C&M AUG.indd - CiteSeerX

OFFICIAL PUBLICATION OF THE AUSTRALASIAN CORROSION ASSOCIATION AND THE ASIAN PACIFIC MATERIALS AND CORROSION ASSOCIATION

Vol 30 No 4, August 2005ISSN 1326-1932

M A T E R I A L S&

2 Corrosion & Materials

Sponsorship Package One: $1,000 includes:• Name in the foundation credits at the back of the book• Logo on the inside front page of the book• Upgrade in ACA foundation level if applicable

Sponsorship Package Two: $2,500 includes:

• All of the above, plus sponsorship of one chapter with logo shown at beginning of the chapter

Benefits of Foundation donations also include:

• Acknowledgement on the permanent honour board at the Australasian Corrosion Association Centre

• Acknowledgement on the ACA website www.corrosion.com.au

• Acknowledgement in the Annual ACA conference proceedings and annually on the front cover of the Corrosion and Materials journal

Sponsorship opportunities for the book will be quite limited, so please don’t hesitate to contact the ACA on (03) 9890 4833 or [email protected] to discuss your involvement in this project

ACA Golden Jubilee updatePitting Wits for 50 years

As part of the Golden Jubilee celebrations the ACA is producing a history book documenting 50 years of the worlds most enjoyable corrosion group. A documented history of the association, the book will take the reader on a journey through the early years of the as-sociation from 1955 until the present day.

Chapters one to four will deal specifically with a history of corro-sion and the Association 1955 – 1969, 1970 – 1985, 1986 – 1995, and 1996 – 2005. Chapters will also be dedicated to the ACA Council, the Operations Committee, the ACA Centre, the ACA Foundation, ACA Branches, the Corrosion and Materials journal as well as a chapter on people who have made great achievements within the ACA and the field of corrosion.

The book will be for sale by the ACA Centre, with a planned first run of 1,500 copies. The book will be updated again in 25 years. Sponsorship opportunities are available for the book.

The remake of the Silver Jubi-lee video for our Golden Jubilee is coming along wonderfully. More than just an update, the new DVD is shaping up to be an exciting and fast-moving film. The aim was to make corrosion an exciting subject that would grab the atten-tion of students and corrosionists alike, and though it sounded like a bit of a challenge, it’s proving to be surprisingly easy. Corrosion-ists cover a huge variety of jobs, working all over the world in some pretty interesting (though not always glamorous!) places. Our greatest challenge in making this film has not been to make corrosion interesting – that’s been easy – but to capture the huge diversity of the corrosion industry.

The following companies have come on board and sponsored the DVD:

DENSO; Hempel (Australia) Pty Ltd; Peerless Industrial Systems; AmaC Corrosion Protection Pty Ltd; Building Research; Carboline Australia Pty Ltd; Corrotek Consultants; Garnet International Sales; Jotun Protective Coatings; Incospec and Associates; International Protective Coatings; Dulux Australia; Galvanizers Association of Aust; United Water International; SA Electrolysis Committee Inc; Cathodic Diecasting QLD; Ameron Coatings; South Coast Surface Protection; Hunter Water Australia Pty Ltd; Australian Foundry Institute; Petro Coating Systems Pty Ltd, ACA New Zealand

The ACA would like to thank these sponsors for working with us to make such an exciting film. We are still seeking further sponsorship. If you want to get your company involved in this project, please contact the ACA on (03) 9890 4833 or [email protected]

The Valicote shoot

Sarah Furman in action

At the movies…

Vol 30 No 4 August 2005 3

Contents

President’s Message

3. . . . . President’s Message4. . . . . In the Driver’s Seat5. . . . . Executive Officer’s Message6. . . . . What’s Rusting8. . . . . Current Awareness Bulletin10. . . . Branch News14. . . . AEC Meeting

Australasian Corrosion Association IncPO Box 112, Kerrimuir Vic 3129, Australia Ph: 613 9890 4833, Fx: 613 9890 7866 Email: [email protected] Internet: http://www.corrosion.com.auPresident: Wayne BurnsExecutive Officer (acting): Mal BrooksOperations Chairman: Warren GreenFinance Director: David RobertsonSenior Vice President: Dean WallJunior Vice President: Fred SalomeCommunications Director: Mike BoardmanEducation Director: Rob FreedmanTechnical Director: Willie MandenoMembership Director: Brad Dockrill

Branches & DivisionsAuckland Division: Jim Knappstein 64 9 276 6620Newcastle: Bill Livingston 02 4941 1749New South Wales: Jim Galanos 02 9763 5611Queensland: Cathy Sterling 07 3821 0202South Australia: Paul Vince 08 8260 0496New Zealand: Mike Boardman 64 9 235 3572Tasmania: Dean Wall 03 6341 1778Taranaki Division: Ron Berry 64 4 758 6165Wellington Division: Barbara Webster 64 4 211 149 9097Western Australia: Clive Funston 08 9211 8519Victoria: John Tanti 03 9884 5884

Technical GroupsBuilding & Concrete Structures: Ahmad Shayan, 03 9881 1658Cathodic Protection: Bruce Ackland, 03 9890 3096Research: Nick Laycock, 64 4 931 3022Mining Industry: Peter Farinha, 08 9458 8112Protective Coatings: Robert de Graaf, 08 9390 3331Refining & Process Industry: Davie Monk, 03 9286 5723Water & Water Teatment: Greg Moore, 08 8204 2118Welding & Corrosion: Graham Sussex, 03 9819 1998

Asia Pacific Materials & Corrosion AssociationChina: Dongbai Sun, University of Science & Technology Japan: Toshio Shibata, Osaka UniversityKorea: Ki Tae Kim, Research Institute of Industrial Science & TechThailand: Ladawal Chotimongkol, Thailand Institute of ScienceVietnam: Phan Luong Cam, Hanoi University

Front Cover: ‘Desert Road, NZ’ courtesy of Mike Boardman

ISSN 1326-1932

Publications DirectorDr Geoffrey Will, Queensland University of Technology

Publications Co-ordinatorLyahna Spencer, Australasian Corrosion Association IncPh: +61-3 9890 4833, Fx: +61-3 9890 7866

EDITORIAL COMMITTEEEditor: Brian Cherry, Monash University, [email protected] EDITORSBruce Ackland – Bruce Ackland & Associates Peter Farinha – Extrin ConsultantsBrian Kinsella – Curtin University Nick Laycock - Materials Performance Technologies Industrial Research LtdWillie Mandeno - Opus International Consultants David Nicholas - Hunter Water Corporation Graham Sussex – Sussex Material SolutionsDavid Young - University of New South Wales Geoffrey Will - Queensland University TechnologyPublished by the Australasian Corrosion Association Inc. (Incorporated in South Australia), PO Box 112, Kerrimuir Vic 3129 for the Australasian Corrosion Association and the Asian - Pacific Materials & Corrosion AssociationSubscriptionPrint Version: ISSN 1326-1932Subscription rates to non members: within Australia: $66, single copies A$16.50, incl GST outside Australia: A$70 posted airmail, single copies A$22 incl GSTOn-Line Version: ISSN 1446-6848Subscription rates to non members: A$22 incl GSTThe views expressed in Corrosion & Materials are those of the indi-vidual authors and are not necessarily those of the ACA, APMACA or BCCA. Publication of advertisements does not imply endorsement by the ACA, APMACA or BCCA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.

15. . . . Technical Group News

18. . . . Evaluating Pipeline Coating Condition on Horizontal Directional Drills – A Review, Brian A Martin

22. . . . Protective Coatings Tutorial Pt 13

23. . . . SUPPLIERS AND CONSULTANTS

Wayne Burns

We are already halfway through our Golden Jubilee Year and celebrations for the ACA’s fiftieth birthday are well underway. The New Zealand branch has already hosted a very successful and well-attended Golden Jubilee dinner, and the Victorian and South Australian branches will have also done so by the time this journal comes out. It’s great to see so many people getting enthusiastic about this milestone achievement of the ACA.

In Queensland, all attention is being fo-cused on the preparations for the Corrosion and Prevention conference to be held 20th – 23rd November 2005. Appropriately, our Golden Jubilee will be held on the Gold Coast. A group of dedicated and hard-working volunteers are powering the preparations for the conference along, and the ACA staff are supporting and aiding them in every way possible.

Anyone who has coordinated or organised a conference on such a scale will know what a huge task it is. So much more than just finding a venue and booking some rooms and catering! This year being the ACA’s Golden Jubilee has inspired our conference committee to make this a truly spectacular affair. The committee members include: Geoff Will, Arthur Austin, Matt Hollywood, Roslyn Burns, Cathy Sterling, Arthur Cox, Phil Harrison, Mike Dinon, Peter Hancock, Graeme Kelly, Allan Sterling, Adrian Dundas, Michael Illidge, David Rigden, Geoff White and myself.

Apart from a huge variety of esteemed speakers, a fantastic partner programme, and the glorious weather and scenery of the Gold Coast, two of the highlights of the conference will be the launch of the ACA DVD and his-tory book. Just as with the conference, a group of volunteers are dedicated to progressing the projects, and are doing a great job at keeping the projects on track. Peter Farinha and Mette Neilsen in WA have been collecting information for the book that will tell the story of the ACA for the past 50 years. Sponsorship opportuni-ties for the book have just come available, so contact the ACA centre to discuss sponsorship of the book. The DVD is also making headway; a lot of filming has taken place and sponsorship is going well. There are still a few places left for sponsorship of the DVD; anyone interested

should contact Lyahna Spencer ([email protected]). Nick Subotsch, Gra-ham Sussex and Paul Taylor in particular are to be congratulated for throwing themselves so whole-heartedly into the project to ensure a quality product.

In any Association, the volunteers who make up committees and boards are to be applauded. At the ACA, committee members, board members, branch secretaries and treasur-ers, technical group officers, editors and associ-ate editors make up a huge network of people that keep the ACA going. Their volunteered time and expertise is essential for making the ACA the highly responsive and valuable as-sociation it is today.

The end of year conference is a fantastic time to meet and network with industry and technology leaders. This is also a great op-portunity to catch up with the ACA leaders and staff, ACA members and other industry representatives. The industry focused technical program is of a world-class standard; all papers are carefully refereed before being accepted. In addition to the papers, there is also the oppor-tunity to attend forums run by industry experts. Workshops and technical tours will complete the conference for those interested.

In addition, there is a lot of fun to be had at the conference: golf on Saturday, the Welcome function on Sunday, a sumptuous Gala dinner on Tuesday evening, and the farewell function on Wednesday to finish the conference off in style. The Partner Program allows spouses to make the most of the magnificent scenery and highlights of the Gold Coast in an informal and enjoyable atmosphere.

Fifty years as an association is a real landmark. I hope to see many of you there in November to share in the celebrations and to make this the biggest and the best conference to date.

Wayne Burns ACA President

mailto:[email protected]

mailto:[email protected]


ACA Matters

Warren Green Operations Committee Chairman

In the Driver’s Seat

We are now well into our 50th year and the Golden Jubilee celebrations are gathering momentum. This year’s conference organised by the Queensland branch and being held on the Gold Coast promises to be the highlight of the year.

Also to mark the 50th Anniversary of the ACA we are updating “The Corrosion Problem” film to market the ACA to a wider audience, including secondary and tertiary students. We have a group of hard working volunteers headed by Nick Subotsch who are fast learning the intricacies of film production. To complement the film, we are also producing a history of the Association in book form called “Pitting Wits”. This promises to be a high quality publication that chronicles the activities of the ACA from its inception. We are grateful to those members throughout the branches who have been able to contribute, and to the volunteers who have been disseminating Association records and compiling and authoring the book.

It is interesting to look back to the inception of the ACA in 1955; this was the same year that the modern computer was invented, Disneyland was opened and Mrs. Norman gave us little Greg. It was also the same year that we lost the ashes test series 1-3 and we went down to the All Blacks 2-1.

In terms of an update on specific ACA op-erational issues I provide the following:

ACA Centre MattersThe ICOMS 2005 Conference (31 May – 3

June) went very well, with 225 attendees, 3 days of presentations and a workshop. MESA was very pleased and so congratulations and thanks to the ACA Centre team.

A business culture with business focuses, attitudes and acumen is continuing to pervade the ACA Centre. The provision of services at a modest profit for the benefit of our members is paramount, therefore cost monitoring and management controls with improvements in efficiency and productivity are occurring.

EducationThe ACA training program for the remain-

der of 2005 is planned to be very busy.The ACA’s Coating Inspection Certificate

Course (CIC) has been very popular with at-tendees taking the opportunity to complete

this course prior to its phasing out at the end of 2005. The Protective Coating and Quality Control course (PCQC) will replace the CIC at the end of 2005. The draft of the PCQC has been completed and is currently being peer reviewed prior to its first presentation at the end of the year.

The attendances at ACA/NACE courses have increased. The Coating Inspector Program (CIP) Level 1 in Kuala Lumpur during June was full and a reservation list for those who were not able to fit into this course has commenced for the next course. A CIP Level 1 planned for Sydney in August is already attracting an increased level of registrations and interest.

The CIP Level 2 courses in Kuala Lumpur, Malaysia in September and Brisbane, Australia in November 2005 also look like filling up quickly. Immediately following the September course in Kuala Lumpur, the ACA will present an in-house course for an International company in Bangkok, Thailand.

ACA CP courses are being held in Sydney in July, Darwin and Perth in August and Auckland in October.

The ACA is facilitating a NACE Cathodic Protection course in Indonesia in August.

The ACA/ACRA Corrosion and Protection of Reinforced Concrete course is being held in Sydney and Melbourne in September. This course is proving to be very popular with very good attendances and requests from various branches for the course to be programmed for their locations.

The full training program for 2005 i s d i s p l a y e d o n t h e A C A’s w e b s i t e www.corrosion.com.au

The schedule for training courses for the 1st half of 2006 is being drafted, so if there are any you would like offered in your area for next year please contact Mal Brooks or Tiani Bradilovic.

FinancialFinancials have now been finalised for the

CAP-04 Conference and a modest surplus was made for the WA Branch and ACA Centre to share.

A modest surplus for the ICOMS 2005 Con-ference is also anticipated for sharing between IMEA and the ACA Centre.

Course income is improving and member-ship revenue is looking good at this stage of the year.

Our accounts receivables continue to fall. Well done to our bookkeeper, Julie Moscrop, for her ongoing focus in this area.

Membership

Improvements are being planned re-garding: Overdue Fees Correspondence regarding fee reminders Returns to Branches Subsidiary Companies – formalise a policy.

Brochure – to be reviewed

Database Information – upgrade and improvements: Management of corporate rep data Reporting to the branch reps and executives Certificates Reps – database to be improved to list all

rep details at a glance – save time link to tech groups

Listing Advice – feedback from database

Membership Pack Development – for new members

Value of Membership:– CPD – formalise a policy Code of Ethics – control acceptable

behaviour Complaints – formalise procedure and

advertise Experts listed for general referrals Membership Drives – advertise methods Corp Benefits – not all managed – follow up

and improve Student Membership – formalise role

and involvement Investigate Membership management

and inceptives by like minded counter-part organisations:- NACE, Eurocorr, UK


Australasian Branch• Mr Alexander Wijaya, Individual • Mr Michael Hurley, Student• Mr Digvijay Charan, Individual

Victorian Branch• Mr Wayne Neil, Student• Mr Alex Crowe, Individual• Ms Cheryl Cameron, Corporate Bronze• Mr Patrick Jean, Individual• Ms Margarita Vargas, Student• Mr Singaravelu Sundaravel, Individual• Mr Andy Steward, Individual• Mr Raymond Ling, Individual

South Australia Branch• Mr Bart Ozog, Student• Mr Col Kupke, Student• Mr Scott Knoblauch, Student• Ms Jan Bon, Student• Mr Cameron Nolan, Student• Ms Josephine Lombardi, Student

Western Australia Branch• Mr Douglas Shipley, Corporate Bronze• Mr Ivan Ruefli, Corporate

Queensland Branch• Mr Jim McMonagle, Retired• Mr Wayne Edwards, Corporate Bronze

New Zealand Branch• Mr Hans Desilvestro, Individual

Corrosion Society, South Africa, China Marketing Database – consider how this may be of benefit to

members

TechnicalA successful AEC Meeting was held in Adelaide in June. Assistance is being provided with organisation of speakers

and Technical Group Forums for the CAP-05 Conference on the Gold Coast.

FoundationThe members of the Victorian Branch of the ACA are to be

congratulated for converting their Foundation loan into a donation. Victoria now becomes a “Gold Donor” to the ACA Foundation.

Warren Green Operations Committee Chairman

In the Driver’s Seat (Continued)

Executive Officer’s MessageI hope you’ve all blocked out 20 – 23 November in your diaries,

clearing the way for your attendance at our 2005 Golden Jubilee Conference on the Gold Coast. The members of the Queensland Branch Conference Committee have been working double-time in an endeavour to provide a truly magnificent event. By the time this issue is distributed, our website should contain the Preliminary Program and Conference Registration form. I encourage you to download a copy and register as soon as possible, taking advantage of our early registration discount.

Also available on our website is the updated course catalogue and schedule for the remainder of 2005 and the start of 2006. We are con-stantly reviewing these items and welcome your input. You will note that we are calling for expressions of interest, if not actual registra-tions, for the courses in early 2006. Notification of this interest will assist us in assessing demand for and financial viability of scheduling individual courses.

Our Publications Co-ordinator, Lyahna Spencer, is always on the lookout for ways of expanding the content of our journal. (You would have noted the Editorial Team’s call for articles in this and previous journals and on our website). We would also welcome your contribu-tions by way of witty stories, humorous anecdotes and observations of life, generally. There are no hard and fast rules here - stories don’t necessarily have to be about corrosion or corrosionists - but libel laws suggest names should be changed to protect us all!

Mal Brooks (Acting) Executive Officer


NACE International will present a seminar on NACE MRO175/ISO 15156, “Petroleum and natural gas industries – Materials for use in H2S-containing environments in oil and gas production”, September 15, 2005, from 8am to 4 pm, at The Westin Calgary Hotel, Calgary, Alberta, Canada.

Before publication of NACE MRO175/ISO 15156 in December 2003, a NACE technical committee spent seven-plus years revising MRO175, particularly the requirements for corrosion-resistant alloys (CRAs), because of the increasing use of existing alloys and

development of new alloys, leading to the need for interpretation.

In this one-day seminar, experts will pres-ent information including background and changes to the standard; the differences be-tween NACE MRO175/ISO 15156 and earlier editions of MR0175; how to select materials using the new standard; and case studies that will include attendee participation.

To register, contact NACE FirstService at +1 281 228 6223 or visit www.nace.org/MRO175Seminar.

NACE TO HOST MRO175/ISO SEMINAR IN CALGARY SEPT 17, 2005-07-08

Sandvik Materials Technology has in-troduced a new product form and launched a range of surface engineered stainless steel strip materials.

Manufacturing processes have been devel-oped to apply coatings with excellent adhesion and purity to stainless steel strip, enabling selected combinations of substrates and surface layers to provide new, enhanced and often unique material properties.

A high degree of manufacturing flexibility enables surface engineered strip to be tailor made to customer specifications. Properties such as electrical conductivity, low resistivity,

corrosion, surface function or decorative ap-pearance can be met or enhanced, making the new Sandvik surface technology products ideal for the electronics industry, for example.

Typical electronic applications include tactile domes, contact springs, shielding and improving the soldering properties of electronic components. Surface engineered strip mate-rial into the electronic market will be branded Sandvik Santronic™.

For fu r t he r i n fo rma t ion con tac t : s u r f t e c h . s m t @ s a n d v i k . c o m o r v i s i t www.smt.sandvik.com

SANDVIK LAUNCHES SURFACE ENGINEERED STRIP MATERIALS

New surface engineered stainless steel strip materials from Sandvik Materials Technology.

NEW ELECTROFUSION INSTALLATION EQUIPMENT

The introduction to Australia of a range of cutting-edge electrofusion control units (ECUs) from Durafuse by Philmac offers significant improvements to quality assurance for pressure polyethylene pipeline installations.

The improved range of ECUs – the Connexion® series – provides an efficient method of jointing polyethylene piping with high integrity.

Meeting diverse market requirements, Connexions® are offered in three configurations and are targeted at all installers and owner/ operators of electrofusion systems, from sole-operator plumbing businesses to high-level util-ity companies with thousands of employees.

Also included in the Durafuse range, and unique to the Australian market, is the Nomad battery-powered electrofusion welder. The No-mad offers a new level of mobility for electro-fusion installations and has major advantages in timely response for emergency repairs.

The electrofusion technique is widely used throughout Australia and offers a simple means of effecting permanent joints to polyethylene pipelines at a relatively low cost.

The characteristics of the electrofusion jointing process make it ideal for mid-size installations (between 110mm and 250mm) and where access to the location of the joint rules out butt-welding techniques. Electrofusion is also widely used on new gas installations due to the permanent nature of the joint.

Fo r fu r t he r i n fo rma t ion con tac t : Jason Mitchell, Group Marketing Manager, Ph: 08 8300 9200.


What’s Rusting

Sources of ignition include flames and sparks from exhaust systems, arc and sparks

from electrical equipment, hot surfaces and static build up.

Chess Flameproof, a division of ASSDA member Chess Engineering Pty Ltd, spe-

cialises in the conversion of materials handling equipment for use in hazardous areas.

Materials handling equipment such as forklift trucks, tow tractors, sweepers, scissor

lifts and boom lifts ranging from 1 ton to 32 tonnes have all been designed and manu-

factured to remove or reduce the risk of the equipment becoming the source of ignition.

Both diesel and battery electric powered forklifts can be flameproofed. Note spark ignition

engines ie. LPG and petrol are not permitted in any hazardous areas.

In addition to flameproofing, Chess Engineering manufactures custom forklift attach-

ments, engine protection systems, speed sensors/controllers and cabins as well as custom

modifications and general forklift engineering.

For more information about stainless steel, contact the Australian Stainless Steel

Development Association on 07 3220 0722 or visit www.assda.asn.au

Toyota forklift built to Zone 1 hazardous area

A stainless steel final flame trap element (centre) and (left) a corrugated stainless steel exhaust flex with braided sleeve used to absorb engine movement and vibration

REDUCING RISK WITH STAINLESS FLAMEPROOF TECHNOLOGY

Where flammable or combustible materials are stored or handled, there can be a severe risk of an explosion

or fire if handling equipment such as forklift trucks are not flameproofed

Flameproofing of material handling equipment is the science of reducing the risk of an explo-

sion or fire by means of specialised principles and technologies.

Three components are needed in order to generate an explosion or fire.

1. A flammable or combustible material eg. liquid, gas or dust.

2. Oxygen eg. air.

3. Ignition source eg. electrical sparks,

mechanical sparks, hot surface and

static discharges.


The following journals have appeared in recent months. If you want to see a full copy of any paper listed, please contact your nearest library participating in the Interloan system, not Build-ing Research.

Corrosion and Materials 30(3) June 20058 M Critchley and R Javaherdashti. Materi-

als, micro-organisms and microbial cor-rosion – a review.

25 Protective coatings tutorial #12: Surface preparation for coatings repair.

26 Corrosion tutorial #44: Principles of water treatment.

Materials Performance 44(4) April 2005 16 M V Veazey. CDU [crude distillation unit]

overhead corrosion: a NACE solution.20 J H Fitzgerald. Misunderstanding CP.26 F M Song et al. Barrier properties of two

field pipeline coatings.34 A Groysman et al. Corrosiveness of acidic

crude oil and its fractions. 40 M Valliappan. Computerised multiplex

corrosion management.46 D Holmes. Comparison of reactive and

refractory metals in selected aqueous environments

50 D H Kelly. Fibreglass reinforced plastic equipment for waste incineration gases.

58 Corrosion basics: stainless steels.

Materials Performance 44(5) May 2005 16 M V Veazey. Keeping clean rooms clean.

[Relates to sprinkler systems.]20 J Schramuk and D J Klopper. Sacrificial

anode retrofit programme for existing cast iron distribution water mains.

26 M J Szeliga. Ductile iron pipeline fail-ures.

32 R A Gummow. Corrosion and CP of pre-stressed concrete cylinder pipe.

38 V E Hock et al. Evaluation of in situ pipe coating process for mitigation of Pb and Cu in drinking water.

48 O Hollander. Real-time linear polarisation corrosion measurements.

52 O Jonas et al. SCC of C steel in nuclear component cooling water systems.

62 J Lichtenstein. Importance of coating thickness.

J Protective Coatings and Linings 22(4) April 2005 8 L R Huffman. Out-of-the-box thinking gets

round [spherical] tank squared away. 17 Polyaspartic coating hits home run at

Florida baseball stadium. 21 Preventing corrosion on insulated pipe-

line.24 An in situ method of characterising coat-

ings over concrete. 27 D Beamish. Looking after your coating

thickness gauge. 30 B Goldie. New anticorrosive pigments

said to be environmentally sensitive and effective.

34 S Kennedy. Controlling quality during abrasive blasting.

40 H Hower. Ask questions and get answers – the keys to success in coating industrial floors.

46 P D Lovett. Floor coatings for food plants: a look at the US market.

52 B J Fitzgerald and S Winnik. Preventing corrosion under insulation in pipeline in the petrochemical industry.

58 A Kaelin. Quality control and quality as-surance.

J Protective Coatings and Linings 22(5) May 2005 6 L R Huffman. Goethals Bridge deck re-

habilitation calls for innovative access system.

9 Painting aged pedestrian bridges. 10 J Dolly. Maintaining access platforms for

safe use. 16 H Langas. Universal primers in newbuild-

ing operations [in shipyards].22 K Kapsanis. Sophisticated or simple, new

products designed to make work easier, safer, faster.

129 D J Zienty. Old tanks, small towns, tight budgets: how does the job get done?

136 G R Stein. A specifier’s perspective on tank painting: review of four practical issues.

Materials and Structures 38(278) May 2005479 J J Valenza and G W Scherer. Mechanisms

of salt scaling [of concrete].489 P V Nygard and M R Geiker. Method for

measuring the chloride threshold level required to initiate reinforcement corro-sion in concrete.

Corrosion Science 47(4) April 2005883 F. Corvo et al. Changes in atmospheric

corrosion rate caused by chloride ions depending on rain regime.

893 E. Szöcs et al. Electrochemical behaviour of an inhibitor film formed on copper surface.

909 F. Iacoviello et al. Effect of “475 °C em-brittlement” on duplex stainless steels localized corrosion resistance.

923 M. Zapponi et al. Prohesion and outdoors tests on corrosion products developed over painted galvanized steel sheets with and without Cr(VI) species.

937 V. Moutarlier et al. EIS characterisation of anodic films formed on 2024 aluminium alloy, in sulphuric acid containing molyb-date or permanganate species.

953 H. Schäfer and H.-R. Stock. Improving the corrosion protection of aluminium alloys using reactive magnetron sputtering.

965 L.W. Tsay et al. Embrittlement of T-200 maraging steel in a hydrogen sulfide solution.

977 E. Cano et al. Rate control for copper tarnishing.

989 K Brunelli et al. Effect of HCl pre-treat-ment on corrosion resistance of cerium-

based conversion coatings on magnesium and magnesium alloys.

1001 Y. Y. Chen et al. Corrosion resistance and mechanical properties of low-alloy steels under atmospheric conditions.

1023 Tran Thi Ngoc Lan et al. The effects of air pollution and climatic factors on atmo-spheric corrosion of marble under field exposure.

1039 S Cai et al. Research on Cu2+ transforma-tions of Cu and its oxides particles with different sizes in the simulated uterine solution.

1049 S Zhang et al. Inhibition effect of metal cations to intergranular stress corrosion cracking of sensitized Type 304 stainless steel.

Corrosion Science 47(5) May 20051063 E. Kuş et al. The concept of the bacterial

battery. 1071 T S Rao et al. Pitting corrosion of titanium

by a freshwater strain of sulphate reduc-ing bacteria (Desulfovibrio vulgaris).

1085 L R Jordan et al. Corrosion and passivation mechanism of chromium diboride coat-ings on stainless steel.

1097 T. Sourisseau et al. Mechanism of copper action on pitting phenomena observed on stainless steels in chloride media.

1119 A. Samide et al. Study of the corrosion inhibition of carbon-steel in dilute am-moniacal media using N-cyclohexyl-ben-zothiazole-sulphenamide.

1129 T Sundararajan et al. Steam oxidation resistance of two-layered Ni–Cr and Al APS coating for USC boiler applications.

1149 G Plascencia and T A Utigard. High tem-perature oxidation mechanism of dilute CuAl alloys.

1165 D. Battocchi et al. Emulation and study of the corrosion behaviour of Al alloy 2024-T3 using a wire beam electrode (WBE) in conjunction with scanning vibrating electrode technique (SVET).

1177 X He et al. Crevice corrosion damage function for grade-2 titanium of iron content 0.078 wt% at 95 °C.

1197 H.C. Ng and R.C. Newman. Amperomet-ric hydrogen permeation measurement in iron using solid polymer electrolyte fuel cells.

1211 A. Bakkar and V. Neubert. Improving corrosion resistance of magnesium-based alloys by surface modification with hydrogen by electrochemical ion reduc-tion (EIR) and by plasma immersion ion implantation (PIII).

1227 B. Davó et al. Inhibition of SCC of alloy AA8090 T-8171 by addition of rare earth salts.

1239 P. Schmuki et al. The composition of the boundary region of MnS inclusions in stainless steel and its relevance in trig-gering pitting corrosion.

1251 C. Blanco-Pinzon et al. Excimer laser surface alloying of titanium with nickel and palladium for increased corrosion resistance.

Current Awareness Bulletin


Prepared for the benefit of ACA members by John Duncan, Building Research


1271 S Suzuki et al. Atomic-scale structure of α-FeOOH containing chromium by anomalous X-ray scattering coupled with reverse Monte Carlo simulation.

1285 K Aramaki. A self-healing protective film prepared on zinc by treatment in a Ce(NO3)3 solution and modification with Ce(NO3)3

1299 X. Zhou et al. The valence state of copper in anodic films formed on Al–1at.% Cu alloy.

1307 L F Li et al. Mechanism of single and mul-tiple step pickling of 304 stainless steel in acid electrolytes.

Corrosion Science 47(6) June 20051325 F.D. de Moraes et al. Influence of dynamic

straining on hydrogen embrittlement of UNS-G41300 and UNS-S31803 steels in a low H2S concentration environment.

1336 M I Abdulsalam. Behaviour of crevice corrosion in iron.

1352 V Shinde et al. Corrosion protective poly(o-toluidine) coatings on copper.

1370 G A Al-Mahdy. Atmospheric corrosion of copper under wet/dry cyclic conditions.

1384 S. Korablov et al. Wet corrosion of nitride PVD films in supercritical solutions.

1403 T. Zakroczymski et al. Effect of hydrogen concentration on the embrittlement of a duplex stainless steel.

1415 X Wu and Y Katada. Strain-rate depen-dence of low cycle fatigue behaviour in a simulated BWR environment.

1429 S. Verdier et al. Formation, structure and composition of anodic films on AM60 magnesium alloy obtained by DC plasma anodising.

1445 A.K. Satpati et al. Electrochemical and XPS studies and the potential scan rate dependent pitting corrosion behaviour of Zircaloy-2 in 5% NaCl solution.

1459 G.S. Duffó and S.B. Farina. Diffusional control in the intergranular corrosion of some hcp metals in iodine alcoholic solu-tions.

1471 Z Lu et al. Probing into the effects of a magnetic field on the electrode processes of iron in sulphuric acid solutions with dichromate based on the fundamental electrochemistry kinetics.

1493 J.H. Xiang et al. The oxidation of two ternary Fe–Cu–10 at.% Al alloys in 1 atm of pure O2 at 800–900 °C.

1506 B S. Tanem et al. Relations between sample preparation and SKPFM Volta potential maps on an EN AW-6005 alu-minium alloy.

1520 D. P Schweinsberg and H J. Flitt. Repro-ducibility of corrosion parameters for the acidic dissolution of pure iron: potentio-static polarisation.

1534 A. Asan et al. Corrosion inhibition of brass in presence of terdentate ligands in chloride solution.

1545 Y Huang and Y Zhu. Hydrogen ion reduc-tion in the process of iron rusting.

1555 W J Chitty et al. Long-term corrosion resistance of metallic reinforcements in concrete—a study of corrosion mecha-nisms based on archaeological artefacts

1582 K Aramaki and T Shimura. Preparation of a two-dimensional polymer film on passivated iron by modification of a car-boxylate ion self-assembled monolayer with alkyltriethoxysilanes for preventing passive film breakdown. Corrosion 61(4) April 2005

307 T. Itagaki et al. Steam oxidation of high-Cr ferritic steels containing Pd.

317 A.A. Efimov et al. Oxidation of steel sur-faces in water solutions.

326 X. Jiang et al. Corrosion inhibitor perfor-mances for CO2 corrosion of N80 steel under static and flowing conditions.

335 J.-K. Kim et al. Corrosion monitoring of Fe-Cu alloys under different drying times and the effect of Cu on their corrosion rate.

341 Z. Wei et al. Inhibition of pitting corrosion by surfactants as a function of tempera-ture.

348 G. Hinds et al. Hydrogen diffusion in super 13% Cr martensitic stainless steel.

355 R.E. Melchers. Effect of alloying on maxi-mum depth of pits in mild steel in marine immersion environments.

364 A.K. Roy et al. Environment-assisted cracking of structural materials under different loading conditions.

371 W. Tanthapanichakoon and A. Veawab Polarization be-haviour and per-formance of in-organic corrosion inhibitors in mono-ethanolamine so-lution containing CO2 and heat-sta-ble salts.

381 V. Arjunan et al. Electrochemical corrosion behav-iour of low-carbon I-beam steels in a simulated Yucca Mountain reposi-tory environment.

392 D.-Q. Zhang et al. Morpholini-um oligomer as a novel vapour p h a s e i n h i b i -tor on the corro-sion of mild steel. Corrosion 61(5) May 2005

403 Y. Yi et al. Effect of an inhibitor on the SCC behaviour of Alloy 600 in a high-temperature caustic solution.

411 K.M. Ismail et al. Influence of zinc and lead on brass

corrosion in dilute sulfuric acid.

420 G.A. El-Mahdy and K.B. Kim. Monitoring of initial stages of atmospheric zinc corro-sion in simulated acid rain solution under wet/dry cyclic conditions.

428 F.J. P Moreno et al. Steel activation in concrete following interruption of long-term cathodic polarization.

437 E. Guilminot et al. Effect of phosphate concentration on the corrosion of Fe in water—polyethylene glycol mixtures.

444 S. Xu et al. Corrosion of UNS R30006 in high-temperature water under intermit-tent mechanical contact.

452 B.G. Pound et al. Ultrasonic mitigation of microbiologically influenced corrosion.

464 M.J. M Portero et al. Anodic polarization behaviour of Cu in concentrated aque-ous LiBr solutions and comparison with Pourbaix diagrams.

473 E. Cano et al. Dicyclohexylamine nitrite as volatile corrosion inhibitor for steel in polluted environments.

480 B.D. Chambers et al. Rapid discovery of corrosion inhibitors and synergistic combi-nations using high-throughput screening methods.

490 Y.-S. Choi et al. Effects of Cr, Co, Cu, Ni, and Ca on the corrosion behaviour of low-C steel in synthetic groundwater.

498 N. Birbilis et al. Simulated transient loss of cathodic protection for buried pipelines.

502 E. Boese et al. Magnesium alloy in contact with coated components.



Protective Coatings Seminar Review by F. Salome

The ACA NSW Branch held its annual Semi-nar on Protective Coatings on May 24th, 2005 at the North Sydney Leagues Club. The pleasingly large audience heard presentations from five speakers before retiring for refreshments and informal discussion.

Jon Wilson of International Protective Coat-ings spoke on Intumescent Coatings. He first explained how these products act to insulate steel, by a process known a Passive Fire Protection, and then explained the design parameters that must be considered when specifying coating type and thickness. Applied in much the same way as other protective coatings, these products offer a useful alternative to bulky materials such as vermiculite or concrete, and are targeted toward refineries, the chemical industry and off-shore installation.

Walter Heim from Heim Surface Technology then spoke on Low Energy Water Blasting for Removal of Hazardous Coatings and Graffiti. In an informal and entertaining presentation, Walter reviewed the mechanics of and equipment used for low pressure water blasting, and showed sev-eral examples of past projects as well as passing around samples of blast nozzles, abrasives and paint strippers, the latter used to soften the coating to facilitate removal.

David Dawson from Munters gave a presenta-tion titled Dehumidification – Whose problem Is It? David gave an extensive review of the use and principles of dehumidification in relation to sur-face preparation and coating work. David empha-sised the importance of lowering dew-point when implementing climate control over such projects. He argued that the cost of dehumidification, which is often seen as an added obstacle to a contractor tendering for work, will bring significant benefits to the owner, in reduced down-times and increased coating performance, and should be specified so that all contractors allow for it in their prices.

Noel Kerswell, from Wattyl, spoke next, on Coating Galvanised Steel. Noel reviewed the problems often experienced in coating galvanised surfaces, and discussed the various views preva-lent within the industry regarding galvanising as a substrate for protective coatings. Noel related his own company’s experience with particular primers for gal, and emphasised that for a difficult substrate such as galvanising, generic specifica-tions such as “etch primer” or “low build epoxy” are not adequate, and that specific products with proven long term performance should be speci-fied by name.

Finally, the Chairman, Fred Salome from CTI Consultants presented a Review of Dry Film Thickness Measurement. Although relatively easy to perform and comprehend, dry film thick-ness measurements are still a common subject of disagreement between contractor, inspector and owner. Particular areas of contention can be the field calibration of instruments, and the adjust-ments for surface roughness, especially if the surface profile is high, as often results in blast chambers using steel grit abrasive. Fred reviewed AS 3894.3, Determination of Dry Film Thickness and compared it to SSPC PA-2, the most common standard worldwide for DFT.

Overall the afternoon was both instructional and entertaining, as well as providing useful networking for the audience came from such di-verse backgrounds as contracting, coating supply, architecture and engineering.

NSW Branch News2005 Technical Meetings

Our upcoming NSW Technical Meeting calendar is as follows:

Concrete Seminar: Wed 24th Aug

ACA/SCAA Joint Meeting: Thurs 15th Sept

Scrap Metal Show: October

Event details are available closer to the event via email, flyers and on our web site.

2007 Conference 25th to 28th Nov 2007

The 2007 Australasian Corrosion Association Conference shall be held in Sydney. Although the conference is over two years away, the NSW com-mittee have begun with preliminary arrangements such as venue selection and sponsorship.

As you can imagine, a tremendous amount of effort is required in putting a conference of this magnitude together. That is why we are looking for enthusiastic and committed persons to assist with arrangements. At this stage all positions are open including Convenor, Technical Convenor, Sponsorship Convenor and social activities co-ordinator.

Should you be interested in assisting with Conference preparations, please contact NSW Mohammad Ali on 9239 7217, [email protected] or Jim Galanos on 9763 5611, [email protected].

SA Branch News

Paint and Coatings Technical Group Meeting Sponsored

by International Paint

About 20 members enjoyed a great night of fun, food, drinks and safety on Tuesday 21st June at the Kentish Arms in North Adelaide. Gary Whittle from International Paint gave a presentation on Health and Safety in the Blast-ing and Painting industry.

Upcoming Events

Tuesday August 23 Technical meeting at Kentish Arms Hotel Sponsored by DENSO Presentation from David Towns Saturday August 27th Jubilee Dinner, 7 for 7:30pm Adelaide Meridien 21 Melbourne Street, North Adelaide

Cost for members and past members and partners approx $55, Non members approx $75. Cost includes entertainment, meal and drinks.

ACA Branch News

Tel: (03) 9561-1311 Fax: (03) 9561-4465Toll Free: 1800 335 810

Email: [email protected]

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WA Branch NewsThe WA Branch June technical presenta-

tion was held in the Bryant room at the WACA ground and was attended by 26 members. Hassan Nabi Zadah, the corrosion engineer responsible for the Dampier to Bunbury Natural Gas Pipeline and Moomba to Adelaide Gas pipelines, gave an enlightening talk entitled “Interference between cathodic protection and earthing systems on pipelines”.

Hassan discussed his experience in deal-ing with the interaction between the interests of the Corrosion and the Electrical Engineer in the design of earthing systems, specifi-cally for onshore gas pipelines. He gave a brief description of Low Frequency Induction (LFI), Earth Potential Rise (EPR) and step / touch potentials as a way of introduction to the types of hazards that may be likely to occur on pipelines. The types of mitigation usually employed to reduce/eliminate these hazards were also described.

Hassan concluded with discussion of the issues that may arise as a result of materials selection i.e. current drain from the pipeline Cathodic Protection systems and galvanic interaction resulting from earthing materials and their connection to the pipeline facilities. The elimination of these problems with various types of decoupling devices was also covered. The majority of members then stayed on for an enjoyable dinner.

Upcoming technical presentationsDate Topic

August 17th Newbuild FPSO Corrosion Protection

October 19th Committee meetingNovember TBA

ACA Branch News

At the Royal NZ Yacht Squadron’s Com-modore’s Room in Westhaven, on Friday 17th June, a special dinner function was organised by ACA Auckland Division to celebrate the 50th Jubilee of the Australasian Corrosion Association. The Golden Jubilee dinner was fully subscribed and attended by sixty ACA members, former committee members and visitors from around the city and the coun-try. Visitors were welcomed from Auckland, Rotorua, Havelock North, Wellington, and also one of our Australian ACA colleagues from Melbourne, Nick Subotsch. In addition, many of the ACA’s sister Technical Groups were represented by the people present, including IPENZ, SCANZ, NZABA, NZSSDA, IMar-EST and NZIC. It was great to have so many friends of ACA present to help celebrate the ACA Golden Jubilee in New Zealand.

The evening commenced with MC Les Boulton presenting a pot pouri of many of the ACA activities conducted by the NZ Branch around New Zealand over recent years. Dur-ing the sumptuous dinner that followed, two Dinner Speakers gave presentations on the life and times of the Auckland Harbour Bridge (1959-2005). The bridge could be viewed through the windows of the Commodore’s Room. First to talk was Jim Watt, Director of Central Coatings Ltd and a former NZ Branch

Committee Member, who described the early days of the bridge from 1959 until the 1970’s, when Davy Metals Industries, an early member of the NZ Branch, were involved in the bridge construction and maintenance painting. Kerry Dalzell, Director of KDA and ACA Committee Member, then presented part two of the bridge’s history, covering the period from the 1980’s until 2005. Both Speakers gave well-illustrated talks and they were thanked for their his-torical contributions by Stan Collins, Auckland Division Chairman. After a social gathering that then went until late, the ACA Jubilee Dinner wound up with everyone agreeing that it was a night to remember.

ACA Auckland DivisionACA Jubilee Dinner, 17th June 2005

The ACA Auckland Division meeting held on June 30th at the Officers Club in Newmarket was a dinner meeting held jointly with the Institute of Marine Engineering Science & Technology (IMarEST), organised by Hum-phrey Ewens. This meeting was nominally the Auckland Division July monthly meet-ing. The well-attended joint dinner meeting was preceded with a social gathering in the lounge at the Officers Club, followed by an excellent meal.

The members present were fortunate to have as after-dinner speaker, Rear Admiral Peter McHaffie. Peter has recently retired from the Royal NZ Navy and he is now Chief Executive Officer for the NZ Coastguard, based at Mechanics Bay in Auckland. His subject for the evening was “Transition from Navy to Coastguard”. Peter’s talk was well illustrated with images of RNZ Navy vessels (older and recent), and the type of fast marine rescue craft

ACA Auckland Division Meeting Report July

(and helicopters) that he has become familiar with in the Coastguard volunteer service. Peter recounted interesting stories from his long naval service and he included images of armed NZ Navy personnel boarding and searching merchant ships in the Persian Gulf during the Iraqi war. His senior managerial service in the Navy (with his own personal Flag Lieutenant to carry out his wishes) was then contrasted with his recent experiences of managing the work of the Coastguard, a group of marine volun-teers who provide a vital service for seafarers around the country. Peter noted that he had to come down to earth in a hurry, in order to achieve the Coastguard’s Charter through the services of people who were mainly part-time mariners and volunteers – a fast learning curve. The excellent dinner meeting concluded with a vote of thanks to the speaker by Kerry Dalzell, representing ACA Auckland.

Contributions WelcomeIf you would like to submit an article

for publication in Corrosion & Materials, please send us your material

by email: [email protected] or fax: 61(0)3 9874 4800.


Nick Subotsch of Peerless Industrial Systems Pty Ltd in Australia spoke to an audience of 19 drawn from ACA Wellington Division, SCANZ and NZWWA on June 20, 2005.

Nick began by talking of the two purposes of coatings and linings for systems containing waste and water. The first is to protect the containment vessel (pipe, tank, etc) from corrosion by the contents (sewage, etc). The second is to protect the contents from contamination by the containment materials, or from species encouraged to develop on the containment walls.

For the first of these applications, he suggested that there are many materials with more than 20 years service – his company has a product for sewerage system coating which is unchanged in 30 years and performs extremely well - but there is no uniform standard that can be applied. He suggested that there was quite a simple decision tree in such cases involving review of the history of use of the product in water and waste systems, the availability of third party data, the extent of the product principal’s support for the product, and a final expert assessment by the specifier.

Decisions in the second area are easier because there is an ex-plicit standard that the coating/lining must meet, namely AS/NZS 4020:2002, which relates to ensuring that potable water quality is maintained. Nick suggested that there is one deficiency in the AS/NZS 4020 standard, in that the manufacturer is allowed to nominate the coating cure temperature. Most choose 20oC, which is a rarely-found condition in practice. He further suggested that specifiers should seek data that shows a pass at a high surface:volume ratio, and this was crucial when considering products which may have certification through routes different from AS/NZS 4020: 2002 compliance (such as through testing to a British Standard).

‘Given that there are potentially such simple decision systems, why then do we get so many coating problems?’ was the next issue that Nick addressed. He focused on two particular modes of failure which seem prevalent: blistering/delamination of coatings on steel clear of weld seams etc, and blowholes/voids in coatings on concrete which allow the liquor to the substrate.

Many modern high-build coatings are applied to steel by spraying (provided the equipment is competent for the task – if the supply lines are too narrow or too long they may simply block). An observation is that in many such jobs there are not coating problems at weld seams, corners, and joints. Nick’s hypothesis is that this is because these areas are stripe coated, and so the surface is thoroughly wetted, whereas if the steel is say at 33-35 oC (easily achieved in afternoon solar warming of tank walls) the sprayed paint cures as it hits the steel and micro-air voids form. These need to be rolled out – Nick showed examples of jobs where this had been done. Conversely, if the steel is too cold the viscosity immediately rises and the coating again doesn’t wet out the surface properly.

Nick showed pictures of a waste treatment tank in a meat works which had sodium hypochlorite solution introduced, showing severe

coating degradation two years after being brought into service. There was a distinct boundary to the damage, which started around 8 feet above the tank floor, and this was consistent with the height to which rollers had been able to reach from the floor.

Nick said his impression is that concrete surfaces have more blow-holes in the surface than 20 years ago, which he attributed to the use of concrete additives which have changed the ability of concrete paste to move and release entrained air when vibrated. (In question time, someone suggested it may also have to do with the shuttering materials used and or the surface release agents on them.) The trapped air, when a coating is applied over the void, expands and creates a pinhole.

Nick suggested there are a number of ways of dealing with such surfaces. One is to render the whole surface. His preference over this is to apply a thin coating layer, make up a slurry with the epoxy coat-ing and silica flour and daub the voids, and then apply a final coat. He finds this method can be more cost-effective in down-time of the facility than rendering the whole surface. Another solution, which he estimated is 60-70% of the cost of rendering, can be to embed a layer of fiberglass tissue (say 25 g/m2 – an off-the-shelf product) into a thin initial coating film, then apply a finishing coat over this.

Nick suggested that insufficient effort is applied to charting the problems which do arise and the likely parameters affecting them, which is an essential first step to their eradication. He suggested that simply adding more ‘quality’ checks is not the answer – the reasons for failure should be eradicated, not failures ‘inspected out’. Sometimes there are practice-related limitations – for example sag when a coating is attempted to be applied too thick, and sometimes the equipment and skills to do the job properly are absent. Nick advocated a proper systems approach to every job – the substrate preparation, materials selection and materials application must all be addressed. There should be a focus on risk assessment and minimization, and the temptation to take short cuts should be avoided.

The Wellington Division Chair, Dr Barbara Webster, thanked Nick for his informative presentation.

John R Duncan Building Research

Materials, Coatings for Water & Waste Treatment

ACA Branch News

L—R: Nick Subotsch, Dr Barbara Webster, Willie Mandeno


Corrosion and Materials, Technological Supplement, publishes papers in the following categories, “Original Research”, “Techno-logical Reviews” and “Case Histories” and such papers are solicited by the Committee of Associate Editors. Letters responding to papers published in the Journal are also considered for publication. Submis-sion of a paper to the journal will be taken to imply that it represents original work not previously published, that it is not being considered elsewhere for publication, and that if accepted for publication, it will not be published elsewhere in the same form.

Papers may be submitted electronically or in hard copy form. All papers must be accompanied by a separate 150 word Abstract and a statement of the category into which a paper falls. As Abstracts are used to direct the paper to appropriate Associate Editors and review-ers, failure to submit an Abstract may result in considerable delays in publication. All papers should be typed with double spacing and wide (3 cm) margins. The associate Editors do not wish to be prescriptive concerning writing conventions, but an appropriate style guide may be found at www.corrosion.com.au, in the “Corrosion and Materials” section.

Paper submissions should be submitted in triplicate and submitted to “The Publications Co-ordinator”, ACA Inc. PO Box 112, Kerrimuir, Vic. 3129, Australia. Electronic submissions should be directed to “The Publications Co-ordinator” <[email protected]>.

REVIEW PROCEDURESAuthors will be informed as soon as possible after the submis-

sion of a paper of the name of the appropriate Associate Editor who is handling their paper. It is to this officer that any correspondence should be directed. All papers submitted are subjected to a rigorous review procedure by independent referees. It is the intention of the Associate Editorial Committee that reviews by two anonymous referees will be forwarded to a potential contributor within six weeks of the submission of an original manuscript. In order to expedite publication authors are encouraged to modify (if necessary) their papers as quickly as possible and to submit the modified version to the appropriate Associate Editor. The decision of that Associate Editor concerning publication is final.

PROOFSAuthors will receive page proofs (including figures) for correction,

and these must be returned to the ACA publications officer within 48 hours of receipt. Please ensure that a full postal address is given on the first page of the typescript, so that proofs are not delayed in the post. Authors’ alterations in excess of 10% of the original composition cost will be charged to authors.

There are no page charges to individuals or to institutions. It is a condition of the acceptance by the editor of a typescript for publica-tion that the publishers acquire automatically the copyright in the typescript throughout the world.

Corrosion and Materials NOTES FOR CONTRIBUTORS


Report of the fifty-fourth meeting of the AEC held on Wednesday 15th June 2005 at the Adelaide Oval, Gil Langley Room, SA.

Thirty AEC members met in Adelaide on Wednesday June 15th. Demonstrating the depth and breadth of interest in proceedings, members came from as far as Brisbane and Melbourne and as wide as Perth and Auckland. Presentations are summarised below.

Issues with AS4853, Electrical Hazards on Metallic Structures, Brian Martin, Brian Martin and Associates

Brian highlighted issues with AS4853 Category A touch voltage limits and their in-consistencies with touch voltage limits in other relevant codes, the lack of a risk management approach for construction and maintenance work, and the resultant high cost to industry. The standard is due for review commencing in 2006. The AEC agreed that a letter should be sent to Standards Australia asking whether they would accept a draft amendment for consideration so that some changes may be made more rapidly and thus provide industry substantial savings.

Electrical aspects of transformer recti-fiers for use on well-coated structures, Rich-ard Brodribb, M. Brodribb Pty Ltd

Richard addressed the various functions required of a modern transformer rectifier to protect a well-coated pipeline. He touched on the various forms of TRU output control (switch mode is his preferred method of control), the effect of highly resistive soil conditions on permanent reference electrodes and the possible need to consider alternative feedback criteria to the TRU control circuit e.g., corrosion rate.

Modelling and Interpretation of Poten-tials on Coated Pipelines, Geoff Cope, Geoff Cope and Associates

Geoff discussed application of attenuation equations to determine the (“ON”) potential

distribution along a pipeline under various scenarios of coating quality and earthing, and how this could be related to the polarised interface (“OFF”) potentials of various sized coating defects in differing soil environments using a simplified electrical model.

Remote sensing for cathodic protection units Brian Martin, Brian Martin and As-sociates

On well-coated pipelines the CP units are usually located at the ends of isolated sections to mitigate telluric effects. Brian proposed that as the attenuation on such lines is essentially zero, one CPU could be located anywhere on the pipeline providing the potential sensing was done at both extreme ends of the section and fed back to the CPU, which would adjust its output to the least pro-tected input. This approach would halve the number of CP systems required and provide flexibility in positioning groundbeds.

Horizontal versus vertical anode ground-beds, David Robertson, United Water, South Australia

David recounted United Water design practices for horizontal anode beds.

Advantages such as no drilling, lower cost, easier to install, better control and verification of installation because you can see what’s going in the ground, anode bed is in a more uniform environment, better venting, gas blocking unlikely, watering usually not required, not so visibly or physically intrusive, less main-tenance

Disadvantages are: need low resistiv-ity at shallow depths, need greater physical separation from foreign assets, require longer anode bed easement, greater possibility of interference.

Where/when to use; rural locations, where space and separation available, preferably low resistivity at shallow depths, where you have cost restrictions, if drilling contractor not avail-able, if distributed anodes are needed.

Dave presented some performance figures for horizontal and vertical groundbeds operated by United Water showing the effects of varying soil resistivity in vertical groundbeds.

Australian Electrolysis Committee Mid Year Meeting – Wednesday 15th June 2005Cathodic protection under disbonded

coatings, Bruce Ackland, Bruce Ackland and Associates

Bruce presented a schematic of the five planes along which disbonding may occur in an organic coating/metal substrate system. H2 does not play a role in the cathodic dis-bondment of coatings, rather alkali attack of the polymer coating at the steel/coating interface is the predominant deterioration mechanism. Cathodic reduction or dissolution of the interfacial oxides may also play a role. The role of H2 is to reduce the ability of the CP current to penetrate the crevice by forming then reducing the effective crevice cross sec-tion and blocking the holiday.

Crevice attenuation can create potentials within hazardous ranges for corrosion and SCC.

The question was asked; do we (CP indus-try) need to develop probes to determine CP levels beneath disbonded coatings?

Corrosion and Prevention 2005-06-28Being the most active industry group we

have secured our spot at CAP05 on Tuesday afternoon November 22. Provisional forum subjects are;a) Performance of carbonaceous backfill. Bruce

Acklandb) Alternatives to Wenner 4-pin resistivity test

method. Mike McCoyc) Deepwell groundbed design in Venezuela. M

Davidsond) Barnes Layer resistivity analysis. Peter

Clarke) Stray current interference testing on rein-

forced concrete foundations; KL light rail Phil Bundy

f) Continue Discussion of AS4853/60479/1768/ESAA handbook. Richard BrodribbSee you there!

Mark Davidson, Secretary +61(0)8 9278 8121,

Mob: +61 (0)419 949 897, Fax: +61(0)8 9278 8336

[email protected]

AEC Meeting


What does it mean to ‘model’ a corrosion process? If you read a typical corrosion journal you will probably come to the conclusion that it can mean many different things, depending on the circumstances. In a very simple case, a ‘model’ might simply be a written explanation of the underlying reasons for experimental results; for example, the high dissolution rate within pits in stainless steel is due to the maintenance within the pit of an aggressive local chemistry, with a lower pH and higher chloride concentration than in the bulk solu-tion outside the pit. At another level, the same ‘model’ might be described using a series of chemical and/or mathematical equations; for example, chemical equations can easily be written out for the hydrolysis of dissolved metal ions to produce local acidity within a pit, and thermodynamic calculations can be used to show the existence of potential-pH conditions in which the passive film is not stable and ac-tive corrosion would be expected. To such a ‘model’ it is then possible to add some kinetic equations (e.g. Tafel’s Law) and use finite-ele-ment methods to run computer simulations of the growth of corrosion pits.

However, the model outlined above is still a long way from a complete description of pitting corrosion. To explain just the results of simple pitting potential measurements in laboratory conditions it is necessary to expand the scope of the model to include multiple pos-sible pitting sites over a rough sample surface, and to develop an accompanying model for the pit nucleation process; i.e. the localized breakdown of passivity. In the corrosion lit-erature there are many proposed pit nucleation ‘models’, some of them including chemical or mathematical formulations for events occurring at the nanoscopic scale of the passive film, but even these make assumptions about the underlying atomistic processes. For example, several models of pit nucleation assume the diffusion of anions through the passive film,

and therefore include in their mathematical description a diffusion constant, D. But this diffusion process itself is something that can be ‘modeled’ and simulated in a computer, rather than just obtained by experiment. Similar argu-ments can be followed to the atomistic level for other parts of the overall model, such as the hydrolysis reactions in the pit solution, or the dissolution of individual atoms from the active pit surface.

This leads to the fashionable concept of ‘multiscale modeling’ that resolves material behaviour at multiple length and time scales by linking atomistic models to continuum ones. Atomistic techniques include Density Functional Theory (DFT), Molecular Dynam-ics (MD) and Kinetic Monte Carlo (KMC) methods, whilst Finite Element Models (FEM) are generally used for solving problems at the

Technical Group News

ResearchCorrosion Science and Supermodels continuum level. In the ultimate case, atomistic

simulations are directly coupled to continuum models such that a full-scale simulation of a macroscopic process, capturing behavior at all length scales, can be run on a computer. In practice, such all-encompassing simulations of corrosion remain some way from fruition, but significant achievements have already been made in some areas of materials science, in-cluding hydrogen-embrittlement of aluminium [e.g. www.engin.brown.edu/faculty/curtin].

What do you think about the future of multiscale modeling in corrosion science? We are always seeking contributions to this journal. Letters concerning multiscale models of corro-sion would be welcome, as would articles on any aspect of corrosion research.

Nick Laycock Research Technical Group Chair


AS/NZS 1518:2002 External extruded high-density-polyethylene coating system for pipes

AS 2228.2-1992 Spectacles - Spectacle frames AS 2239-2003 Galvanic (sacrificial) anodes for cathodic

protection AS 2518-1992 Fusion-bonded low-density polyethylene

coating for pipes and fittings AS 3680-1989 Polyethylene sleeving for ductile iron pipe-

lines AS 3703.2-1989 Long-span corrugated steel structures - De-

sign and installation AS 3750.1-1994 Paints for steel structures - Epoxy mastic

(two-pack) - For rusted steel AS/NZS 3750.10:1994 Paints for steel structures - Full gloss epoxy

(two-pack) AS/NZS 3750.13:1997 Paints for steel structures - Epoxy primer

(two pack) AS/NZS 3750.14:1997 Paints for steel structures - High-build epoxy

(two-pack) AS/NZS 3750.15:1998 Paints for steel structures - Inorganic zinc

silicate paint AS 3750.18-2002 Paints for steel structures - Moisture cure

urethane (single-pack) systems AS 3750.2-1994 Paints for steel structures - Ultra high-build

paint AS/NZS 3750.3:1994 Paints for steel structures - Heat resisting

- Exterior AS/NZS 3750.4:1994 Paints for steel structures - Bitumen paintAS/NZS 3750.5:1994 Paints for steel structures - Acrylic full gloss

(two-pack) AS/NZS 3750.6:1995 Paints for steel structures - Full gloss poly-

urethane (two-pack) AS/NZS 3750.8:1994 Paints for steel structures - Vinyl paints -

Primer, high-build and gloss AS/NZS 3750.9:1994 Paints for steel structures - Organic zinc-rich

primer AS/NZS 3862:2002 External fusion-bonded epoxy coating for

steel pipes AS 4321-2001 Fusion-bonded medium-density polyethylene

coating and lining for pipes and fittings AS 4397-1996 Electroplated coatings of zinc on steel fasten-

ers with imperial threads AS/NZS 4534:1998 Zinc and zinc/aluminium-alloy coatings on

steel wire DR 04148 CP Application of polyethylene sleeving for

ductile iron piping DR 04149 CP Polyethylene sleeving for ductile iron

piping DR 04186 Paints for steel structures - Part 1: Epoxy

mastic (two-pack) - For rusted steel DR 04187 Paints for steel structures - Part 2: Ultra

high-build paint DR 04188 Paints for steel structures - Part 3: Heat

resisting - Exterior DR 04189 Paints for steel structures - Part 5: Acrylic

full gloss (two-pack)

DR 04190 Paints for steel structures - Part 10: Full gloss epoxy (two-pack)

DR 04191 Paints for steel structures - Part 19: Metal primer - General purpose

DR 04192 Paints for steel structures - Part 20: Anticor-rosive metal primer - Solvent-borne - Lead and chromate free

DR 04193 Paints for steel structures - Part 21: Undercoat - Solvent-borne

DR 04194 Paints for steel structures - Part 22: Full gloss enamel - Solvent borne

DR 04195 Paints for steel structures - Part 23: Semi-gloss enamel - Solvent-borne

DIN (46 Items)DIN EN 10169-3 Continuously organic coated (coil coated) (2003) steel flat products - Part 3: Products for

building interior applications DIN EN 10288 (2003) Steel tubes and fittings for on and offshore

pipelines - External two-layer extruded polyethylene based coatings

DIN EN 10289 (2004) Steel tubes and fittings for onshore and offshore pipelines - External liquid applied epoxy and epoxy-modified coatings

DIN EN 10290 (2004) Steel tubes and fittings for onshore and offshore pipelines - External liquid applied polyurethane and polyurethane-modified coatings

DIN EN 1065 (1998) Adjustable telescopic steel props - Product specifications, design and assessment by calculation and tests

DIN EN 12068 (1999) External organic coatings for the corro-sion protection of buried or immersed steel pipelines used in conjunction with cathodic protection - Tapes and shrinkable materials

DIN EN 12269-1 Determination of the bond behaviour (2000) between reinforcing steel and autoclaved

aerated concrete by the “beam test” - Part 1: Short term test; English version of DIN EN 12269

DIN EN 12269-2 Determination of the bond behaviour (2004) between reinforcing steel and autoclaved

aerated concrete by the beam test - Part 2: Long term test

DIN EN 12487 (2000) Corrosion protection of metals - Rinsed and non-rinsed chromate conversion coatings on aluminium and aluminium alloys; English version of DIN EN 12487

DIN EN 12499 (2003) Internal cathodic protection of metallic structures

DIN EN ISO 12944-8 Corrosion protection of steel structures by(1998) protective paint systems - Part 8: Develop-

ment of specifications for new work and maintenance (ISO 12944-8:1998)

DIN EN 13349 (2002) Copper and copper alloys - Pre-insulated copper tubes with solid covering

DIN EN 13509 (2003) Cathodic protection measurement tech-niques

STANDARDSThe following standards come from the website http://www.standards.com.au/online/

Protection and Corrosion (searched by abstract)AS & AS/NZS (35 items including 12 Drafts)



DIN EN 13811 (2003) Sherardizing - Zinc diffusion coatings on ferrous products - Specification

DIN EN 1403 (1998) Corrosion protection of metals - Electro-deposited coatings - Method of specifying general requirements

DIN EN 1537 (2001) Execution of special geotechnical works - Ground anchors; English version of DIN EN 1537:1999 + AC:2000

DIN EN ISO 17834 Thermal spraying - Coatings for protection(2004) against corrosion and oxidation at elevated

temperatures (ISO 17834:2003) DIN 18182-4 (1987) Accessories for the installation of gypsum

plasterboard; nails DIN 18364 (2000) Construction contract procedures (VOB)

- Part C: General technical specifications in construction contracts (ATV); Corrosion pro-tection of steel and aluminium structures

DIN 18807-1 (1987) Trapezoidal sheeting in building; trapezoidal steel sheeting; general requirements and determination of loadbearing capacity by calculation

DIN 18807-9 (1998) Trapezoidal aluminium sheeting and connec-tions in building - Part 9: Structural detailing and installation

DIN 18914 (1985) Thin-walled cylindrical steel tower silos DIN EN 22063 (1994) Thermal spraying -Zinc, aluminium and their

alloys (ISO 2063:1991, modified) DIN 28054-5 (1996) Powder coatings on metallic components for

use in process engineering DIN 30672 (2000) Tape and shrinkable materials for the cor-

rosion protection of buried or underwater pipelines without cathodic protection for use at operating temperatures up to 50 øC

DIN 30675-1 (1992) External corrosion protection of buried pipes; corrosion protection systems for steel pipes

DIN 30675-2 (1993) External corrosion protection of buried pipes; corrosion protection systems for ductile iron pipes

DIN 30678 (1992) Polypropylene coatings for steel pipes DIN 3476 (1996) Corrosion protection of water valves and

pipe fittings by epoxy powder or liquid epoxy resin linings - Requirements and testing

DIN EN 364 (1993) Personal protective equipment against falls from a height; test methods; german version EN 364:1992

DIN EN ISO 4543 Metallic and other non-organic coatings (1995) - General rules for corrosion tests applicable

for storage conditions (ISO 4543:1981) DIN 4680-1 (1992) Stationary, above ground, steel pressure ves-

sels for the storage of liquefied petroleum gas; dimensions and mountings

DIN 4680-2 (1992) Stationary, partially sunk, steel pressure ves-sels for the storage of liquefied petroleum gas; dimensions and mountings

DIN 4753-10 (1989) Water heating installations for drinking water and service water; cathodic corrosion protec-tion of uncoated steel vessels; requirements and testing

DIN 4753-6 (1986) Water heating installations for drinking water and service water; cathodic corrosion protection of enamelled steel containers; requirements and testing

DIN 50902 (1994) Protective coatings on metals - Concepts, ap-plication methods and surface preparation

DIN 50926 (1992) Impressed current cathodic corrosion protec-tion in the bottom zone of unalloyed steel fuel oil storage tanks

DIN 50927 (1985) Planning and application of electrochemical corrosion protection of internal surfaces of apparatus, containers and tubes (internal protection)

DIN 50928 (1985) Corrosion of metals; testing and assessment of the corrosion protection of coated metallic materials in contact with aqueous corrosive agents

DIN 50929-2 (1985) Corrosion of metals; probability of corrosion of metallic materials when subject to corro-sion from the outside; service components inside buildings

DIN 50934-1 (2000) Methods for evaluation of effectiveness of water treatment equipment for corrosion control - Part 1: General

DIN 50934-2 (2000) Methods for evaluation of effectiveness of water treatment equipment for corrosion control - Part 2: Equipment for reducing the release of corrosion products into drinking water

DIN 51524-3 (1990) HVLP hydraulic oils; minimum require-ments

DIN 55928-8 (1994) Corrosion protection of steel structures by the application of organic or metallic coat-ings - Corrosion protection of thin-walled structural members

DIN 55928-9 (1991) Corrosion protection of steel structures by the application of organic or metallic coat-ings; composition of binders and pigments for coating materials

DIN EN 990 (2003) Test methods for verification of corrosion protection of reinforcement in autoclaved aerated concrete and lightweight aggregate concrete with open structure

ISO (4 Items)ISO 11303:2002 Corrosion of metals and alloys - Guidelines

for selection of protection methods against atmospheric corrosion

ISO 15710:2002 Paints and varnishes - Corrosion testing by alternate immersion in and removal from a buffered sodium chloride solution

ISO 16701:2003 Corrosion of metals and alloys - Corrosion in artificial atmosphere - Accelerated corrosion test involving exposure under controlled con-ditions of humidity cycling and intermittent spraying of a salt solution

ISO 17834:2003 Thermal spraying - Coatings for protection against corrosion and oxidation at elevated temperatures

JIS (3 Items)JIS H 8651:1995 Processes for corrosion protection of mag-

nesium alloys JIS H 9124:1999 Recommended practice for zinc coating

(Hot-dipped) JIS Z 1903:1995 Petrolatum paste for corrosion protection


For more information about standards or this report, please contact Arthur Austin, [email protected]


Evaluating Pipeline Coating

SUMMARYHDD are usually installed in areas where the pipe is impractical to

repair, so they have to comply with the full design life requirements of the pipeline with no repair option. There are a number of circum-stances in which pipe in HDD can not be cathodically protected and can be subject to high rates of corrosion. In spite of this the acceptance criteria for pipe in HDD is of a lower standard than would be accepted for normal trenched construction.

1. INTRODUCTIONHorizontal Directional Drilling (HDD) has become a widely used

technique for installing sections of underground pipeline in areas that would otherwise cause a variety of problems. Whilst it was initially used to overcome major natural barriers such as large river crossings and very steep or collapsing slopes, it has now become cost effective to use on some shore line crossings as well as rail, road and creek crossings.

However, sharp edges associated with the hole geometry, rocks falling into the HDD, and the high pulling forces combine to create an environment where there is a significant likelihood of coating damage. This is usually mitigated by providing the pipeline within the HDD with an abrasion resistant coating. However damage can still occur. As pipelines typically have design lives in excess of 40 years, and HDD are usually installed in areas where coating maintenance and pipe repair are impossible, some assurance is required that the corrosion protection coating is in a satisfactory condition. The cost of failure in some of these areas, in terms of pollution costs, the results of ignition, loss of product, penalty for loss of supply, injury, public relations, and replacement of the entire HDD, can be immeasurable.

As the use of HDD has become more common and there are more HDD installers in the market, prices have become more competitive, but it appears to be at the expense of quality. Occasionally there is little attention given to hole cleaning, and smaller machines are used that do not have the extensive mud preparation and circulation equipment of larger machines. Smaller operators occasionally do not have the experience of the mud properties and the velocity required to clean the hole. Better specifications are required that provide for real time quality monitoring prior to the pipe being pulled in.

Specifiers may require the use of HDD in areas that are unsuit-able without a casing, may provide inadequate geotechnical data, and may accept the lowest tender which may not use the appropriate equipment or casing if necessary for the environment. They may also

Evaluating Pipeline Coating Condition on Horizontal Directional Drills

Brian A MartinBrian Martin & Associates, Corrosion Engineers

select the abrasion resistant coating based on vendor information and cost rather than on a proper investigation, performance requirements and a risk analysis.

A common test method is required that has a high level of reliability in identifying coating defects, at the time of HDD installation, that are not acceptable for the long term integrity of the pipeline.

2. TEST METHOD DEVELOPMENT

2.1 Early HDD - No Testing

HDDs were not used in the Australian area until the early 1990s. The Kutubu Pipeline, which was constructed from 1991, had two major river crossings. In 1990 they were designed as open cut river banks and a bottom-towed pipe. Because the rivers frequently carry high flood flows with associated high water velocity, the construction difficulty associated with the open cut technique resulted in the contrac-tor electing to construct the crossings using HDD. The technique was new to Australia and so it was decided to leave coating quality issues to the overseas specialist HDD operators engaged by the contractor. The pipe was provided with a double coat of extruded high density polyethylene over mastic (HDPE/M), and then a 25mm thick coating of spiral wire reinforced concrete.

Unfortunately the substructure of the area was limestone which contained caverns of varying size. When the drill goes through a cavern it can hit the rock on the other side and then move in any direction across the rock surface for a short distance before it bites into the rock. The result is that the hole may not be concentric so that when the pipe is pulled in it may bear directly on the edge of the surface causing damage. This can remove long strips of the corrosion coating, and in this case remove the spiral wire-reinforced concrete coating as well. The accumulated disbonded concrete coating formed a plug in the HDD, jamming the pipe. The problem was resolved after removing the pipe by the use of a steel casing over the full length of the HDD. The pipe, with insulating spacers, was pulled into the casing.

2.2 DCVG

Prior to 1994 some HDDs were tested using the Direct Current Voltage Gradient (DCVG) coating defect survey technique, but this system has decreasing sensitivity with depth and is of limited value for deep drills. Also, as most HDD are installed because of site access difficulties, the site is often not particularly accessible for DCVG surveys.



2.3 On-Potential SwingThe on-potential swing test method was used on pipelines in Aus-

tralia from 1994 to 1997, including the Moomba to Sydney Ethane Pipeline where the results were reported by Ian Fotheringham (1). This test method involves applying a cathodic protection (CP) cur-rent to the pipe, before it is tied-in to the rest of the pipeline, so that its potential is moved in the negative direction by at least one volt. The associated CP current is measured. The criterion used for this test was that the current requirement should not exceed 1µA/m2 of pipe area. This seemed an appropriate figure as most new pipelines at the time drew an average CP current of about that value, so it was not demanding more than the mean value of the entire pipeline, and it was a hard metric number.

2.4 On-PotentialThe Osborne Lateral was constructed in 1998 and included an

850m HDD under the saline Port Adelaide River in Adelaide. As the pipeline was in a saline environment of very low resistivity, it was not possible to move its potential in the negative direction by at least one volt without imposing extremely high current densities. To pro-vide an immediate solution for the HDD in the saline environment, the 1µA/m2 of pipe area criterion was applied at an on-potential of -900mV Cu/CuSO4 on-potential. However this was not suitable for general use as in non-saline environments the current density would vary with soil resistivity.

2.5 Polarization ChangeThe testing methodology was reviewed in 1999 when the Longford

to Sydney Eastern Gas Pipeline was in its design phase. After the review it was concluded that despite its limitations, a test method that used the CP current density of the HDD pipe as a criterion appeared to be the best available at the time.

In developing the test it was necessary to determine the potential at which the test current should be measured. It was decided to use polarization change, the difference in potential between the natural potential and the off-potential, as this prevented soil resistivity and natural potential from affecting the result. The initially used current density criterion of 1µA/m2 for the Ethane Pipeline was simply changed to 1µA/m2/100mV for the Polarization Change test criterion.

Figure I presents Polarization Change test results from an HDD. Polarization was carried out for 30 minutes but there was little change in the current output after 5 minutes. However the off-potentials con-

tinued to polarize with -908, -966 and -998 mVCu/CuSO4 measured at 10 minute intervals. This test method is the most widely used test method in Australia at present, however it does have some limitations which require resolution.

3. TEST METHOD LIMITATIONS AND NECESSARY IMPROVEMENTS3.1 Large Defects in High Resistivity Environments

The use of a CP current density criterion for the HDD pipe may be reasonable if the current is drawn by a large number of small de-fects. However experience has shown that most current is drawn by a small number of large defects. Therefore on a very long HDD, all of the current may just go to one large defect. If the defect is in a low resistivity stratum then it should be readily cathodically protected. However if it is in a high resistivity stratum, such as rock, then the resistance to earth of the defect may be too high to allow sufficient current to flow to protect it. The pipe would then not be protected and may corrode.

This can be addressed by using the data collected during the exist-ing Polarization Change test to also calculate Coating Resistance in terms of ‘current density per square metre per 100mV IR drop’. Thus instead of dividing the current density by the Polarization Change, it is divided by the difference in the On-Potential and the Off-Potential. This provides a parameter which is more sensitive to coating defects in high resistivity strata, and also caters for artificially less negative natural potentials.

If appropriate criteria are developed for both tests, and an HDD passes both tests, there is a higher probability of the coating being satisfactory than if only one is met.

3.2 Cathodic Protection ShieldingThe test does not indicate the presence of areas of possible shield-

ing of the CP. CP shielding occurs where there is a crevice between the pipe steel and another object so that there is a high electrical resistance to the flow of CP current along the crevice. Very high rates of corrosion, of up to 0.5mm/year, can occur in such crevices. Tighter crevices tend to result in higher corrosion rates. There are typically two causes of crevices:

• Coatings that have become disbonded as a result of me-chanical damage during installation of the pipe. This can result in a crevice between the steel and an insulating layer of coating which can result in CP shielding. The formation of such crevices has been found to be a particular problem on some Dual Layer FBE Coated HDD (See Figures II to IV from the North Queensland Gas Pipeline.).

• The rock or stones that cause gouging of the coating to ex-pose the steel are likely to be in contact with the steel when the pulling-in of the pipe is completed. This will result in a crevice between the gouging surface and the pipe steel, creating a crevice and shielding CP.

There are no field tests presently available that can detect the presence of shielded surfaces, so it would appear that the only way Figure I Potential and current plots of an HDD test.



Figure V: CP requirements on Ethane HDD

µA/m2 No. HDD>1 2

<1 >0.1 6<0.1

>0.014

<0.01 >0.001

4

<0.001 12 Figure IV: The compressive stress during pulling in fractured the bond between the steel and the FBE. This section

of coating was lifted off the pipe by finger, exposing the steel.

Figure II: The compressive force from a gouge caused a fracturing of the bond between the coating and the steel,

leaving non-adherent coating on the surface which can result in shielding of the CP.

Figure III: A gouge to the steel fractured the coating bond to the steel for 8mm in each direction which can result

in shielding of the cathodic protection.

to address this issue is to use coatings that are not prone to forming crevices and are resistant to gouging. Whilst considerable testing has been carried out on HDD coatings to measure their resistance to gouging, there does not appear to have been much work carried out on failure modes that can result in the formation of crevices. Additional work is required in this area.

At another location a gouge of less than 25% of coating thick-ness caused a fracturing of the bond between the FBE and the steel. Whilst this did not expose the steel to the environment it does show the sensitivity of the bond to propagating crack mechanical failure, in a similar way in which a 3mm diameter stone chip on 400 micron FBE can cause a 100mm diameter loss of adhesion.

3.3 Void Annular SpaceThe test will not detect coating defects in areas where there is no

electrolyte in the annular space of the HDD. This can occur in HDD that are above the water table. In such HDD there can be condensa-tion on exposed pipe steel surfaces which can cause a high rate of corrosion that can not be mitigated by CP. Such void annular spaces can occur when:

• The annular space is not filled with mud, or when• The mud in the annular space leaks out at rock fissures or into a dry porous environment.

The solution in such cases may include: • Topping the mud up as a maintenance operation.• Using a cement based grout seal the drilled hole.• Using a cement based grout to fill the annular space, providing there are no stress implications.• Provide the drill with a steel casing. The implications of the alternative solutions needs careful evaluation.

3.4 Current Density CriterionThere is an amount of field data that indicates that the 1.0 µA/m2/

100mV criterion used for acceptance of HDD coating is inadequate:

Ethane CriterionThe criterion used on the Moomba to Sydney Ethane Pipeline was

1µA/m2. It was simply changed to 1µA/m2/100mV for the Polariza-tion Change test criterion without a detailed evaluation of Ethane Pipeline test conditions. A subsequent evaluation revealed that the Ethane Pipeline testing was carried out at a mean polarization change of 840mV (1). Thus the mean criterion used on the Ethane Pipeline was equivalent to 0.125µA/m2/100mV, not the 1µA/m2/100mV used in the present criterion.

Intact CoatingThe Ethane Pipeline test results (1),

summarized in Figure V, indicate that the coating CP requirements covered a wide range of values. This may indicate that intact coating draws an insignifi-cant current, and that any current over say 0.001µA/m2 reflects an amount of coating damage.



Excavation ResultsFigure VI presents test results of a number of coating tests on

HDD. The HDD with current densities in excess of 1µA/m2/100mV Polarization Change, and the SEAGas HDD, have been investigated and the damage measured and rectified. The results are:

a) 16.3 µA/m2/100mV (Ethane) [Test failure result was 29 µA/m2 which calculates to 16.3 µA/m2/100mV.] “Most of the pipes were found to be deformed with extensive damage to the coating.”b) 8.0 µA/m2/100mV (EGP) Coating was abraded from two raised circumferential welds. c) 5.0 µA/m2/100mV (EGP) Coating was scraped along five pipes where they made contact with buried steel.d) 1.4 µA/m2/100mV (TGP) There was multiple scratching through the coating back to the steel over a 2m length of pipe.e) 1.4 µA/m2/100mV (TGP) Two scratches back to the steel. f) 1.0 µA/m2/100mV (Ethane) [Test failure result was 9 µA/m2 which calculates to 1.0 µA/m2/100mV.] “the coating on several pipes was found to be severely abraded.”g) <1.0 µA/m2/100mV (SEAGas)Three defects of 2.0%, 3.0% and 5.9% IR respectively. (Another

recent pipeline had a defect >20%IR and passed the Polarization Change test.)

New Generation CoatingsCommissioning the CP on pipelines with new generation coatings

results in mean pipeline current densities of the order of 0.5µA/m2 or less. This is for the entire pipeline including all buried valves and fit-tings, and is typically for a polarization change of at least 300mV. That is equivalent to a current density of 0.17µA/m2/100mV Polarization Change. A relatively short section of pipeline should be expected to perform better than this, especially as the section of pipeline involved often can not be repaired or maintained over the entire pipeline life and thus particular care is required.

SummaryThe presently used criterion of 1.0µA/m2/100mV is likely to allow

defects in pipe that are impossible to repair due to their location, and that would not be accepted for pipe installed in an open cut trench. This should be addressed by developing a lower criterion.

4. CONCLUSIONS The present system for accepting coating condition on HDD pipe

is flawed and can result in allowing coating defects that are not con-sistent with the long term integrity requirements of pipe that can not be readily maintained or replaced. To provide such security work is required in the following areas:

• Evaluate the use of the Coating Resistance test, in addition to the Polarization Change test, for testing coating condition.

• Evaluate coatings used in HDD for their resistance to loss of adhesion leaving crevices between the coating and the steel that can result in cathodic protection shielding.

• Evaluate grouting options to ensure that electrolyte surrounds the pipe in HDD that are above the water table.

• Evaluate the current density criterion to be used in the Polarization Change test and the Coating Resistance test.

5. REFERENCE1. Fotheringham & P.Grace, Corrosion & Materials, 22, 3, pp5-8 (June 1997)

6. ACKNOWLEDGEMENTSThe information presented in this paper was derived from

personal involvement with the projects and information provided by others involved. I give my thanks to the companies that have allowed me to present the information so that others may benefit from their experiences.

µA/m2/100mV

Ethane EGP TGP SEAGas

>1 2 2 2 0<1 >0.1 2 4 17 1

<0.1 >0.01 5 4 17<0.01 >0.001 2 0 74

<0.001 17 2 10

Figure V1: CP requirements on HDD per 100mV polarization


There are many factors that must be taken into consideration when selecting a coating system. Ex-

amination of these will assist the specifier in reducing the large number of possible coating systems for a given

structure to a manageable number. While structural design decisions can be based on precise quantitative data, the

choice of a protection system is largely based on qualitative factors. This is because many of the variables affecting the decision, from environ-ment through to differences in products from different manufacturers, cannot be precisely defined. As a result, there is unlikely to be only one system that will satisfactorily provide the desired features. It is tempting for the specifier to base selection on one of the few quantifiable factors, namely price, rather than consider the less definable features. This is unfortunate because cost is usually of lesser importance.

Some of the factors in no particular order, which must be considered by the specifier are described in the following paragraphs. Some other factors that may also determine the optimum coating selection will be addressed in forthcoming issues of Corrosion & Materials.

Substrate and Surface Condition. The substrate or surface to be coated is a primary determining factor.

While in this publication steel is the substrate of most interest, it must be remembered that some of the work may be galvanized or have some other metal coating, or the system may also be required to coat nearby concrete, timber or non-ferrous metals. If such non-ferrous substrates must be protected as well, the systems available will be limited as many coatings are compatible only with a clean steel surface. However, quite a number can be applied to other metals as long as the surface has been properly prepared. The composition of the steel has no effect on paint coatings, but may influence items to be pickled or galvanized. High strength steels should not be pickled, as there is the possibility of introducing hydrogen embrittlement, although this is usually driven out by subsequent galvanizing. Cold worked steels may become embrittled after galvanizing.

The condition of the steel surface can influence coating selection. Most new structures would normally be made from steel covered with mill scale or only slight rusting, and virtually any metallic or organic coating can be used if the surface is properly prepared. If surfaces are new, every effort should be made to take advantage of the ideal, and only, opportunity to carry out a proper, long-life and economic coating job.

If the surface is badly corroded, then the surface is much rougher and thicker coats would be required. It should be recognised that any coating placed over a rusted and pitted surface will not last as long as the same system applied over new steel, even with the best surface prepara-tion. This is because there will often be invisible corrosive salts at the bottom of the pits. Galvanizing is not generally applied over surfaces that have rusted and pitted. A surface that still has an intact coating will require specific treatment and coating selection is limited, as described in the chapter on maintenance. For example, the new coating must be compatible with the old coating.

Environment.The environment to which the coating will be subjected is another

factor. An aggressive environment, such as an off-shore structure or tank in a chemical plant, will require a far higher quality coating system than a structure built in a rural area. The various factors which influence the environment, and the means to categorise it, have been described in previous tutorials. Operating temperature is also important. Chlorinated rubbers and vinyls are not suitable for temperatures above 65 deg C and galvanizing or zinc-rich coatings do not perform well in hot, wet conditions. Silicone paints, inorganic zincs or metal spray coatings are required for high temperatures. Metal and inorganic zinc coatings do not suffer degradation due to UV light. If the structure is to have cathodic

protection, coatings must be resistant to cathodic disbonding. A coat-ing may have a requirement for graffiti resistance, abrasion resistance or some other specific need. The earlier tutorials on paints and metal coatings describes their strengths and weakness and how they behave in various environments. The specifier must consider all environments the coating will be subject to over its lifetime.

System Life. The life of the system will depend greatly on the environment, with

a given system in a benign environment lasting many times longer than the same system in an aggressive environment. If only a short life is required, a cheaper, lower quality system may be sufficient. In many situations, repair and maintenance are usually possible so a coating need not last the life of the structure, rather the life requirement is the time which can elapse before major or general maintenance is required. This is known as ‘life to first maintenance’.

Design.The design of the structure influences the choice of protective coating.

Hot dip galvanizing is limited to items that will fit in the available bath. Furthermore, it cannot be used with sealed hollow sections and thinner sections may distort. On the other hand, galvanizing can coat the insides of small sections that could not be treated by any other method. Metal spray can generally be used on items of any size, but it can be difficult to apply the coating in corners or other areas with restricted access for spraying. Paint systems can generally be used with structures of any shape or size. As a general rule, difficult or complicated structures should be given long-life systems to reduce the amount of costly maintenance.

Factors influencing coating selection

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ACA/ACRA CORROSION & PROTECTION OF REINFORCED CONCRETEA two-day certificate course of prevention and remediation in concreteMelbourne 05-Sep-05 – 06-Sep-05Sydney 28-Sep-05 – 29-Sep-05

NACE COATING INSPECTION PROGRAM CIP LEVEL 1The CIP Level 1 Course is an intensive presentation of the basic technology of coating application and inspection over a full 60 hours of personal instruction and practice. This course provides both the technical and practical fundamentals for coating inspection work on structural steel projects.Brisbane 03-Oct-05 – 07-Oct-05

PROTECTIVE COATING QUALITY CONTROLThis is a three-day course that focuses specifically on the skills, procures and documentation required to fulfil the QA function of coating application. Adelaide 05-Oct-05 – 07-Oct-05

CATHODIC PROTECTION ADVANCEDA five-day certificate course in design installation and monitoring of cathodic protectionAuckland 10-Oct-05 – 14-Oct-05

COATING INSPECTION REFRESHERA one-day course to upgrade your ACA coating inspection certificationPerth 19-Oct-05 – 19-Oct-05For further information regarding these courses, please contact Tiani Bradilovic, Training Coordinator, (03) 9890 4833, [email protected]

Thank YouThe ACA would like to acknowledge and thank BLASTMASTER for their gener-ous donation of equipment for the ACA’ s Courses.The ACA strives to produce the best training courses and this donation helps us to keep the standard expected of the ACA.

NACE CIP Level 1, Kuala Lumpur, June 2005

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