01/2014 12/08/2015 12/08/2015 23/04/2014

Some inspectors have cross – accredited to the internationally recognised NACE Coatings Inspection Program. In those cases, the validity of their ACA certification has been reconfirmed.

Every care has been take to ensure that at the time of publishing the information is correct. The Australasian Corrosion Association Incorporated does not accept any responsibility for any consequences which may arise from the use of this information. Those wanting to engage a Coatings Inspector should rely on their own judgement and if necessary

seek other advice as to whether the person has suitable work experience and references for the work proposed.

No legal liability for negligence or otherwise can be accepted by The Australasian Corrosion Association Incorporated for the information or the use of the information contained in this listing.

If you have any queries please contact The Australasian Corrosion Association Incorporated directly on +61(0)3 9890-4833 or via email to aca@corrosion.com.au

Darrel Craig

2810

3/08/2014

Phillip Foster

2254

3/08/2014

Dean Crase

4137

6/07/2016

Rob Francis

720

31/12/2017

Jay Cumner

3492

11/06/2014

John Paul Fraser

3773

11/06/2014

Dean Currie

2092

3/08/2014

76

31/12/2017

David Daly

7343

31/12/2016

Robert Freedman Brett Gale

3774

12/08/2015

Kerry Dalzell

1052

30/05/2013

David Gates

2599

19/04/2015

Cheryl Dalzell

3940

19/04/2015

Ian Glover

393

28/02/2015

Roman Dankiw

872

30/11/2013

Shane Goggin

2857

13/08/2013

Ross Darrigan

1489

27/10/2013

Robert de Graaf

719

31/12/2017

Phil Goldsworthy

2083

27/10/2013

John Dixon

1118

11/06/2014

Frederick Gooder

88

3/08/2014

Ben Biddle

1279

28/02/2015

Mark Blacklock

3501

2/07/2015

Timothy Blair

2088

31/01/2014

Trevor Domin

4031

11/06/2014

Wayne Gray

3606

2/12/2014

Matthew Boyle

1429

30/04/2013

Peter Donovan

1888

30/01/2014

Ray Grose

2956

31/12/2017

Kingsley Brown

2603

31/10/2015

Peter Dove

1203

31/05/2013

Paul Haggerty

1433

31/10/2014

Sean Anthony Burke

3428

30/01/2014

Phill Dravitski

1593

31/03/2015

Jim Haig

394

12/08/2015

William Dunn

3386

27/10/2013

Harold Burkett

361

18/01/2013

Ray Harcourt

1326

23/04/2014

Elliot Burns

972

19/04/2015

Kenneth Dunn

1296

6/07/2016

Brian Harris

1054

9/09/2013

Micah Butt

2397

1/10/2013

Nick Edwards

1992

2/12/2014

Peter Hart

1

31/10/2015

Brian Carrick

1792

27/10/2013

Dave Elder

155

28/02/2013

Darrin Hatton

3206

30/01/2014

Luis Carro

2212

31/12/2017

Todd Elkin

3402

19/04/2015

Shane Hawker

7342

31/12/2016

Terry Carroll

1477

11/06/2014

John Elomar

4204

19/04/2015

Rohan Healy

3184

31/12/2017

Wayne Clarke

3603

11/06/2014

Tony Emery

4130

2/07/2015

Bronte Henning

178

31/10/2013

Ian Clifton

1160

31/07/2014

Tony Evans

2086

6/07/2016

Chris Heron

1619

31/05/2013

Gregg Cobban

2213

2/12/2014

Wayne Ferguson

893

31/12/2017

Don Herrigan

4033

12/08/2015

Rod Cockle

1410

30/11/2015

Greg Hill

1434

30/11/2013

2219

30/01/2014

John Cooke

3235

18/07/2013

Nathan Fernance

Shaun Hinks

3208

23/04/2014

Cameron Cooper

Chris Fisher

2985

9/09/2013

Frank Hiron

2888

30/05/2013

466

6/07/2016

Jerry Forslind

1129

31/10/2014

Matt Hollywood 1744

31/05/2014

p.30 CORROSION & MATERIALS

COATING INSPECTION CERTIFICATE

Paul Howe

3177

30/01/2014

Garry Matthias

1481

30/04/2013

Douglas Shipley

2221

2/07/2015

Paul Hunter

2988

31/12/2017

4352

6/07/2016

Michael Sillis

844

31/12/2017

Jeffrey Hurst

1746

30/05/2013

David McCormack

John Simoni

3596

2/12/2014

2/07/2015

Peter McCormack

4353

31/12/2017

Gary Smith

2512

3/08/2014

2218

30/11/2015

Trevor Smith

1035

31/12/2017

Gary Hussey

3984

Clinton Iliffe

4034

12/08/2015

Brett Meredith

Luciano Ioan

2965

18/07/2013

Andrew Miles

1031

30/09/2014

Laurence Snook

1526

31/12/2017

Basyl Jakimow

3230

23/04/2014

Wayne Mitchell

3357

2/07/2015

Vic Spunner

2272

18/07/2013

Tom Jensen

2889

2/12/2014

John Mitchell

1042

31/12/2017

Michael Stacey

1864

30/05/2013

31/12/2012

Colin Mogridge

2010

27/10/2013

2960

15/07/2013

9/09/2013

Vic Monarca

2053

6/07/2016

Dragan Stevanovic

Bryan Moore

462

23/04/2014

Steven Stock

3923

6/07/2016

Wessel Mulder

7351

31/12/2017

Lex Stolk

3216

31/10/2014

Peter Myatt

1907

11/06/2014

Steve Storey

3176

30/01/2014

Raymond Street

3173

31/05/2013

Peter Sutton

3183

31/12/2017

Wayne Johnson Robert Johnson

2576 2625

Matthew Johnson

2359

12/08/2015

Robert Johnson

3354

12/08/2015

Michael Johnstone

2964

18/07/2013

Peter Nicholson

4086

12/08/2015

Ross Kaddatz

3793

30/05/2013

Eric Norman

7430

31/12/2016

2087

27/10/2013

1121

30/05/2013

7353

31/12/2017

Michael Thorne

1825

9/09/2013

Stephen Keller

3212

30/05/2013

Dennis O’Loughlin

Adam Thomas

Roger Kearney

Sean O’Sullivan

1933

9/09/2013

Junior Tiaiti

2991

3/08/2014

Graeme Kelly

721

31/12/2017

Mark O’Sullivan

4059

30/01/2014

Russell Tierney

2000

2/12/2014

Shane Kennedy

3373

9/09/2013

Gerald Owen

7341

31/12/2016

David Towns

2702

27/10/2013

Donald Kirchner

1905

11/06/2014

Clifford Parkes

3607

2/07/2015

Dennis Tremain

1036

31/12/2017

Robert Kirkham

2009

30/01/2014

Rick Pascoe

2605

23/04/2014

1082

30/05/2013

2269

2/12/2014

David van Tricht Andy Vesco

3783

19/04/2015

Paul Vince

7355

31/12/2017

Leonard Kong

3538

3/08/2014

Stephen Pearce

Joseph Kowal

553

30/06/2014

Mervyn Perry

268

31/12/2017

1513

31/12/2017

Charles Vincent

1827

31/03/2013

Harry Kronberger

1516

2/12/2014

Lorraine Pidgeon

Narend Lal

3355

11/06/2014

Graham Porten

2257

3/08/2014

Andrew Walker

2969

18/07/2013

John Lane

1784

2/12/2014

David Power

2487

19/04/2015

David Walters

1910

11/06/2014

Alan Lee

3539

9/09/2013

Brian Probert

1190

31/07/2014

Troy Ward

2571

30/01/2014

David Lepelaar

3356

11/06/2014

John Puljak

3780

12/08/2015

Roy Warry

859

30/05/2013

Neil Alan Lewis

2598

30/05/2013

Barry Punter

1843

31/10/2015

Paul Weston

2129

23/06/2014

Daniel Lillas

4445

30/11/2014

James Rebetzke

1862

11/06/2014

Mark Weston

883

31/12/2017

Peter Luke

3795

11/06/2014

Greg Reece

3508

19/04/2015

Charles Wheeler

3943

19/04/2015

Jonathan Mace

4035

6/07/2016

Tony Ridgers

421

30/11/2015

Geoffrey White

75

31/10/2013

Rick Roberts

1316

28/02/2013

Peter Whitmore

681

30/05/2013

Dean Rowe

4200

2/07/2015

Gary Whittle

1794

31/10/2014

Stephen Sach

3013

30/01/2014

Craig Williams

4176

12/08/2015

Valentine Scriha 1896

12/08/2015

Kevin Sellars

7352

31/12/2017

Geoff Woodman

1171

31/07/2014

Kevin Sharman

627

30/11/2015

Stephen Yates

1615

30/05/2013

Tracey Sherman

1829

9/09/2013

Spencer Macsween

3170

Willie Mandeno

1216

31/12/2017

Bradley Marsh

3232

18/07/2013

Craig Martin

2276

18/07/2013

George Martin

669

2/07/2015

Robert Wayne Mason

1076

30/05/2013

31/12/2017

Please note: this list is current as at 21 November 2012

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

ACRA AWARDS FOR EXCELLENCE IN CONCRETE REPAIR AND PROTECTION Award winners raise the bar yet again T

he Australian Concrete Repair Association (ACRA) recently held their biennial Awards night in Sydney. This event was established back in 2000 to provide an opportunity for ACRA members to promote and showcase the great work they do in the field of concrete repair.

The Awards night is the biggest night of ACRA’s event schedule and was well attended by ACRA members, guests and their partners at the fantastic venue in Darling Harbour.

Commenting on the Awards night, ACRA’s president, Andrew Dickinson, said, “The awards showed yet again that ACRA members have raised the bar in terms of innovation, professionalism and overall excellence in concrete repair.

David Mahaffey observed that “Newly emerged technologies since the first ACRA Awards in 2000 have come a long way. One such example is the up-scaling of carbon fibre strengthening from a repair technique to a virtual construction technique on a scale many times greater than anything undertaken anywhere else in the world.”

While Ian Godson’s comment was: “I was particularly pleased with the number of entries this year from beyond Sydney.

From Newcastle, Coffs Harbour, Fairy Meadow and Swansea in NSW as well as Dampier and Kalgoorlie in WA, North Haven in SA, Melbourne in Victoria and Cairns in Queensland.

Showing that the organisation is truly coming of age as a national association, recognised around the country.

And the entries were...

There were eight categories judged this year, with the following outcomes:

Paul Sweatman (second left) accepted the crowning award for BASF under the eye of judges Ian Godson (l.), David Mahaffey (r.) and Sharyn Machin(c.)

Judges see trends The judges agree. Commenting on the trends that emerged this year, the judges offered fresh insights, each from his or her own perspective: Strata Community Australia (NSW)’s Sharyn Machin from a strata management perspective, Mahaffey Associates’ David Mahaffey from a technical standpoint and Infracor Consulting’s Ian Godson as a longtime observer of the evolution of ACRA as an organisation.

Said Sharyn Machin: “I was impressed by the way the member companies took away the project brief but did their own investigations, enabling them to come back to the client with a better, more practical approach. The way they dealt with the client was incredible—in the high range of professionalism.”

p.32 CORROSION & MATERIALS

Industrial / water / wastewater —mega projects Won by BASF Australia for the West Gate Bridge FRP strengthening upgrade project in Melbourne.

Chosen by the judges because of “the use of carbon fibre strengthening, which has provided a highly cost-effective and innovative remedy to a potentially very costly problem”.

Industrial / water / wastewater—large projects Won by Water Infrastructure Group for the rehabilitation of six maintenance holes, three on Northern Main Sewer and three on Southern Main Sewer. Chosen by the judges because “it is a complex project involving numerous repair processes as well as a very onerous requirement for client/public interface, which appears to have been managed well”.

Marine / industrial up to $3M—large projects Won by Duratec Australia/ Rio Tinto for the Rio Tinto Dampier Salt Ltd mooring dolphin remediation in Dampier, WA. Chosen by the

judges because “the contractor won the work on the basis of a well thought out alternative design that provided the client with significant cost savings”.

Also in this category, a merit award went to GHD for the Swansea Bridge rehabilitation because “the entry provides good detail of depth of the investigation, design and implementation process [factoring in] the complexities of considering impacts on flora and fauna into the design and construction process”.

Residential—large projects Won by RM Watson for Nathan Towers in Neutral Bay. Chosen by the judges because of “the management aspects of the project [given that], whilst it appears to be a relatively straight forward project from a technical point of view, the way in which the project was run required well-planned interactions and scheduling to ensure that the needs of all parties were met”.

Also in this category, a merit award went to Dapcor Building Services for Marine Parade remediation in Maroubra because “it illustrates the opportunity that exists to do more than just concrete repair, thereby adding significantly to the value of a building”.

Marine / industrial— medium projects Won by Marine & Civil Maintenance for Brooks Creek & Fairy Creek Bridges concrete repair and cathodic protection in Fairy Meadows. Chosen by the judges because “even though it appears to be a normal concrete repair/CP project, there was a need to adapt to adverse conditions and apply a wide range of repair and protection systems”.

Commercial/residential up to $1 million— medium projects Won by Diagnostech for Miramar Apartments in Sydney. Chosen by the judges because of “the care taken in the investigation and planning of the concrete repair work to a heritage building”.

Also impressive was “the use of the expertise that exists within the ACRA network”.

Small projects Won by Volumetric Concrete Australia for the Taxiway A1 trial slab replacement at Sydney Airport.

Chosen by the judges because “it displays an innovative approach to the problem of timely completion in airport pavement repair work”.

Long term performance Won by Consolidated Quality Projects for the United Dental Hospital in Surry Hills. Chosen by the judges because “this project is a fitting recipient of the award as testimonials by the membrane supplier and original consulting engineer confirm the project is performing well after eight years”.

And the award of awards Repair industry Excellence Award went to BASF for the West Gate Bridge FRP strengthening upgrade project in Melbourne This the judges described as heralding a new era, not only in the sheer scale of the project, but also because of the emergence of carbon fibre strengthening from a repair technology into the mainstream of construction work.

Wrap-up President Andrew Dickinson presented the awards at a cocktail party in Darling Harbour and wrapped up the evening by thanking all who attended, but particularly those who made submissions and the judges who sweated over the task of making the hard choices between them. “As a showcase of how good teamwork between consultant, materials supplier and contractor can achieve best possible outcomes, the ACRA Awards for Excellence have once again set the standard against which all concrete repair work will be judged.” At least, that is, until the next Awards in 2014, when we expect ACRA members will raise the bar yet again.

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

TECHNICAL INTRODUCTION

Designing For Corrosion Protection – Part 2 In the previous discussion, various common traps for steel designers that can compromise corrosion protection were examined. This theme is continued here, including a discussion on sheltering, in the author’s practical experience, one of the most prevalent corrosion issues in coastal infrastructure and dwellings.

Sheltering The concept of “sheltering” and how it causes accelerated corrosion can be a difficult concept for designers to understand. The term “sheltering” with respect to corrosion protection can be counter-intuitive at first glance since sheltering will normally evoke thoughts of extra protection.

Steel that is sheltered is not exposed fully to the elements, but the external atmosphere still has access to it. A common example of a sheltered building component is an eave. The material under the eave is exposed to the environment, but it does not normally have rain falling on it or direct sunshine. This means that it is not subject to either the washing effect of the rain or the drying effect of the sun. If the component is located in a coastal area, then it is likely that there will still be the deposition of salt spray on any steelwork under the eave. This salt spray is then allowed to sit on the surface of the steelwork without being promptly dried by the sun or washed off by the rain. This means that the corrosion process can be accelerated compared to if it were fully exposed.

Sheltering affecting a paint coating.

p.34 CORROSION & MATERIALS

A further complication is that when the salt spray eventually dries, the chloride solids are left behind because they are not washed away by the natural process of rain. At times of high humidity or condensation, the chlorides will again be dissolved, but this time, the moisture will have a much greater concentration of salt than would normally be the case.

This is because a larger amount of chloride solids are dissolved in less water than would be the case for the original seawater. This increases the conductivity of the solution making it a more efficient electrolyte.

The greater conductivity causes accelerated corrosion of the so-called “sheltered” steelwork.

It is important in corrosive environments that sheltered steel is designed out where possible and, if this is not possible, then greater corrosion protection is required.

Corrosion protection systems that rely on the drying-wetting cycle to develop a protective patina to perform at their optimum level are particularly susceptible to sheltering.

This includes galvanized steel and electroplated steel. For example, in galvanized steel, the interruption of the drying-wetting cycle will retard or totally prevent the development of the protective zinc carbonate patina (refer Corrosion and Materials April 2012 p 41). The lack of a patina greatly reduces the protective capacity of the galvanized steel.

An example of designing out the problem of sheltering in a coastal environment is the Geelong Carousel Pavilion in South Western Victoria.

The structure is located directly on the foreshore of Port Phillip Bay. The Pavilion houses the oldest and most valuable carousel in Australia, hand carved in the United States in 1892.

All of the structural steel in the Pavilion is hot dip galvanized and most of it is exposed to the sea. The design of the overhanging roof on the Pavilion means that sheltering would be an issue as it faces directly onto the sea with the prevailing winds regularly blowing salt spray onto the structure. The design of the structure paid due consideration to corrosion through the use of bolting, the minimization of “corrosion hotspots” due to proper detailing and the expanded metal roofing that reduced the wind loading and allowed the beneficial washing effects of rain on the external steelwork.

Appropriate Material and Corrosion Protection Systems for Specific Environments The best design will not mask the problems of inappropriate material selection. Materials that perform well in one environment can perform poorly in another. Microclimates can cause a significant difference in corrosion performance even on the same structure. Also, the location and orientation of the structure (notwithstanding the corrosivity of the environment) can have an impact on

Corroded steel beam protruding from under an elevated house in a sheltered position in a coastal environment.

TECHNICAL INTRODUCTION

Geelong Carousel Pavilion – note areas that would normally be sheltered are accessible to washing and drying due to use of expanded metal mesh for external roofing (courtesy City of Greater Geelong).

Steel stump under house in coastal setting – it was impossible to determine original coating from observation.

Materials also perform differently on exposure to various atmospheres or contaminants in the environment.

Using the example of galvanized steel again, it behaves amphoterically, like aluminium and lead. Amphoteric metals will tend to corrode at both a low pH and a high pH. In the case of galvanized steel, it actually performs a little better at a higher pH than a lower one, but for the sake of this example, it is sufficient to say that the performance at either end is worse than if it were in

HCI

0

2

4

Alkaline: film dissolving

Stable film

Acid: film dissolving

Galvanized steel, as can be seen from the discussion above on sheltering, is much more suited to environments where it is exposed to the washing effect of the rain and the drying effect of the sun. Placing galvanized steel (without extra protection) in sheltered or continuously damp and shaded areas will usually result in more rapid deterioration of the steelwork due to the inability of the galvanizing to develop its protective patina. Examples of this include swimming pools, under jetties, in manufacturing processes with high humidity or condensation and so on. In these sorts of areas, then extra protection is required or galvanizing may be dispensed with altogether in favour of another protection system, for example a multi-coat paint system or even another material might be considered instead of mild steel.

a neutral environment of pH around seven. There is nothing a designer can do except to account for the fact that galvanized steel has an increased rate of corrosion and therefore reduced durability if the environment is acidic or highly caustic. The designer may find that the required compromises require the use of an alternative material or corrosion protection system.

Corrosion Rate

the selection or otherwise of what is the most economical and durable method of corrosion protection. It is always important to remember that corrosion protection is definitely not a “one size fits all” process, rather a number of issues need to be considered and then a selection made from the available alternatives. Rarely is there a single solution to a corrosion problem.

NaOH

6

8

pH

10

12

14

16

Graph of pH vs corrosion rate of zinc (GAA).

Engineered coatings, such as paints, can be developed with specific characteristics and used in coating systems that will allow them to perform well in particular environments. This means that systems can be developed and used for specific situations. Such environments can include indoor swimming pools, pulp and paper mills, acidic mining activities and highly corrosive coastal situations such as oil platforms and wharves.

On occasions, the economic viability of a corrosion protection system will not be totally dependent on its corrosion protection characteristics. The selection of the appropriate corrosion protection for steel might be more dependent on initial economic savings coupled with substantial economies in service.

These economies can be the result of the reduction or elimination of maintenance and its associated labour costs and lost service time and also in the deferral of the replacement of structures and equipment. For example, the remote location of many infrastructure installations places great demands on the transportation and erection of steelwork that will minimise damage to corrosion protection coatings and also reduce the cost of travel for maintenance. The robustness of a corrosion protection material may then take precedence over lower cost corrosion resistance. Alternatively, systems that can be easily set up on site, such as cathodic protection or wrapping tapes may make them more suited to applications where large amounts of steel need to be transported over large distances.

The above comments need to be taken in context. For example, in an architectural application, the robustness of a coating may still not be suitable since precautions will need to be taken to prevent scratching and scuffing of the final finish. The steelwork may be fit for purpose from a corrosion resistance aspect, but its aesthetic functionality may not be so.

In an instance such as this, alternative corrosion protection systems could be considered economically superior when weighed up against the fact that the coated steel will require extra care and materials in packing and transport

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

TECHNICAL INTRODUCTION

and this will add to the relative cost.

This also includes issues such as on-site maintenance and repair.

Structural engineers, architects, steel fabricators and various contractors need to work together to determine the best economic and durability outcome of their specific corrosion protection systems.

Welding Fasteners were discussed with respect to dissimilar metals in the previous article, however, welding of structural steel also presents issues for corrosion protection and there are number of potential problems that can occur.

A poor weld can introduce pinholes and cavities that will be difficult to protect with most coatings and will also trap contaminants that can accelerate corrosion. It is important that welds are produced with the least amount of “imperfections” possible. Pinholes and cavities are not only unsightly, but they pose a real risk to the integrity of the corrosion protection system at the weld.

Also, depending on the procedure used, welding can produce “splatter” of the weld material onto other areas of the steel. Splatter is not only unsightly, it can diminish the durability of steelwork. If splatter is not removed during the preparation for coating, it can result in the protective coating over the splatter material not achieving an adequate thickness and therefore increasing the likelihood of corrosion.

This is exacerbated by the fact that the small metallic particles will corrode more quickly. Although this sort of initial corrosion is not usually a problem in terms of structurally compromising the steel, it can leave unsightly rust streaks.

achieved through the use of zinc rich paints of which there are a number of different types and systems depending on the corrosivity of the area in which the steelwork is to be placed in service.

This is generally successful in inland and benign environments, but the welding and repair of steel in coastal areas is difficult to achieve successfully and normally is not recommended.

It is not only a matter of selecting the correct zinc rich paint, but the application must then be followed exactly as per the manufacturer’s instructions. This is not impossible, but can often be difficult to achieve in coastal areas with their high humidity and constant salt spray. It would be preferable to use an alternative system such as bolting which insures that all of the steelwork is protected by the same system. It is worth noting, that due to their lower zinc thickness, galvanized bolts will require greater inspection and maintenance.

Stainless steel also requires careful attention after welding. This is not only due to the routine issues of splatter and other contaminants. The temperature required during some welding processes can result in surface defects and contamination that can reduce the life of the steel. The heating can result in discolouration of the steel around the weld known as “heat tint”. This discolouration indicates the formation of chromium oxide scale on the surface of the stainless steel. These oxides reduce the corrosion resistance of the steel and need to be removed together with the chromium depleted layer beneath during post-welding treatment.

Refer to the ASSDA website for further specialised information.

A similar problem can occur on galvanized steel that is welded after galvanizing. The splatter lands on the surface of the surrounding galvanized steel and if it is not promptly removed, it corrodes and then marks the surrounding the area with a distinctive “rusty” colour. This is very difficult to remove without damaging the galvanizing.

Another problem introduced with the welding of galvanized steel is that it requires that the galvanized coating be removed in the area of the weld due to OH&S reasons (fumes) and also to ensure the integrity of the weld. This means that the weld area then needs to be repaired, ideally to a level matching or exceeding the corrosion protection level of the galvanizing. This is usually

p.36 CORROSION & MATERIALS

a suitable base so that the dry film thickness of the coating will meet the manufacturer’s recommendations and not compromise the corrosion protection of the steel structure. Some examples from AS/NZS 2312 of poor detailing and recommended detailing are shown below. (p) Poor weld finish affecting surface coating Protective paint system

Irregularities

Weld insufficiently flat Accumulated dirt

(AS/NZS 2312).

Satisfactory weld preparation Smooth weld surface

(AS/NZS 2312).

Conclusion Designing for the corrosion protection of steelwork involves much more than just selecting a protective coating or system. The design of the steelwork will greatly affect the efficacy of any system selected and this should be taken into consideration at the initial design stage, not just as an afterthought at the conclusion of the design and specification stage. Economic considerations also play a significant role in the selection of corrosion protection systems and should not be ignored in the interests of just considering the first suitable system.

A general knowledge of both effective steel design and different protective systems will give professionals involved in the specification and design of infrastructure a well-stocked “toolbox” with which to work.

Emmanuel Pimentel

Galvanized bridge rail on the Great Ocean Road Victoria – note the attempted repair with zinc rich paint and its performance compared to the surrounding galvanizing (courtesy Vicroads).

One of the most important detailing factors for a weld is to make it as smooth as possible prior to the application of a protective coating.

This will insure that the weld provides

Acknowledgements and further reading AS/NZS 2312 – Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings Australian Stainless Steel Development Association (ASSDA): www.assda.asn.au Galvanizers Association of Australia (GAA): www.gaa.com.au

COATINGS GROUP MEMBER PROFILE

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

A: MAC Coatings Pty Ltd was established in 1998 by Managing Director Denis McElligott after 20 years in the industrial painting industry.

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

A: In its inception MAC Coatings employed 4 people.

Q: How many do you currently employ?

A: MAC Coatings currently employs around 12 fulltime workers. Depending on projects this has increased at times to 20-25.

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

A: MAC Coatings main offices are in North Shore, Geelong. However we conduct works right across the state including Geelong, Melbourne, Gippsland and Murray Regions. We also service other states including works in South Australia and New South Wales.

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

A: Our core business is surface preparation and application of protective coatings. This encompasses a range of techniques and services including, brasive Blasting, A High Pressure Washing, Application of High Build Coatings Tank and Pipe Preparation and Coating Floor Coatings Pipe Wrapping Preparation and coating of all steel structures Concrete corrosion control Decorative coatings Q: What markets do you cover with your products or services? eg: oil & gas, marine, chemical process, general fabrication, tank lining, offshore etc.

A: MAC Coatings service both the industrial and commercial sectors.

The majority of our work however, is in the Petro Chemical and Waterboard industries. Projects often include preparation and coating new/existing tanks and pipes, long term asset maintenance, spot corrosion control and complete blast and recoat. We also apply coatings to commercial building such as, schools, factories, offices.

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

A: Our work is both yard and site based.

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

A: MAC Coatings facilities in Geelong are situated on over 3 acres and offer a massive undercover blasting booth and spray booth. Our ability to work on site runs parallel with our ability to work off site with a number of mobile blast units servicing our client’s needs.

and design make this very aesthetically pleasing on the eye, while still keeping corrosion at bay.

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

A: At MAC Coatings we believe investing in your employees is essential. Training and development of staff ensures they have the knowledge and skills required to complete the task. The works we conduct are specific, and critical in the fight against corrosion, doing it right the first time brings a positive outcome for both client and contractor.

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

A: MAC Coatings has an internal training scheme but also uses the services of external training sources when required.

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

A: MAC Coatings strive to provide the best asset protection. With our full ISO accreditation in OHS, Quality and Environment we ensure all projects are completed safely and to a high quality.

We conduct a range of specialty works including confined space, heights, full encapsulation works, floor coatings and concrete corrosion repairs.

MAC Coatings Pty Ltd 1 Coonil Crescent North Shore Vic 3214 PO Box 167 Corio Vic 3214 Ph – 5277 1243 Fax – 5272 2631 www.maccoatings.com.au

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

A: Two of the most satisfying projects MAC Coatings have completed the last two years include: Potable Water tank at Inverloch for South Gippsland Water – MAC Coatings were engaged to conduct complete blast and recoat of the internal and external of the tank. This project was particularly pleasing as MAC Coatings achieved a high quality outcome, with great client satisfaction.

Werribee River Pedestrian Bridge – MAC Coatings were required to abrasive blast and apply protective coatings to the internal and external walls of the bridge. Its striking colour

Werribee Pedestrian Bridge.

Inverloch Water Tank.

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

ACA CORPORATE MEMBERS

ACA Corporate Members PLATINUM MEMBERS

Standard

Jotun blue

Black and white

GOLD MEMBERS Remedia Consulting Pty Ltd

p.38 CORROSION & MATERIALS

ACA CORPORATE MEMBERS

ACA Corporate Members Corporate Silver

Corporate Bronxe

Action Alliance Group

A. S. Harrison & Co Pty Ltd

Anode Engineering Pty Ltd Applus RTD Pty Ltd

AB and P Abrasive Blasting & Painting ABSAFE Pty Ltd Acacia Corrosion Control

Arup Pty Ltd

ACTEW Corporation Limited

Atteris Pty Ltd

Adtech FRP Pty Ltd

Australian Maritime Systems Ltd

Advanced Aqua Blasting

Australian Pipeline Trust Management Services - APA Group (WA)

Airservices Australia

Cape - Australia

Alfabs Protective Coatings Pty Ltd

CTI Consultants Pty Ltd

Alloy Yachts International Ltd

Elite Concrete Protection & Repair

Albany Port Authority

Allunga Exposure Laboratory AMAC Corrosion Protection Pty Ltd

Engineered Surface Preparation

Andersal Pty Ltd

Extrin Consultants

Anti Corrosion Technology

Favcote Pty Ltd

APA GasNet OPS Pty Ltd

Galvanizers Association of Australia

APT AM Holdings Pty Ltd

Geopave/Vic Roads Grange Resources (Tasmania) Pty Ltd

ARC West Group Pty Ltd ArmorGalv (Aust) Pty Limited ASC Pty Ltd

Hobson Engineering

Asset Integrity Australasia Pty Ltd

Hydro-Chem Pty Ltd

ATCO Gas Australia

Kaefer Novacoat (WA) Pty Ltd

Aura Engineering Pty Ltd

Melbourne Water Oliver Spray Equipment

Aurecon Australia Pty Ltd Aurecon PPI Ausblast

Olympus Australia

Auscor Pty Ltd

Opus International Consultants Ltd

Austral Wright Metals

Origin Energy

Australian National Maritime Museum

Pan Abrasives

Ausvic Pty Ltd

Petro Coating Systems Pty Ltd Plant & Platform Consultants Ltd

BAE Systems Australia BASF Australia Ltd Bayer Material Science Pty Ltd

Rhino Linings Australasia Pty Ltd

BCMG Pty Ltd

RKF Engineering Services

Blastcorp Pty Ltd

Rosen Australia Pty Ltd

Bluey Technologies

Rotafab Pty Ltd Scientific Solutions Pty Ltd

BP Refinery (Bulwer Island) BP Refinery (Kwinana) Pty Ltd BRANZ Limited

South Coast Surface Protection

Brisbane Abrasive Blasting

Supreme Steel Products Ltd

Buel Pty Ltd

Telstra Corporation

Bundaberg Sandblasting Pty Ltd

Transpacific Industrial Solutions Veolia Environmental Services

C. P. Plating Pty Ltd Caltex Australia Petroleum Pty Ltd Caltex Refineries (QLD) Ltd

Water Corporation of Western Australia

Cameleon Paints

Worley Parsons Ltd

Cathodic Diecasting (QLD) Pty Ltd continued over…

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

ACA CORPORATE MEMBERS

CEM International Pty Ltd

Holmes Consulting Group

Centreport Limited

Horiso Pty Ltd

Champion Technologies

Hunter Water Australia Pty Ltd

Chevron Australia Pty Ltd

HVAC Queensland Pty Ltd

Chiron Chemicals

Hydro Flow Pty Ltd

City West Water

Hydro Tasmania

Clarkes Painting Services

idec Protective Coatings Pty Ltd

Clavon Pte Ltd

Inductabend Pty Ltd

Commercial Industrial Painting Services Pty Ltd

Industrial Composite Contractors

Contract Resources Pty Ltd

Industrial Galvanizers Pty Ltd

CORE Water Management Solutions Pty Ltd

Innovative Corrosion Management Pty Ltd

Corrosion Electronics Pty Ltd

Inspec Consulting

Corrosion Specialists Pty Ltd

Inspection & Consultancy Services Ltd

Costin Roe Consulting

Integrated Petroleum Solutions

Couplertec Electronic Rustproofing

International Corrosion Services Pty Ltd

Cox Coating Pty Ltd

Intertek Moody

Cradle Mountain Water

Invensys Rail Pty Ltd

Crest Restoration Services Pty Ltd

Ionode Pty Ltd

CSIRO CMSE

IPCQ

Dapcor Building Services Pty Ltd

ITW AAMTECH

DBP Transmission

ITW Buildex

Department of Transport and Main Roads

Jacobsen Colourplus Ltd

Dept for Manufacturing, Innovation, Trade, Resources and Energy

Jurong Shipyard Pte Ltd

Dept of Infrastructure, Energy & Resources

Keppel Prince Engineering Pty Ltd

Dept of Transport

KGB Protective Coatings

Diagnostech Pty Ltd

Korvest Ltd - Galvanising Division

Dimet Anti-Corrosion Pty Ltd

Kulin Group Pty Ltd

Doito Pty Ltd

Linetech Consulting

DSTO

LinkWater

Dulux NZ Ltd

Liquigas Ltd

EM&I (Australia) Pty Ltd

Longmont Engineering

Emeco International

Loy Yang Power Ltd

Energex Ltd

Lyttelton Port of Christchurch

Energy Safe Victoria

M Brodribb Pty Ltd

Energyworks Ltd

M. Waters Abrasive Blasting Services

Esso Australia Ltd

Mac Coatings Pty Ltd

Firma Industries

Mahaffey Associates Pty Ltd

Fremantle Ports

Maintenance Systems Pty Ltd

Fremantle Sailing Club

Marden Corrosion Services P/L

Freyssinet Australia Pty Ltd

McBerns Pty Ltd

Germanischer Lloyd (Australia) Pty Limited

McCoy Engineering Pty Ltd

Giovenco Industries (Aust) Pty Ltd

McElligott Partners Pty Ltd

Gippsland Cathodic Protection

McElligotts (Tas) Pty Ltd

Gippsland Water

McKechnie Aluminium Solutions Limited

Gladstone Ports Corporation Ltd

Metal Spray Suppliers (NZ) Ltd

Gladstone Regional Council

Methanex New Zealand Ltd

GORODOK Pty Ltd

Metrocorp Technologies

GPR Electrical (WA) Pty Ltd

Metz Specialty Materials Pty Ltd

Greater Wellington Regional Council

Mighty River Power

Halcrow Group Limited

Mills Sign & Painting Service

HERA

Mobil Refining Australia Pty Ltd (Altona Refinery)

p.40  CORROSION & MATERIALS

ACA CORPORATE MEMBERS

MTK Consulting

Shell Refining Australia

Multicoat Pty Ltd

Shoreguard Marine

Nalco Australia Pty Ltd

Sika (NZ) Ltd

Nanmah Pty Ltd

Sika Australia

NDT Equipment Sales Pty Ltd

Silver Raven Pty Ltd

New Zealand Aluminium Smelters

SLH Contracting (2008) Ltd

New Zealand Steel Ltd

South East Water Limited

Newcastle City Council

Southern Cross Building Products

NMT Electrodes (Australia) Pty Ltd

Special Metals Pacific Pte Ltd

Norblast Industrial Solutions Pty Ltd

Structural Systems (Remedial) Pty Ltd

North Queensland and Bulk Ports Corporation

Sulco Limited

Northport Ltd

Summit Fertilizers

NPC Industries Pty Ltd

SunWater Limited

NZ Refining Co Ltd

SVT Engineering Consultants

Orrcon Operations Pty Ltd

Syntech Distributors Ltd

Osborne Cogeneration

TAFE NSW - Sydney Institute

OSD Pipelines

Tandex Pty Ltd

Outokumpu Pty Ltd

Tas Gas Networks

Pacific Quality Corrosion Control

Tasmanian Ports Corporation Pty Ltd

Pacific Remedial Solutions

The Valspar (Australia) Corporation Pty Limited

Pacific Resins Pty Ltd

Thomas Contracting Pty Ltd

Paint N Colour

ThyssenKrupp VDM Australia Pty Ltd

PCCS Trust

Tincone Pty Ltd

PCWI International Pty Ltd

Titanium Anode Corporation Pty Ltd

Phillro Industries Pty Ltd

Titanium Electrode Products (Australia) Pty Ltd

Polymer Group Ltd

Total Corrosion Control Pty Ltd

Port Kembla Port Corporation

Total Paint Protection

PPG Performance Coatings (M) Sdn Bhd

Total Surface Protection

Prendos New Zealand Ltd

Townsville Port Authority

Preservation Technologies

Transcote Pty Ltd

ProDigital Pty Limited

Transend Networks Pty Ltd

Prokote Pty Ltd

Transfield Services

Pumpline Pty Ltd

Transpower New Zealand Ltd

QLD Dept Main Roads - Structures Division

Tri-Star Industries Pte Ltd

QLD Painters & Maintenance Services Pty Ltd

Tropical Reef Shipyard Pty Ltd

Queensland Alumina Ltd

Tyco FCP

Queensland Nickel Pty Ltd

Tyco Water Pty Ltd

Queensland Sugar Limited

Universal Corrosion Coatings Pty Ltd

Queensland Urban Utilities

Valicote Pty Ltd

Quilter Consulting Pty Ltd

Vector Gas Limited

Rail Corporation

Vincent Painting

Reinforced Earth Pty Ltd

WAG Pipeline Proprietary Ltd

Reno Blast

Wairau Paint Centre Ltd

Resene Paints Ltd

Wannon Region Water Corporation

Rheem Australia Pty Ltd

Waterway Constructions Pty Ltd

Rightway Industrial Ptyl Ltd

Willall Industries Pty Ltd

RM Watson Pty Ltd

Woodside Energy Ltd

Roads and Maritime Services

Yarra Valley Water

Rust Bullet Australia Rust-oleum Industrial Coatings

Corporate Member list accurate as of 22/11/2012

SGS NZ Ltd

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

MEMBER TALES FROM ABROAD

Qatar: A Small Land of Great Opportunities for the Australian Corrosion Industry One of the unavoidable impacts of the global financial crisis (whose impact on Australian industries and universities alike can still be felt) was a change of career (even temporarily) for some professionals in the field of corrosion technology. I was not an exception, therefore, after a one year fixed contract with Curtin University (Dept. Of Civil Eng.), I accepted an offer by The Centre of Advanced Materials at Qatar University.

The state of Qatar is located on the southern shore of the Persian Gulf.

Its immediate neighbour by land is The Kingdom of Saudi Arabia and its neighbours by sea are The Emirates and The Kingdom of Bahrain. Like many of the Gulf Cooperation Council (GCC) members, the majority of the population are mainly expats (while the total population of Qatar is estimated around 1 million, only about 200 thousand are Qataris).

It was a first-ever experience and like all such experiences, it was both exciting and terrifying! After I arrived in Qatar and started to know my environment, I realised that all of my fears were baseless. Qataris are very kind people and because of the cosmopolitan nature of their society, it is quite easy to blend with the locals and understand and like their customs and traditions. I also found that Qatar is one of the safest countries for foreigners to visit.

As the Assistant Professor of Corrosion Engineering and Materials Science, my role was to work with the local industry, prepare research proposals and establish a professional culture of corrosion and materials.

While Qatar is known for the world’s largest natural gas reservoir (The Northern Dome which is jointly used with Iran), this small Gulf State also has oil and mining industries such as aluminium and steel production.

QATALUM, for example, is a joint

A visit to QATALUM Aluminum Plant

venture between Qatar and Norway (Hydro). The products of QATALUM are exported to countries such as China to be later used in making products such as anodes.

The biggest oil & gas company in Qatar is QP (QatarPetroleum). There are other companies that are active as either main operators or running their refineries such as RasGas, QatarGas, ExxonMobil, Dolphine Energy, Shell Refinery and so on. In addition to all that, for a country where more than 80% of its water is produced via desalination, water and wastewater industry are of vital importance. This is in addition to the relatively huge desalination units which are now operative and those that will be soon in circuit.

Also, many North American universities such as Texas A&M have branches in Doha (the capital). All these branches are located at “Education City” which is a technological compound near Doha.

Qatar has one national university,

A session with female high school

A view of RasGas Refinery students on “Al-Bairaq” program in Qatar with a group of QU students Head of the Centre for Advanced Materials, Dr. Mariam Corrosion A short view of Materials Characterisation and

A. Al-Maadeed (3rd from left, front row) with a group of students & academics from NTNU university (Norway) p.42 CORROSION & MATERIALS

at QU Laboratory of The Centre of Advanced Materials

MEMBER TALES FROM ABROAD

The Albairaq Team with some of the male students

A view of “Pearl” of Doha

A view of the CBD of Doha near The Persian Gulf

“Katara” beach near Doha at night Qatar University, where among science, engineering and humanities, corrosion is also taught and researched.

The Centre of Advanced Materials at Qatar University has very good facilities for corrosion investigation, NDT, welding, mechanical testing and materials characterisation.

This Centre has very robust relationships with both the local industries (in the areas of applied research, consulting and problemshooting as well as design and performing of industry short courses) and universities (collaboration on organising joint research projects and annual conferences) as well as highly reputational international university and research centres.

It may be surprising for some readers to know that I was not teaching under and post-graduate students; I was employed to concentrate more on design, materials selection, failure analysis, training Post-Doc researchers, equipping the metallurgy and corrosion laboratory as well as actively communicating with reputable international research institutes and universities to define joint venture research (both applied and fundamental) proposals.

To gain closer correspondences with the local gas, oil and mining industry, I implemented “lunch-on” lectures on corrosion and especially MIC. During these short presentations

during lunch breaks, I delivered the main ideas about corrosion management techniques, microbial corrosion, concrete deterioration (in Qatar, instead of liquid water, ice is used to make up the concrete and this concrete can bring about some interesting features such as decreasing the possibility of biodeterioration due to the use of frozen water) and the like topics. Also I was actively taking part as both key speaker and member of consulting panels where in the region were being organised in relation to subjects such as integrity management in oil and gas industries or pipeline corrosion management.

Attending these conferences in addition to those organised regularly by Qatar University’s Materials Technology Unit gave me invaluable opportunities to establish interpersonal networking with both corrosion professionals and senior industry management.

All of my efforts started to become fruitful after about seven months or so as industry started to renew and re-establish ties with Qatar University.

Our proposals for better integrity management as well as problem solving and taking part in forensic engineering and materials selection and design practices started to result in getting more consulting jobs.

program which is still going on and is one of the most successful educational enterprises in the region, secondary school students were being trained in topics such as corrosion, concrete technology and polymer science by the university academics. They were given experiments to carry out and were asked to interpret the results, write a report and then present it at three levels: for their peers and teachers, for a selected committee of university academics and finally to present their projects in front of the University President, and a panel of judges mainly consisted of the scientific adviser to the Amir, a representative from UNESCO and industry representatives such as the CEO of ExxonMobil Qatar. Before I left Qatar, the last Al-Bairaq had been fully sponsored by Shell Qatar.

The only continent that has no active presence in either Qatari industry or research is Australia. It was heart breaking to see that Australia does not have a consulate there. While universities such as Wollongong University have branches in Duabi, for example, no Australian university has any presence in Qatar. CSIRO is not a known name while the Dutch TNO (which more or less is the Dutch equivalent of CSIRO) has a very active presence at Qatar Science and Technology Park. Australian corrosion professionals are not known in Qatari industries and with subsea oil and gas projects coming along, the empty place of Australian corrosion professionals was felt even more. Personal experiences showed me that there is a great potential in the Qatari market for Australians. Especially in corrosion protection and design (materials selection, CP design and equipment, coating, MIC) which are among areas where QP, RasGas, QATALUM and the like industries are showing great interest to negotiate with Australian educated corrosionists. With no doubt, the Qatari industry and research community can be regarded as a golden opportunity for Australian enterprises especially now that regular direct flights

by QatarAirways from Perth to Doha have become operative.

Dr. Reza Javaherdashti (Former) Assistant Professor of Corrosion and Materials and Senior Industry Consultant at The Centre of Advanced Materials, Qatar University

In addition to all that, The Centre for Advanced Materials also initiated an educational program that was known as “Al-Bairaq” (The Flag). During this

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

PROJECT PROFILE

Restoring the Pride of an Australian Icon Structural Systems (Contractor) in conjunction with Diagnostech (Superintendent) were engaged on behalf of the NSW Office of Environment and Heritage for the restoration works to the Green Cape Lighthouse in Eden, New South Wales.

This heritage listed icon of Australia is well over 100 years old and boasts the beginning of a construction revolution in Australia.

29 metres, it is the second tallest lighthouse in New South Wales. It is situated in the picturesque Ben Boyd National Park, 25km south of Eden.

Green Cape Lighthouse The Green Cape Lighthouse was built in 1883 and was the first cast concrete lighthouse tower in Australia and also the largest mass concrete structure in New South Wales at the time. At

The existing, corrosion affected state of the Lighthouse at the time of the works was in principal due to the harsh Category E environment of the peninsula and surrounding natural reserve.

The Green Cape precinct is made up of the Lighthouse Tower and attached Oil Store along with two separate living quarters - those being the Head Keepers Cottage and the Assistant Keepers Cottage.

Figure 2 – Lighthouse Tower prior to works.

Restoring the Pride Restoration works began in June 2012 and involved a number of repair methods and application designed to ensure the precinct was returned to its former glory.

Due to the unusually high exposure levels of salts on the precinct, a completely enclosed / wrapped scaffold system was utilised during the restoration process. This approach helped to minimise the direct line of attack from winds and air-born chlorides when attempting delicate tasks such as that of re-coating the lighthouse. The proprietary system known as Monarflex can be seen in Figure 1.

Lighthouse Tower and Oil Store The Lighthouse structure and attached Oil Store, both contained significant areas of cracking and spalling concrete which needed to be addressed. The Oil Store in particular presented a challenge, as large horizontal cracks had developed both internally and externally.

Figure 1 – Lighthouse Tower complete with scaffold and encapsulation.

p.44 CORROSION & MATERIALS

The Oil Store stands directly attached to the Western elevation of the lighthouse tower. Given its heritage significance and existing state, an in-depth understanding of its original construction was required prior to determining a remediation method that would best suit this independent element of the lighthouse.

PROJECT PROFILE

Having been one of the first reinforced mass concrete structures in Australia, the current state of the Oil Store was evidently exhibiting severe lateral cracking which was occurring at regular intervals around the perimeter of the structure.

This cracking was being caused from the severe corrosion of what appears to be steel reinforcing bands within the concrete walls of the Oil Store.

Investigation pockets were opened during the early stages of the works to confirm this – Figure 3 shows the state of the steel bands effectively causing these lateral cracks.

In order to remedy the Oil Store, these steel bands were partially removed in sections and the voids filled with a suitably high-strength cementitious repair mortar.

In addition to the above, crack stitching was undertaken on the external face of the Oil Store as shown in Figure 4.

After the Lighthouse and Oil Store facade had been repaired, it was then sealed using Ardex WPM 330 an anticarbonation waterproof membrane.

This stage was crucial, as it provides the structure with a physical barrier to prevent any future corrosion. Again, the fully wrapped scaffold provided excellent working conditions as it not only reduced curing time, but also helped reduce the ongoing build up of salts and residue on the substrate.

Lantern Enclosure The Lantern of the lighthouse is known to be an ‘irreplaceable’ element, as it contains an original first order Chance Brothers Fresnel Lantern.

As such – protection of this lantern was a crucial element in establishing for these works.

Figure 3 – Corroded steel reinforcing bands.

Figure 5 – General View of the Green Cape precinct – Keepers Cottages.

The Lantern Enclosure – which sits at the top of the lighthouse is made up of a delicately combined steel and brass framed structure which includes forty-eight (48) glazing panels. As part of the restoration works, the enclosure was to be de-glazed and the frame work to be stripped of its numerous coatings, corrosion treated, re-coated and finally re-glazed.

Recognising the need for extreme quality and environmental control for this work in particular, a proprietary Peel Away product was used to remove the existing coatings – which, in some areas was up to 10mm thick. This product ensured minimal reliance was made on capturing debris as the existing coating remained adhered to the Peel Away product and was able to be bagged immediately and appropriately removed off site.

Corrosion to the framework of the enclosure was evident from two (2) sources - Minor galvanic corrosion as a result of direct contact between dissimilar metals (brass and steel) as well as Chloride corrosion due to the existing environment and air-born chlorides.

Once treated, the frame surface was primed and coated using a proprietary Dulux coating system. It was also important during this application to ensure regular washing of the surfaces was maintained, in an effort to stop any build up of salts or residues.

Keepers’ Cottages The Assistant Keepers Cottage is used as tourist accommodation for most part of the year. Tourists from all over Australia and the World are known to frequent the Green Cape site. As such the Head Keepers Cottage is currently used as the Office and permanent accommodation for the National Parks & Wildlife Service.

The Head Keeper attends to the Assistant Keepers’ maintenance requirements along with servicing tours and alike into the Lighthouse Tower itself.

Over time, both Keepers’ Cottages have suffered from the effects of significant corrosion and as a result, required numerous repairs both externally and internally. Nearly 5,000 corroded fixings and fixtures had to be removed and replaced with new 316 grade stainless steel elements.

In addition to the stated corrosion issues, general remedial repairs were undertaken to both cottages to ensure their future longevity.

Re-Birth of an Australian Icon With the investment into an Australian icon that is the Green Cape Lighthouse and surrounding precinct successfully complete, we can ensure the future of our cultural heritage looks just as bright as the light that once shone from this great treasure.

Nour Nwiran, Structural Systems

Figure 4 – Lateral cracking on the external walls of the Oil Store.

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

PROJECT PROFILE

Neptune champions ACFM in Australia At one of the world’s busiest commodity ports, a Western Australian company, Neptune, has successfully applied an emerging technique of non-destructive testing (NDT) to the inspection of more than 6.3 kilometres of weld. This technique could revolutionise the examination of subsea and offshore structures, pipelines and ship hulls.

Combining technologies The ACFM (alternating current field measurement) technique uses a combination of a surface sensor probe and an alternating current that is induced into the inspection area.

ACFM is commonly used for detecting and sizing surface breaking defects in metals. It is particularly suited to the inspection of welded structures that have been painted, as defects can be located and profiled through several millimetres of coating, thus negating the need for, and costs associated with, removing and reapplying protective coatings.

ACFM is also well suited to most applications where Magnetic Particle or Liquid Penetrant Testing is commonly used, for example, detection of stress corrosion cracking in stainless steels.

Explanation: Under the ACFM method, if no defects are present, the alternating current produces a uniform magnetic field above the surface. Conversely, if a defect is present, the current is disrupted, thus creating non-uniformity in the magnetic field that is measured by the sensors in the probe.

Two components of this magnetic field are measured; one provides information about the depth or aspect ratio of the defect while the other shows the positions of the defects’ ends. The two signals are used to confirm the presence of a defect and, together with a sizing algorithm, measure its length and depth.

Advantages of the ACFM method of inspection include:

qually effective application to parent E material and welds on conductive metals (ferritic or non-ferritic).

Particularly suited to the detection and sizing of fatigue cracks at the toes of welds, including all butt, fillet, node and nozzle welds an be applied to hot surfaces and C underwater an provide length, depth C and orientation information simultaneously. Defects up to 25mm in depth can be sized accurately o need to remove protective N coatings from the inspection area Single pass scan ermanent digital data record for P third party review CFM Inspector does not need to be A at the probe

1. Positive Defect Indication The signal received below shows a clear butterfly plot of a more significant magnitude and deflection on the Bx and Bz traces. After Magnetic Particle Inspection this was identified as the “typical defect indication” which was an area of crazed like cracking and a more isolated linear defect measuring around 5mm.

Image 1a: Bx Trace

Image 1b: Butterfly Plot

Image 1c: Bz Trace

Image 1d: Corresponding test area after paint removal.

p.46 CORROSION & MATERIALS

PROJECT PROFILE

Portability of the equipment I nspections can take place whilst equipment is in service ide temperature range for W inspection (-20° C to 500° C) ustom probes can be developed to C suit specific inspection area/shape (e.g. turbine discs) Common applications for the technique include: Lifting points, subsea/offshore structures; cranes, processing pipes, jacket legs, structural steel, pressure vessels, towers, ship hull welds, furnace wall tubing, theme park structures, and bridges, while many other applications can also be catered for with task specific procedures.

Taking on the Challenge As the only company in Australia operating under combined accreditation from NATA for compliance with ISO 17025 (NDT), IRATA for Rope Access and DNV for ISO 9001, Neptune has actively championed the application of ACFM in Australia; a technique that it uses in combination with the more commonly used Ultrasonic Testing (UT) and Magnetic Particle Inspection (MPI) methods.

Their team of IRATA qualified ACFM technicians were to assess, and repair as required, over 6km of weld and adjacent parent metal without causing

any disruption to the working ship loading facility, in the short time frame of 2 months.

Furthermore, the team had five weeks to mobilise (appoint and induct staff, arrange equipment, obtain all site approvals) across the Christmas/New Year period, amidst a record cyclone season.

“Onsite, most of the welds to be inspected were in difficult to access locations that required the use of specialised rope access techniques,” explained Neptune Asset Integrity Services’, Joe Mihic.

“In some instances, the ropes were anchored over rails that resulted in them lying across the path of a working ship loader, therefore stringent communications, scheduling, emergency stopping and standby rescue protocols had to be planned, implemented, rehearsed and observed.

“Similarly, with the majority of the wharf extending over the water, rigorous safety protocols were implemented to ensure the risks to personnel and those associated with equipment falling in to the water were minimised as much as possible.

Specific rescue plans were created, rehearsed, implemented and audited.

“The need to comply with the (facility) operator’s safety standards also required an audit of Neptune’s safety record

2. The work scope involved the testing of 6km of welds using ACFM NDT.

and safety management plan, while several planned and spot audits were conducted throughout the duration of the tender,” he added.

Collaboration: The combination of Neptune’s expertise and the collaboration between all parties in relation to the tasks at hand resulted in the successful completion of the project to client specification, under budget and ahead of schedule.

The rope access technique that was employed uses adapted caving and climbing techniques to provide a safe method of working at height and gaining access to difficult locations.

The primary advantage of rope access lies in the safety and speed with which technicians can get to and from difficult locations, enabling them to carry out their work, often with minimal impact to other operations.

The combination of total man hours and the particular risk level for a particular task (man at risk hours) is often reduced dramatically compared with other means of access. The technicians employed on the project worked 19,883 man hours with zero reportable incidents.

By T. Cunningham (Inspections Manager), A.Leslie (NDT InspectorACFM) & D.Marr (NDT InspectorACFM). Neptune – Asset integrity Services.

3. A team of IRATA trained ACFM technicians were mobilised to perform the NDT and repair works.

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

UNIVERSITY PROFILE

Corrosion at UQ The corrosion group at The University of Queensland (UQ) is led by Prof Andrej Atrens. Andrej Atrens is Professor of Materials at UQ, where he has been since 1984 with interests in stress corrosion cracking and corrosion of Mg, patination of copper, stainless steels, SCC & HE of steels. He has a BSc (Hons) and PhD from Adelaide University and a DEng from UQ. CURRENT AND RECENT RESEARCH PROJECTS 1. Biodegradation of Mg. Nor Ishida Zainal Abidin, graduating PhD student, Funded by CAST CRC Justification. Biocorrosion of a Mg implant will remove the Mg implant from the body after the implant has completed its function. Examples include cardiovascular stents.

Achievements. We have developed reliable methods to measure the corrosion rate in a synthetic body fluid; and found a good correlation between laboratory test and in vivo in rats.

2. Stress Corrosion Cracking and Corrosion of Mg alloys. Dr Zhiming Shi, Post Doctoral Fellow, Prof Zhixia Qiao Tianjin University (5 months),

Fuyong Cao, PhD student, Catalina Taltavull PhD student Rey Juan Carlos University, Spain (visiting UQ for 4 months) Funded by ARC Centre of Excellence Design in Light Alloys, GM Global Research & Development, Endeavour Fellowship.

Justification. Corrosion prevents the more widespread use of Mg alloys in applications where their light weight provides significant benefits Achievements. We have developed reliable methods to measure the corrosion rate and have shown that the widely used electrochemical methods typically produce inappropriate values.

3. Flammability of Mg alloys.

Dr Arvind Prasad, Post Doctoral Fellow, funded by CAST CRC and Boeing Research & Technology. This project is completed.

Justification. Mg alloys have recently been shown by others to have better flammability than some Al alloys used inside commercial aircraft. This opens up significant opportunities for weight saving by the replacement of Al internals using Mg alloys.

Achievements. Our experiments, carried out in the foundry, exposed one end of a cylindrical Mg-alloy specimen to a flame. Burning always self-extinguished once the flame was removed. Specimen tips of pure Mg, AZ61, and AZ91 ignited only after some melting typically after prolonged flame exposure whereas there was no ignition for Mg-5Y. Vigorous burning requires a continued supply of Mg vapour. A critical alloy concentration is required to change ignition behaviour.

The figure shows an image from a flame test using pure Mg. The specimen and fallen molten blob both ignited. The detached blob continued to burn whereas the specimen self-extinguished.

4. Hydrogen influence on metallic components for clean energy. Qian Liu PhD student, Funded by an ARC Linkage with Alstom Switzerland.

Justification. Influence of hydrogen on steels for the hydrogen economy is important, because small lab scale equipment can use exotic materials, but more conventional engineering materials will need to be used for a practical hydrogen economy.

Status. Qian Liu, PhD student, has completed a year of research into the influence of hydrogen on one steel using the Linearly Increasing Stress Test (LIST). Qian is currently spending 5 months in the Alstom laboratories in Baden Switzerland, carrying out fatigue experiments under hydrogen charging conditions.

Typical corrosion morphology was different in the adjoining grains. Some grains exhibited superficial corrosion with some filiform corrosion. The adjacent grains exhibited deep layered corrosion. HZG Mg ingot after immersion for 7 days in 3.5%NaCl saturated with Mg(OH)2. Z Qiao, Z Shi, N Hort, N Zainal Abidin, A Atrens, Corrosion behaviour of a nominally high purity Mg ingot produced by permanent mould direct chill casting, Corrosion Science, 61 (2012) 185-207.

p.48 CORROSION & MATERIALS

OF INTEREST TO PROSPECIVE RESEARCH STUDENTS Two recent students have completed PhDs in international collaborative mode: (i) Nick Winzer and (ii) Ming Liu. Nick Winzer’s program was from 08.04 to 11.07. He spend 15 months at GKSS (GKSS Forschungszentrun Geesthacht GmbH, Germany, now HelmholtZentrum Geesthacht). His PhD thesis consisted of five journal papers on stress corrosion cracking of Mg alloys.

Ming Liu’s program was from 02.07 to 07.11. He spent 14 months based at EMPA (Swiss Federal Laboratories

UNIVERSITY PROFILE

5. A Prasad, Z Shi, A Atrens, Influence of Al and Y on the ignition and flammability of Mg alloys, Corrosion Science, 54 (2012) 153-163.

6. M Liu, PJ Uggowitzer, AV Nagasekhar, P Schmutz, M Easton, G Song, A Atrens, Calculated phase diagrams and the corrosion of diecast Mg-Al alloys, Corrosion Science 51 (2009) 602-619.

for Materials Testing and Research, part of the Swiss Federal Institute of Technology), with three periods of 2 months each at the Laboratoire de Physico-Chimie des Surfaces, CNRSENSCP (UMR 7045), Ecole Nationale Supérieure de Chimie de Paris (ENSCP), (French National Graduate School of Chemistry) Paris, France (one of the best laboratories worldwide in surface science and its application to corrosion). Ming’s PhD consisted of five published papers on Mg corrosion and surface analysis.

10 SIGNIFICANT PUBLICATIONS SINCE 2007 1. A Prasad, P.J. Uggowitzer, Z. Shi, A Atrens, Production of high purity magnesium alloys by melt purification with Zr, Advanced Engineering Materials, 14 (2012) 477-490.

2. MC Zhao, M Liu, G Song, A Atrens, Influence of the β-phase Morphology on the Corrosion of the Mg Alloy AZ91, Corrosion Science 50 (2008) 1939-1953.

3. Z Shi, JX Jia, A Atrens, Galvanostatic anodic polarisation curves and galvanic corrosion of high purity Mg in 3.5%NaCl saturated with Mg(OH)2, Corrosion Science 60 (2012) 296-308.

4. Z Qiao, Z Shi, N Hort, N Zainal Abidin, A Atrens, Corrosion behaviour of a nominally high purity Mg ingot produced by permanent mould direct chill casting, Corrosion Science, 61 (2012) 185-207.

7. N Winzer, A Atrens, W Dietzel, G Song, KU Kainer, Comparison of the Linearly Increasing Stress Test and the Constant Extension Rate Test in the Evaluation of Transgranular Stress Corrosion Cracking of Magnesium, Materials Science and Engineering A, 472 (2008) 97-106.

8. NI Zainal Abidin, AD Atrens, D Martin, A Atrens, The corrosion of high purity Mg, Mg2Zn0.2Mn, ZE41 and AZ91 in Hank’s solution at 37 °C, Corrosion Science 53 (2011) 3542-3556.

9. M Liu, P Schmutz, PJ Uggowitzer, G Song, A Atrens, The influence of Yttrium (Y) on the corrosion of Mg-Y binary alloys, Corrosion Science 52 (2010) 3687-3701 10. A Atrens, M Liu, NI Zainal Abidin, Corrosion mechanism applicable to biodegradable magnesium implants, Materials Science and Engineering B, 176 (2011) 1609-1636.

Peer-reviewed research publications since 2007: 55 journal publications, 6 book chapters

CONTACT DETAILS Professor Andrej Atrens Head Division of Materials Engineering The University of Queensland, Brisbane, Qld Australia 4072 CRICOS Provider Number: 00025B T: (07) 3365 3748; International Tel: +61 7 3365 3748 Andrejs.Atrens@uq.edu.au

Aerial view of UQ.

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

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p.58 CORROSION & MATERIALS

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Form M1589