1 Inside this Issue: University Profile: Deakin University Project Profile: Cathodic Protection of a 1.2km long Harbour Tunnel Technical Note: Copper Based Antifouling Coatings on Aluminium Hulls Technical Note: Effect of Surface Roughness on the Corrosion of 316-type Stainless Steel Research Paper: Shedding light on Corrosion Research Paper: Underprotection of Mild Steel in Seawater, the Calcareous Film Official Publication of the Australasian Corrosion Association • www.corrosion.com.au Vol 36 No 6, December 2011 ISSN 1326-1932 & M A T E R I A L S
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Inside this Issue:University Profile: Deakin University
Project Profile: Cathodic Protection of a 1.2km long Harbour Tunnel
Technical Note: Copper Based Antifouling Coatings on Aluminium Hulls
Technical Note: Effect of Surface Roughness on the Corrosion of 316-type Stainless Steel
Research Paper: Shedding light on Corrosion
Research Paper: Underprotection of Mild Steel in Seawater, the Calcareous Film
O f f i c i a l P u b l i c a t i o n o f t h e A u s t r a l a s i a n C o r r o s i o n A s s o c i a t i o n • w w w . c o r r o s i o n . c o m . a u
Vol 36 No 6, December 2011ISSN 1326-1932
& M A T E R I A L S
Xtroll and Xtroll GlobalOver 25 years ago Ian Ashworth made his first product simply called Xtroll. Approximately 5 years later with more products being developed the name Xtroll was converted into a trademark for use on all his products. Xtroll Global was established in August 2000 to manufacture and market a range of products under the trademark Xtroll. The company manufactures a range of products under the categories of: Rust treatment and prevention, Paint and coatings, Concrete Masonry and Asbestos sealers and coatings, Timber sealers and coatings, and Cleaning products. The world class products give customers great value for money, due to a combination of high coverage rates, product excellence and the simple fact that they really work. Additionally the company provides customers with complete technical advice about the products and their many and varied applications.
As always the primary focus of the company will be to provide quality products that put simply, really do work. The extensive range of Xtroll products fits this bill, and of course this includes Xtroll’s amazing corrosion treatment and prevention products. Led by Xtroll’s flagship product Rust Conqueror and very well supported by products like Xtroll Silver, Xtroll Metalguard and Xtroll GP Primer, these products when used correctly can, will and do treat and stop existing corrosion on any metal. Additionally the products can be used to prevent the onset of rust on all new metals. Xtroll products are easy to use, normally only requiring basic preparation and being simple to apply correctly.
Rust Conqueror effectively uses the rust on the metal when being used to treat rust. To prepare the surface for treatment simply remove loose flaky material, degrease and rinse. Once dry apply Rust Conqueror in multiple light coats until a glossy varnish like finish is achieved. This system ensures that the product penetrates, saturates and encapsulates all of the rust, effectively binding the rust back to the material, while at the same time locking all air and moisture out. The completed system can be painted over with either solvent based or water based products so long as appropriate drying times have elapsed. Rust Conqueror is based on organic products and is safe and easy to apply. Rust Conqueror can be applied in a wide variety of environments and temperatures making it exceptionally versatile.
When used as part of a system with Xtroll Silver or Xtroll Metalguard, the life of aged materials can be significantly improved. This fact coupled with the ease of preparation and application, mean that you can really save money on maintenance costs. Simpler easy to achieve preparation saves you time, while ease of application means no special equipment or training is required. Add these facts to the excellent coverage rate offered by the products and the simple truth is that you will save time and money which is crucial in today’s economic climate.
Rust Conqueror is also an ideal rust preventative when used to protect new metals. Simply degrease and rinse the surface to which it is to be applied and once dry apply sufficient product to ensure a gloss varnish like finish. This ensures a non porous finish which effectively prevents air and moisture from contacting the surface therefore preventing rust. Being essentially a clear coating that will last more than 18 months in direct sunlight, with a coverage on new material of up to 30 square meters per litre, and being readily coated with either enamel or acrylic paints after a simple wash and rinse to remove any contaminants that may have settled on the surface, the product is ideal and economical for use as a protective coating on materials that may be prone to rusting while in storage or transport.
Air and moisture
Air and moisture
In the diagram above air and moisture are able to penetrate through the rust layer and make contact with the metal surface
which promotes yet more rust.
In the diagram above the Rust Conqueror has penetrated the rust layer and encapsulated it into the protective film. This process prevents air and moisture from being able to contact the metal surface, therefore treating both the existing rust and also preventing further rusting.
Metal substrate
Metal substrate
Layer of rust particles
Layer of rust particles that have been treated with Xtroll Rust Conqueror
For more information on Xtroll products or to find your nearest supplier please contact Global Paint Solutions via, email [email protected], Ph 02 6568 4040, Fax 02 6568 2971 or via Mobile 0488 438 438. Alternatively visit xtrollglobal.com.au to view the full Xtroll range of products on line.
Vol 36 No 6 December 2011 www.corrosion.com.au 3
Front Cover Photo Shell Todd Oil Services Maui Production Station Oaonui, New Zealand. The Maui Coating Refurbishment Project 2011. Pipe rack painting – Carboline Coatings.
30» ProjectProfile:Cathodic Protection of a 1.2km long Harbour Tunnel
33» CoatingsGroupMemberProfile
34» TechnicalNote:Copper Based Antifouling Coatings on Aluminium Hulls
36» TechnicalNote:Effect of Surface Roughness on the Corrosion of 316-type Stainless Steel
38» ResearchPaper: Shedding light on Corrosion
44» ResearchPaper: Underprotection of Mild Steel in Seawater, the Calcareous Film
49» SuppliersandConsultants
The ACA is a founder member of the World Corrosion Organization
ISSN1326-1932Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257PublicationsDirectorMohammad Ali – GHD, [email protected] Cherry – Monash University, [email protected]: Bruce Hinton – Monash University, [email protected] Practice: Willie Mandeno – Opus International Consultants,
[email protected]: Ian Booth – Australasian Corrosion Association, [email protected] Atrens – University of Queensland Nick Birbilis – Monash University Lex Edmond – Monash University Harvey Flitt – Queensland University of Technology Maria Forsyth – Monash University Rob Francis – Aurecon Australia Warren Green – Vinsi Partners Doug John – Curtin University of Technology Graeme Kelly – Corrotec Services Nick Laycock – STOS Grant McAdam – Defence Science and Technology Organisation David Nicholas – Nicholas Corrosion John Robinson – Mount Townsend Solutions Paul Schweinsburg – Queensland University of Technology Raman Singh – Monash University Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science and Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South WalesAdvertisingSalesWesley Fawaz - [email protected] Ph: 61 3 9890 4833, Fax: 61 3 9890 7866SubscriptionPrint Version: ISSN 1326-1932 Subscription rates to non members: Within Australia: A$72.60, incl GST, single copies A$16.50, incl GST Outside Australia: A$77, excl GST posted airmail, single copies A$22 incl GST On-Line Version: ISSN 1446-6848 Subscription rates to non members: A$22 incl GSTThe views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.AustralasianCorrosionAssociationIncPO Box 112, Kerrimuir Vic 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: [email protected] Internet: www.corrosion.com.auPresident: Ian MacLeodChief Executive Officer: Ian BoothOperations Chairman: John GrapigliaFinance Director: Paul VinceSenior Vice President: Peter DoveJunior Vice President: Allan SterlingImmediate Past President: Roman DankiwTechnical Director: Graham SussexEducation Director: Geoffrey WillMembership Director: Fred SalomeCommunications Director: Bryan PikePublications Director: Mohammad AliNewcastle Representative: Matthew DafterNew Zealand Representative: John DuncanBranches&DivisionsAuckland Division: Sean Ryder 64 9 261 1400Newcastle: Karen Swain 61 0 418 854 902New South Wales: Denis Jean-Baptiste 61 0 404 646 272Queensland: Cathy Sterling 61 7 3821 0202South Australia: Alex Shepherd 61 8 8267 4744Tasmania: Grant Weatherburn 61 0 418 120 550Taranaki Division: Ron Berry 64 27 671 2278Wellington Division: Alistair MacKenzie 64 4 473 3124Western Australia: Gary Bennett 61 0 408 413 811Victoria: John Tanti 61 3 9885 5305TechnicalGroupsCathodic Protection: Bruce Ackland 61 3 9890 3096Coatings: Matthew O'Keeffe 61 437 935 969Concrete Structures & Buildings: Frédéric Blin 61 3 9653 8406Mining Industry: Peter Farinha 61 8 9456 0344Petroleum & Chemical Processing Industry: Fikry Barouky 61 402 684 165Research: Nick Birbilis 61 3 9905 4919Research: David Young 61 2 9385 4322Water & Water Teatment: David Mavros 61 419 816 783Welding, Joining & Corrosion: Graham Sussex 61 3 9495 6566Young Corrosion Professionals: Erwin Gamboa 61 8 8303 5473*all the above information is accurate at the time of this issue going to press.
& M A T E R I A L S
Xtroll and Xtroll GlobalOver 25 years ago Ian Ashworth made his first product simply called Xtroll. Approximately 5 years later with more products being developed the name Xtroll was converted into a trademark for use on all his products. Xtroll Global was established in August 2000 to manufacture and market a range of products under the trademark Xtroll. The company manufactures a range of products under the categories of: Rust treatment and prevention, Paint and coatings, Concrete Masonry and Asbestos sealers and coatings, Timber sealers and coatings, and Cleaning products. The world class products give customers great value for money, due to a combination of high coverage rates, product excellence and the simple fact that they really work. Additionally the company provides customers with complete technical advice about the products and their many and varied applications.
As always the primary focus of the company will be to provide quality products that put simply, really do work. The extensive range of Xtroll products fits this bill, and of course this includes Xtroll’s amazing corrosion treatment and prevention products. Led by Xtroll’s flagship product Rust Conqueror and very well supported by products like Xtroll Silver, Xtroll Metalguard and Xtroll GP Primer, these products when used correctly can, will and do treat and stop existing corrosion on any metal. Additionally the products can be used to prevent the onset of rust on all new metals. Xtroll products are easy to use, normally only requiring basic preparation and being simple to apply correctly.
Rust Conqueror effectively uses the rust on the metal when being used to treat rust. To prepare the surface for treatment simply remove loose flaky material, degrease and rinse. Once dry apply Rust Conqueror in multiple light coats until a glossy varnish like finish is achieved. This system ensures that the product penetrates, saturates and encapsulates all of the rust, effectively binding the rust back to the material, while at the same time locking all air and moisture out. The completed system can be painted over with either solvent based or water based products so long as appropriate drying times have elapsed. Rust Conqueror is based on organic products and is safe and easy to apply. Rust Conqueror can be applied in a wide variety of environments and temperatures making it exceptionally versatile.
When used as part of a system with Xtroll Silver or Xtroll Metalguard, the life of aged materials can be significantly improved. This fact coupled with the ease of preparation and application, mean that you can really save money on maintenance costs. Simpler easy to achieve preparation saves you time, while ease of application means no special equipment or training is required. Add these facts to the excellent coverage rate offered by the products and the simple truth is that you will save time and money which is crucial in today’s economic climate.
Rust Conqueror is also an ideal rust preventative when used to protect new metals. Simply degrease and rinse the surface to which it is to be applied and once dry apply sufficient product to ensure a gloss varnish like finish. This ensures a non porous finish which effectively prevents air and moisture from contacting the surface therefore preventing rust. Being essentially a clear coating that will last more than 18 months in direct sunlight, with a coverage on new material of up to 30 square meters per litre, and being readily coated with either enamel or acrylic paints after a simple wash and rinse to remove any contaminants that may have settled on the surface, the product is ideal and economical for use as a protective coating on materials that may be prone to rusting while in storage or transport.
Air and moisture
Air and moisture
In the diagram above air and moisture are able to penetrate through the rust layer and make contact with the metal surface
which promotes yet more rust.
In the diagram above the Rust Conqueror has penetrated the rust layer and encapsulated it into the protective film. This process prevents air and moisture from being able to contact the metal surface, therefore treating both the existing rust and also preventing further rusting.
Metal substrate
Metal substrate
Layer of rust particles
Layer of rust particles that have been treated with Xtroll Rust Conqueror
For more information on Xtroll products or to find your nearest supplier please contact Global Paint Solutions via, email [email protected], Ph 02 6568 4040, Fax 02 6568 2971 or via Mobile 0488 438 438. Alternatively visit xtrollglobal.com.au to view the full Xtroll range of products on line.
ACA/ACRACorrosion&ProtectionofConcreteStructuresMemberStatus Fee GST TotalFeeAUMember $918.18 $91.82 $1010.00AUNonMember $1150.00 $115.00 $1265.00NZMember* $920.00 NZNonMember $1150.00Wollongong March 14th–15thTasmania October 04th–05th
NACE-CoatingsInspectionProgramCIPLevel1MemberStatus Fee GST TotalFeeAUMember $3236.36 $323.64 $3560.00AUNonMember $3700.00 $370.00 $4070.00NZMember* $3235.00 NZNonMember $3715.00Brisbane Jan/Feb 30th–04thSydney March 19th–24thDarwin April 16th–21stAdelaide May 07th–12thNewcastle June 18th–23rdPerth August 13th–18thTasmania September 03rd–08thNewZealand October 08th–13thMelbourne Oct/Nov 29th–03rdPerth December 03rd–08th
NACE-CoatingsInspectionProgramCIPLevel2MemberStatus Fee GST TotalFeeAUMember $3236.36 $323.64 $3560.00AUNonMember $3700.00 $370.00 $4070.00NZMember* $3235.00 NZNonMember $3715.00Brisbane February 06th–11thSydney March 26th–31stAdelaide May 14th–19thMelbourne July 02nd–07thPerth August 20th–25thNewZealand October 15th–20thMelbourne November 05th–10thPerth December 10th–15th
1800-RentDH (736 834) Melbourne Sydney Adelaide Perth Brisbanewww.rentdh.com [email protected] 24 hours a day / 7 days a week on-call service
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Carboline has been global leader in the High Performance Coatings industry for over 63 yrs. For corrosion solutions and coating systems that are cost effective, talk to the Protective Coatings Professionals.
The % gloss retention data of a coating tabulated after exposure to atmospheric UV light is an indication of the coatings resilience to thermal and/or photooxidative degradation reactions (as described above). White pigmented coatings are traditionally chosen for testing purposes as white pigmentation (rutile TiO2) upon absorption of UV light converts oxygen to superoxide and hydroxide ions to hydroxyl radicals. The photoactivity of TiO2 is thus used by coatings chemists to further accelerate the UV induced degradation of the polymers under test. QUV data has been used by many coatings chemists to simulate what would happen to a coating in the ‘real world’. Many papers have been published on this subject, whilst QUV studies offer a comparative guide to exterior performance they cannot replicate ‘real data’. As we will see from this study QUV B is NOT a good indicator of real world performance (refer to the gloss retention data extracted from 5 degrees North , Allunga and QUV B studies for the New Generation 420 g/l Siloxane. <refer Figures 1 and 2>).
Figure one: ‘Real data’ – Gloss/ colour retention data from Allunga exposure site northern queensland. Figure two details the % gloss retention of the same coatings as experimentally determined in QUV studies.
Allunga Weathering(5 degrees North)
0
20
40
60
80
100
120
0 10 20 30 40 50 60Months
Retention o
gloss, %
Epoxy Siloxane New Generation PSX 420 g/L (5° N) PU NISO
Discoloration Allunga Weathering
0
1
2
3
4
0 10 20 30 40 50 60Months
∆
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New Generation PSX 420 g/L (5° N) PU NISO
Back Next
Corrosion & Prevention 2004 Paper 054 Page 2
The need to reduce VOC has meant that most formulations have focused on: 1. waterborne coatings 2. solvent free coatings (eg polysiloxane variants) 3. powder coatings 4. UV and/or hot melt technologies
Each of these chemistries has its own problems but in general liquid, ambient cure technologies generally use low molecular weight, highly functionalised diluents which generally create durability problems for the formulator/ end user. Polysiloxane coatings offer a unique ‘fix’ to this problem as highly skilled organic chemists have been able to hybridize low viscosity organic polymers with solvent free silicon functional diluents and oligomers. This paper will focus on some properties and attributes of a new generation of siloxane coatings which have rapid cure, excellent corrosion resistance, low VOC and extreme durability. This dissertation will compare and contrast the properties of this class of coatings with conventional coatings and other siloxane coatings which are present in the marketplace. 3 WHY ARE SILOXANE COATINGS UNIQUE? The energy content of one mole (one quanta) of UV light is sufficient to destroy the covalent bonding network prevalent in most polymeric materials. Free radicals are generated by the photophysical processes of adsorbed UV light. The nett result is generation of hydroperoxides and peroxides i.e. the polymer ends up being photo oxidized (refer scheme one). (3) Initiation step UV light Polymer P• (i) Propagation step P• + O2 POO• (ii) POO• + PH POOH + P• (iii) Termination step P• + P• P-P (iv) 2 PO• POOP (v) P• + PO• POP (vi)
Scheme One: Photooxidation induced by UV light The combined effects of photolysis and photooxidation of polymers leads to chain scission and/or crosslinking reaction of the UV degraded polymer. The nett effect of these processes is obvious to all coatings chemists i.e. chalking, cracking, checking, reduction in tensile and mechanical property strength and change in glass transition temperature. In simple words the coating fails.
Silicon based polymers are uniquely resistant to photolysis and photo oxidation. This can easily be rationalized when one considers that:
1. The Si-O bond is already oxidized in an oxidized state and unlike Carbon-Carbon bonds cannot be oxidized further. 2. The bond strength or bond dissociation energy for a C-C bond is 145 Kcal/mole cf. a Si-O bond which is 193.5 Kcal/mole (measured at 298K) (4)
In addition siloxane chemistry is also extremely resistant to thermal oxidation reactions to use an analogy one needs only to look at the chemistry of everyday glass (a giant siloxane polymer network). Glass for example melts at 1400oC and upon cooling yields an extremely chemically resistant and thermally resistant material. To use a coatings analogy one could utilize common inorganic zinc or heat resistant siloxane coatings which are capable of providing long term heat resistance at 760oC or greater.
4 GLOSS RETENTION OF SILOXANE COATINGS CF. ORGANIC COATINGS Figure one details the gloss retention (60 degree) and colour retention of a good quality polyurethane coating, two commonly used NISO coatings, an epoxy siloxane (VOC 120 g/L) and a new generation rapid cure siloxane coating. This data is ‘real data’ as transcribed from the Allunga exposure station in Northern Queensland.
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Corrosion & Prevention 2004 Paper 054 Page 1
RECENT ADVANCES IN POLYSILOXANE COATINGS
LHP Gommans* S Yi Chu* K Constable* E. Hemmings** and L. Bailey** *Ameron (New Zealand) Limited **Ameron (Australia) Pty
Summary:. This publication briefly describes the performance and mechanical property attributes of a newly patented polysiloxane technology. The technology manifests itself as a low VOC, rapid curing technology, curing quickly at VOC’s as low as 120 g/l. Two technologies of differing VOC’s are described in this paper, one at 120 g/l and the other at 420 g/l. These technologies have been compared and contrasted with conventional, non compliant polyurethane and NISO technologies.
Keywords: Polysiloxane, VOC, Durability, Rapid Cure, Isocyanate Free 1 INTRODUCTION Polysiloxane coatings (1) are unique class of coating as they offer the coatings formulator some outstanding attributes, some of the key features of this technology are:
1. Extremely low VOC (as low as 100 g/L depending upon the formulation route taken). 2. Outstanding (breakthrough) colour and gloss retention (again dependant upon the unique blend of inorganic-organic resin componentry utilised). 3. Extremely good abrasion, dirt pickup and graffiti resistance properties (again formulation dependant). 4. Better corrosion resistance at lower dft’s when used in combination with inorganic zinc, epoxy zinc and surface tolerant epoxies.
Most polysiloxane technology is based on 2K chemistry but 1K siloxane coatings can be formulated as well. Ameron originally developed its siloxane technology (Epoxy Siloxane) for structural steel and concrete to replace the conventional 3 Coat Coating system (2 epoxy coats/1 P/U coat). The advantages of siloxane chemistry are well documented, and as Ameron has pioneered in this area there exists a wealth of literature for the interested reader to delve into (1). This paper discusses some new generation polysiloxane coatings which have been developed with the OEM and new projects markets in mind. OEM and new project markets, of course , have differing requirements to the Maintenance/PC/Marine area- namely rapid cure speeds and improved flexibility. This new siloxane chemistry has been compared with conventional urethane and NISO (Acrylic/Acrylic or Acylic/Epoxy) technologies. Mechanical property attainment, durability (real world and laboratory), corrosion resistance and an environmental perspective relating to the VOC’s that can be attained through formulation of IPN siloxane chemistries will be presented. Polyurethane coatings have been offered up as the doyen of coatings on a global basis for many, many generations. This is because polyurethanes offer an excellent all around range of properties to the applicator, architect and specifier alike. However, in recent years polyurethane coatings have come under a health and safety cloud as this technology has issues with worker safety (respiratory sensitisation) and compliance (dropping below 250 g/l in VOC is an extremely difficult task for this technology). Polysiloxanes, as we will see from this paper may offer a solution as a safer, more durable, faster drying and lower VOC technology.
2 THE WORLD, GREENHOUSE GASES, VOC EMMISSIONS AND THE FUTURE The need to conserve energy is no more apparent than when one looks to the language used in the preamble to the Kyoto protocol and also continued pressure on fuel and gas prices. To state the obvious, burning fossil fuels for energy generation creates greenhouse gases, including of course CO2. (2) Unfortunately, greenhouse gases have a lifespan in the stratosphere of many hundreds of years, thus generation of greenhouse gases is a problem which will have ramifications for many generations. From a coatings perspective then the message is simple- develop coatings with long lifetimes to first maintenance, that contain low levels of solvent (to reduce generation of tropospheric low level ozone/smog) and that do not need external heat sources to cure them.
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The Journal of Protective Coatings & Linings(JPCL)hasannouncedtheCliveHareHonors,auniqueawardthatrecognisesthedistinguishedachievementsof24thoughtleadersworldwidewhohaveadvancedthetechnologyofprotectiveandmarinecoatingsinthepastdecade.
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TheAucklandNovembermeetingwasheldon2ndNovemberatTheLandingHotel.ThespeakerwasLesBoulton(PrincipalConsultant,Les Boulton & Associates Ltd)addressingthesubjectof“Corrosion of building assets – problems and prevention”.
Work experience and work in responsible chargeWork experience in corrosion or corrosion related field is defined as practical experience in corrosion mechanisms, causes, control and monitoring. It covers the investigation, design or
implementation of corrosion control. The work must be technical in nature (not sales for example) and in the corrosion field. Metallurgy, welding inspection, Non Destructive Testing (NDT) etc, are not acceptable, except when directly related
to corrosion.Work in responsible charge in corrosion or a corrosion related field is, work experience as defined above, which includes a level of responsibility requiring technical judgement. The applicant must be in technical control and have technical responsibility. Work such as design, specification,
and failure analysis etc are considered responsible work in charge, as opposed to routine testing or application of corrosion control measures, ie painting or installing anodes.
Affect on ACA MembershipACA accreditation as a Corrosion Technician/Technologist will have no affect on a member’s privileges including their right to vote, hold any office or participate in any associated activity.
Application procedureA completed application form with accompanying payment and documentation should be sent to the ACA Certification Scheme, PO Box 112, Kerrimuir VIC 3129 or faxed to +61 3 9890 7866. Your application will be initially assessed and you will be contacted if any further information is
required. The ACA will contact your referees and then forward your application to the Certification Review Board (which meets periodically - approx every 3 months) for assessment. You may be contacted by the ACA or one of the Certification Review Board members if further information is
needed to properly assess your application. Once reviewed, you will receive notification by letter as to the Certification Review Board’s decision.For further information on the Certification Rules,
Application Form or the Complaints Process, please visit our website at www.corrosion.com or call the ACA on +61 3 9890 4833.
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ACA Certified Corrosion Technologists and TechniciansTheACA’sCertificationprogramforACACorrosionTechniciansandTechnologistsrecognisesthosewitheducationandexperienceinthecorrosionindustry.ACorrosionTechnicianhasatleast4yearsworkexperienceandhasattendedanumberofformaltrainingcourses,whilstthoseawardedCorrosionTechnologisthaveatleast10yearsworkexperienceandhaveobtainedfurthertraining.Foramoredetailedexplanationoftheeligibilitycriteria,pleaseconsultourACACertificationProgram
CERTIFICATION PROGRAMWorking toward Professional Development in Corrosion
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Crown Conference Centre • Melbourne, Victoria, Australia • 11–14 November 2012
Call for PapersSubmissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2012. Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are:
Close of Abstracts: 30th March 2012
Acceptance of Abstracts: 13th April 2012
Receipt of Papers: 29th June 2012
Submit an AbstractPlease refer to www.corrosion.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (30th March 2012).
Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process for Corrosion & Prevention 2012.
Guide to SubmissionPapers submitted to the Corrosion & Prevention 2012 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/permission from their organisation. Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary. All authors whose papers are accepted are required to attend the conference to present.
The DestinationConsistently voted one of the world’s most livable cities, Melbourne is a lively and cosmopolitan city that combines a fanatical love for the creative arts and good living with a state-wide sports addiction to make a city like no other. Set around the shores of Port Phillip Bay, the central business district is located on the northern banks of the picturesque Yarra River.
But it is within Melbourne’s hidden laneways where the city truly comes to life, where mainstream culture takes a back seat to allow for one-off boutiques, unique galleries, tiny cafés and hidden bars. With an eclectic dining scene that offers a startling array of the world’s great cuisines, from popular favourites to the truly ground breaking.
Although Melbourne is celebrated as Australia’s home to the arts, sport and shopping, just one hour’s drive from the city takes you a world away from the urban frenzy. With destinations like the Yarra Valley, The Great Ocean Road and Victoria’s Goldfields region you can take your pick from 100 local vineyards, rest and relax at award winning day spas, tee off at world class golf courses or even enjoy a swim with the dolphins.
Melbourne is a creative, exciting, ever-changing city with extraordinary surprises to be discovered in every basement, rooftop and laneway. The possibilities are endless, so forget what you think you know. Take a chance, lose yourself in Melbourne.
First Announcement & Call for Papers
Corrosion Management for a Sustainable World:Transport, Energy, Mining, Life Extension and Modelling
Technical TopicsPapers for the Conference are expected to cover a wide range of topics relating to all aspects of the corrosion industry. This will span the spectrum of fundamental research and science, to large-scale engineering and industrial implementation of corrosion technology. This will include an understanding of corrosion mechanisms, corrosion prevention, and management of corrosion issues, along with computational and modelling aspects. The following topics will be considered:
Corrosion Science and Research
Corrosion Engineering and Industrial Implementation
Corrosion Modelling
Case Studies
Corrosion in Energy Systems and Distribution Networks
Contractor Perspectives
Advances in Corrosion Prevention and Cathodic Protection
Corrosion Management
Protective Coatings
Industry SectorsThis conference will have material of value to those working within the following industries:
Civil Infrastructure
Defence
Mining
Oil and Gas
Energy Transmission
Education and Research
Power
Water
Manufacturing
Maintenance
Government
Transport
Marine Engineering
Materials Engineering
Coating Inspection and Surveillance
Asset Managers, Corrosion Specialists and Consultants
Conference ConvenorIan Godson
Technical ChairsNick Birbilis
Bruce Hinton
Neil Campbell
CommitteePeter Dove
Sarah Furman
Dean Ferguson
Sponsorship and ExhibitionSponsorship will enable your company to make a significant contribution towards the success of Corrosion & Prevention 2012. In return, the conference offers strong branding and exposure in a focussed and professional environment. As with every Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services.
For further information, please contact the Australasian Corrosion Association on +61 (0)3 9890 4833 or [email protected]
Your HostsThe Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, industry association, established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion.
The mission of the ACA is to promote the co-operation of academic, industrial, commercial and governmental organisations in relation to corrosion and its mitigation and for disseminating information on all aspects of corrosion and its prevention by promoting lectures, symposia, publications and other activities.
A S Harrison & Co Pty LtdAB and P Abrasive Blasting & PaintingABSAFE Pty LtdACTEW AGL DistributionAction Painters Auckland (2007) LtdAdtech FRP Pty LtdAdvanced Aqua BlastingAirservices AustraliaAlbany Port AuthorityAlfabs Protective Coatings Pty LtdAlloy Yachts International LtdAllunga Exposure LaboratoryAmaC Corrosion Protection Pty LtdAP Kempe EngineeringAPA GasNet OPS Pty LtdAPT AM Holdings Pty LtdARC West Group Pty LtdArmor GalvASC Pty LtdAsset Integrity Australasia Pty LtdATTARAurecon Australia Pty LtdAurecon PPIAurora EnergyAusblastAuscor Pty LtdAustral Wright MetalsAustralian Maritime CollegeAustralian National Maritime MuseumAustralian Paper ManufacturersBachalani Constructions Pty LtdBAE Systems AustraliaBASF Australia LtdBayer Material Science Pty LtdBCMG Pty LtdBCRC (NSW) Pty LtdBianco Structural SteelBlastcorp Pty LtdBP Refinery (Bulwer Island)BP Refinery (Kwinana) Pty LtdBRANZ LimitedBredero Shaw Australia Pty LtdBrisbane Abrasive BlastingBuel Pty LtdBundaberg Sandblasting Pty LtdCaltex Australia Petroleum Pty LtdCaltex Refineries (QLD) LtdCameleon PaintsCameron Applied Research and Developments Pty LtdCathodic Diecasting (QLD) Pty LtdCEA Australia Pty LtdCEM International Pty LtdCentreport LimitedChampion TechnologiesChevron Australia Pty LtdChiron ChemicalsCity West WaterClarkes Painting ServicesClavon Pte LtdCommercial Industrial Painting Services Pty LtdContract Resources Pty Ltd
CORE Water Management Solutions Pty LtdCorrocoat Engineering (Aust) Pty LtdCorrosion Electronics Pty LtdCorrosion Specialists Pty LtdCostin Roe ConsultingCouplertec Electronic RustproofingCox Coating Pty LtdCradle Mountain WaterCrest Restoration Services Pty LtdDepartment of Transport and Main RoadsDept of Infrastructure, Energy & ResourcesDept of Planning and InfrastructureDiagnostech Pty LtdDimet Anti-Corrosion Pty LtdDoito Pty LtdDukes Painting Services Pty LtdDuratec Australia Pty LtdEM&I (Australia) Pty LtdEnergex LtdEnergy Safe VictoriaEnergyworks LtdEsso Australia LtdFirma IndustriesFremantle PortsFremantle Sailing ClubFreyssinet Australia Pty LtdGalvanizers Association of AustraliaGanellen Asset ServicesGermanischer Lloyd (Australia) Pty LimitedGiovenco Industries (Aust) Pty LtdGippsland Cathodic ProtectionGippsland WaterGladstone Ports Corporation LtdGORODOK Pty LtdGPR Electrical (WA) Pty LtdGrange Resources (Tasmania) Pty LtdGreater Wellington Regional CouncilHalcrow Group LimitedHamersley Iron Pty LtdHERAHolmes Consulting GroupHoriso Pty LtdHunter Water Australia Pty LtdHydro Flow Pty LtdHydro Tasmaniaidec Protective Coatings Pty LtdIndustrial Composite ContractorsIndustrial Galvanizers Pty LtdInnovative Corrosion Management Pty LtdInspection & Consultancy Services LtdInternational Corrosion Services Pty LtdInvensys Rail Pty LtdIonode Pty LtdIPCQITW AAMTECHITW BuildexJacobsen Colourplus LtdKeppel Prince Engineering Pty LtdKGB Protective CoatingsKorvest Ltd - Galvanising DivisionKulin Group Pty LtdLinetech ConsultingLinkWater
Liquigas LtdLongmont EngineeringLordco NZ LtdLothway-TBS Pty LtdLoy Yang Power LtdLyttelton Port of ChristchurchM Brodribb Pty LtdM Waters Abrasive Blasting ServicesMahaffey Associates Pty LtdMaintenance Systems Pty LtdMarden Corrosion Services P/LMcCoy Engineering Pty LtdMcElligott Partners Pty LtdMcElligotts (Tas) Pty LtdMcKechnie Aluminium Solutions LimitedMetal Spray Suppliers (NZ) LtdMethanex New Zealand LtdMetrocorp TechnologiesMetz Specialty Materials Pty LtdMills Sign & Painting ServiceMobil Refining Australia Pty Ltd (Altona Refinery)MTK ConsultingNalco Australia Pty LtdNanmah Pty LtdNDT Equipment Sales Pty LtdNew Zealand Aluminium SmeltersNew Zealand Steel LtdNewcastle City CouncilNMT Electrodes (Australia) Pty LtdNorblast Industrial Solutions Pty LtdNorth Queensland and Bulk Ports CorporationNorthport LtdNPC Industries Pty LtdNZ Refining Co LtdOrigin EnergyOrrcon Operations Pty LtdOsborne CogenerationOutokumpu Pty LtdPacific Resins Pty LtdPaint N ColourParchem Construction SuppliesPCCS TrustPCWI International Pty LtdPhillro Industries Pty LtdPolymer Group LtdPort Kembla Port CorporationPPG Performance Coatings (M) Sdn BhdPrendos New Zealand LtdPreservation TechnologiesPrimary Industries & Resources of South AustraliaPro-Fast Protective CoatingsProkote Pty LtdPumpline Pty LtdQLD Dept Main Roads - Structures DivisionQLD Painters & Maintenance Services Pty LtdQueensland Alumina LtdQueensland Nickel Pty LtdQueensland Sugar LimitedQueensland Urban Utilities
Rail CorporationReinforced Earth Pty LtdRema Tip Top Industrial Pty LtdReno BlastResene Paints LtdRheem Australia Pty LtdRightway Industrial Pty LtdRM Watson Pty LtdRoads & Traffic Authority of NSWRTA Weipa Pty LtdRust-oleum Industrial CoatingsSea Coatings Australia Pty LimitedSGS NZ LtdShell Refining AustraliaShoreguard MarineSika (NZ) LtdSika AustraliaSilver Raven Pty LtdSLH Contracting (2008) LtdSouth East Water LimitedSpecial Metals Pacific Pte LtdStanwell CorporationStructural Systems (Remedial) Pty LtdSubspection Pte LtdSulco LimitedSummit FertilizersSunWater LimitedSVT Engineering ConsultantsSyntech Distributors LtdTAFE NSW - Sydney InstituteTandex Pty LtdTas Gas NetworksTas Protective CoatingsTasmanian Ports Corporation Pty LtdThe Valspar (Australia) Corporation Pty LimitedThomas Contracting Pty LtdThyssenKrupp VDM Australia Pty LtdTitanium Anode Corporation Pty LtdTitanium Electrode Products (Australia) Pty LtdTotal Corrosion ControlTotal Paint ProtectionTotal Surface ProtectionTownsville Port AuthorityTranscote Pty LtdTransend Networks Pty LtdTransfield ServicesTranspower New Zealand LtdTri-Star Industries Pte LtdTropical Reef Shipyard Pty LtdTyco FCPTyco Water TechnologiesUndersea Construction LtdValicote Pty LtdVector Gas LimitedWAG Pipeline Proprietary LtdWannon Region Water CorporationWater Corporation of Western AustraliaWillall Industries Pty LtdWoodside Energy LtdYarra Valley Water
CORPORATE BRONZE
Listaccurateat7/11/11
Corrosion & Materials30
Cathodic Protection of a 1.2km long Harbour Tunnel A1.2kmlong4.35mdiametercross-harbourtunnelwasconstructedin1996foranironoreconveyor.Thisused5,154reinforcedconcreteliningsegmentsboltedtogetherbymildsteelboltslocatedwithinboltpockets.Sinceearlyinitsconstructionthetunnelexperiencedseawaterleakagethroughsegmentsealsandgroutports.Duetothewaterpressure,leakageoftunnelsunderaharbourisnotuncommonandregularwashdownandmaintenancewouldberequired.However,withaconveyorthatoperatescontinuously,itisonlypossibletoundertakeminimalmaintenance.Overtimesaltwateringresscausedseverecorrosionoftheexposedmildsteelboltassemblies.Thiscorrosionhasledtosurfacecrackingandspallingoftheconcrete(Figure1).Thesaltencrustationfromleakshadresultedindiffusionofchloridesintotheconcretetherebyinitiatingreinforcementcorrosion.Concreteremediationandinstallationofanimpressedcurrentcathodicprotection(ICCP)systemwasrequiredinordertoachievethedesiredlifeof50yearsforthis15yearoldasset.
We have a large blasting and painting facility in Hemmant, on the south side of Brisbane. We do work for projects that are located all over Australia and overseas, however our operation is focused here at our facility. We do offer limited on-site services to our existing clients.
We do a wide variety of different jobs so it is difficult to measure the tonnage. We have quite a large capacity and currently have 2 of our 3 rooms running full time, including a small crew on night shift. We are not running at full capacity and hope to build this up over the next 12 months.
We recently completed a difficult project for ACLAD, which included odd shaped and twisted fins for the external of the new ABC premises in Southbank. This project was pleasing because we established specialised hangars in order to paint the fins without having to turn them. The building looks amazing and it is pleasing to drive past and know that we contributed to the completion of the project.
Where possible, research the job before it arrives and establish a materials handling solution which will help save time and increase quality assurance outcomes.
We do both internal and external training for our staff. We are lucky enough to have some industry veterans in our company who are willing to train some of the younger employees on the tricks of the trade.
Copper Based Antifouling Coatings on Aluminium HullsTraditionallycopperbasedantifoulingcoatings(mostlyCuprousOxide)havenotbeenusedonaluminiumhullsduetheconcernthatcorrosionofthehullwilloccurduetotheelectrochemicalpotentialdifferencesbetweenthecuprousoxideandthealuminiumhull.Recentlaboratoryinvestigationandareviewoffieldexperiencehasshownthatthereareotherfactorsthatareimportanttobeproperlycontrolledtoavoidcorrosion.
Effect of Surface Roughness on the Corrosion of 316-type Stainless SteelIntroductionCorrosionwasdetectedonanumberofwiresof3mmdiametermadefromstainlesssteelasshowninFig.1.Itwasfoundthatthecorrosionhadoccurredevenbeforethewireswereexposedtoservice.TheserviceenvironmentwasnearneutralpHwaterwhichwasslowflowing.AchemicalanalysisofthewireshadshownthatthewiresmettherequirementsofASTMA314specificationsfor316-typestainlesssteels.TheseresultsindicatedthattheCrcontentofthewireswasclosetothelowerlimitingvaluesforspecificationas316-typestainlesssteel.Significantly,Ccontentwas0.04%andScontentabout0.01%.Itiswellknownthat316-typestainlesssteelshave2-3%Moaddedspecificallytoresistpittingcorrosioninchlorideenvironments.Stainlesssteelsarealsogenerallypassivatedbeforetheyareusedinservice.Corrosioninthisinstancewasnoteasilyexplained.
Agent for:LIDA® – Mixed Metal Oxide Anodes• Strip, Rod, Tubular, Ribbon, Disk and Wire
• Sacrificial Anodes• Silicon Iron Anodes• Transformer Rectifiers• Reference Electrodes
–Zinc, Aluminium and Magnesium• Calcined Petroleum Backfill• Surge Protection, Insulation–Copper, Zinc and Silver
Prevent corrosion on your:-PIPELINES, TANKS, BRIDGES, WHARVES, OFFSHORE PLATFORMS
Tel: +61 (03) 94672520 or 0413 201562
Committed to Professional Service, Competitive Pricing and Customer SatisfactionEmail: [email protected] • www.pipecorr.com.au
Corrosion and Coating Failure InvestigationsFitness for Purpose and Remnant Life AssessmentExpert Witness and Litigation SupportCorrosion, Materials & Mechanical EngineersApplied Scientists, Metallurgists, Coating InspectorsNDT Technicians
Unit 2, 26 Baile RoadCanning ValeWestern Australia6155
CATHODIC PROTECTION Applications include:
- Oil and gas pipelines - Water pipelines - Above and below ground storage tanks - Reinforced steel in concrete - Ships’ hulls - Jetties and wharves - Condenser water boxes in power stations