Steelwork Corrosion Control

Steelwork Corrosion Control, Second Edition......Page 2
ACKNOWLEDGEMENTS......Page 13
CONTENTS......Page 4
CHAPTER 1: INTRODUCTION......Page 14
CONTENTS......Page 0
1.1 HEALTH AND SAFETY CONSIDERATIONS......Page 17
2.1 CORROSION: THE BASIC PROCESS......Page 18
2.2 THE ELECTROCHEMICAL NATURE OF CORROSION......Page 20
2.3.1 POTENTIAL......Page 22
2.3.3 PASSIVITY......Page 23
2.4 CORROSION IN AIR......Page 24
2.5 CORROSION IN WATER......Page 27
2.5.2 OPERATING CONDITIONS......Page 28
2.5.4 CORROSION RATES OF STEEL IN WATER......Page 29
2.7 BACTERIAL CORROSION......Page 30
2.8 HEALTH AND SAFETY CONSIDERATIONS......Page 31
FURTHER READING......Page 32
CHAPTER 3: SURFACE PREPARATION......Page 33
3.1.2 MILLSCALE......Page 34
3.1.3.2 WATER-SOLUBLE CONTAMINANTS......Page 38
3.1.4 ROUGHNESS......Page 42
3.1.5 SURFACE DEFECTS AND WELDS......Page 43
3.2.1.1 LIQUID SOLVENT CLEANING......Page 44
3.2.1.4 DETERGENTS......Page 45
3.2.2 HAND- AND POWER- TOOL CLEANING......Page 46
3.2.3.1 AIR BLAST-CLEANING......Page 48
3.2.3.2 VACUUM BLAST-CLEANING......Page 50
3.2.3.3 CENTRIFUGAL BLAST-CLEANING......Page 51
3.2.3.4.1 LOW-PRESSURE WET/ABRASIVE BLAST-CLEANING......Page 53
3.2.3.4.4 ULTRA-HIGH PRESSURE WATER JETTING......Page 55
3.2.3.5 ABRASIVES FOR CLEANING STEEL......Page 57
3.2.4 INNOVATIVE METHODS......Page 62
3.2.4.2 LASER CLEANING......Page 63
3.2.5 FLAME CLEANING......Page 64
3.2.6 PICKLING......Page 65
3.2.6.3 PICKLING PROCEDURES......Page 66
3.2.7 IRON AND ZINC PHOSPHATING......Page 67
3.3.1 GENERAL......Page 68
3.3.2 OPEN NOZZLE BLAST- CLEANING......Page 69
3.3.3 PRESSURE WATER JETTING......Page 70
REFERENCES......Page 71
4.2.1.1 PRIMING COAT......Page 77
4.1 GENERAL REQUIREMENTS......Page 73
4.2 THE NATURE OF PAINT......Page 75
4.3 PROTECTION BY PAINT FILMS......Page 78
4.3.2 INHIBITIVE PIGMENTS......Page 79
4.3.3 BARRIER COATINGS......Page 80
4.4.1 ADHESION......Page 83
4.4.2 FLEXIBILITY......Page 84
4.4.4 ABRASION RESISTANCE......Page 85
4.4.5 PERMEABILITY......Page 86
4.4.7 AGEING OF PAINT FILMS......Page 87
4.6 BINDERS......Page 88
4.6.1 OXIDATION TYPE......Page 89
4.6.1.3 EPOXY ESTERS......Page 90
4.6.2.1 CHLORINATED RUBBER......Page 91
4.6.2.4 BITUMEN......Page 92
4.6.3.1 EPOXY......Page 93
4.6.3.3 OTHER BINDERS......Page 94
4.7 PIGMENTS......Page 95
4.7.1 INHIBITIVE PIGMENTS......Page 96
4.7.2 OTHER PIGMENTS......Page 97
4.7.3 EXTENDERS......Page 99
4.8 SOLVENTS......Page 100
4.9.1 OIL- BASED AND OLEO- RESINOUS PAINTS ( OXIDATION DRYING)......Page 101
4.9.2.1 CHLORINATED- RUBBER PAINTS......Page 105
4.9.2.3 VINYL PAINTS......Page 107
4.9.3 CHEMICAL REACTION PAINTS......Page 108
4.9.3.1 EPOXIES......Page 109
4.9.3.3 TWO- PACK POLYURETHANES......Page 112
4.9.3.5 MOISTURE- CURING URETHANES......Page 113
4.9.4 ZINC- RICH COATINGS......Page 114
4.9.4.2 INORGANIC ZINC- RICH PAINTS......Page 115
4.9.7 HEAT- RESISTANT COATINGS......Page 117
4.9.8 OTHER COATING MATERIALS AND FILLERS......Page 119
REFERENCES......Page 121
FURTHER READING......Page 122
5.1 METHODS OF APPLICATION......Page 123
5.1.1 BRUSH APPLICATION......Page 124
5.1.2 ROLLER APPLICATION......Page 126
5.1.3 AIRSPRAY APPLICATION......Page 127
5.1.4 AIRLESS SPRAYING......Page 129
5.1.5 APPLICATION OF PLURAL- COMPONENT PAINTS BY SPRAY......Page 131
5.1.6 ELECTROSTATIC SPRAY......Page 133
5.1.7 OTHER APPLICATION METHODS......Page 134
5.1.7.2 FLOW COATING......Page 135
5.2 APPLICATION CONDITIONS......Page 136
5.2.1 PRE- OR POST- FABRICATION......Page 137
5.2.2 THE PAINTING SHOP......Page 138
5.2.3.1 TEMPERATURE......Page 139
5.2.3.2 RELATIVE HUMIDITY......Page 140
5.2.3.3 VENTILATION......Page 141
5.2.5 PREPARATION OF PAINT BEFORE USE......Page 142
5.4 PAINT MANUFACTURERS’ DATA SHEETS......Page 143
5.5.1 AIRLESS SPRAY......Page 145
5.5.2.3 EXPLOSIVE HAZARD......Page 146
5.5.2.6 SOLVENT VAPOUR DENSITY......Page 147
5.5.2.9 SOLVENT HAZARD......Page 148
5.5.2.13 TOXICITY......Page 149
5.5.2.15 WATER- BORNE COATINGS......Page 152
REFERENCES......Page 153
6.1.1.1 INTERNAL TANK BOTTOM CORROSION......Page 155
6.1.1.4 EXTERNAL WALL CORROSION......Page 156
6.1.2.1 ORGANIC COATINGS......Page 157
6.1.3.1 DESIGN REQUIREMENTS......Page 159
6.1.3.3 VENTILATION......Page 160
6.1.3.4 DEHUMIDIFICATION......Page 161
6.1.3.6 HEALTH AND SAFETY MATTERS......Page 162
6.2 POWDER COATINGS......Page 163
6.2.1 APPLICATION METHODS......Page 164
6.3 COIL COATINGS......Page 165
6.4 WRAPPING TAPES......Page 168
6.5 FIRE PROTECTION......Page 170
6.6 PIPELINES......Page 171
6.6.1 SUBSEA PIPELINES......Page 172
6.6.1.1 COAT AND WRAP......Page 173
6.6.1.2 FUSION- BONDED EPOXY COATINGS......Page 174
6.6.1.3 POLYETHYLENE COATINGS......Page 175
6.6.2 BURIED PIPELINES......Page 177
REFERENCES......Page 179
7.1 APPLICATION METHODS......Page 181
7.1.1.1 HOT- DIP GALVANISING......Page 182
7.1.1.3 REACTIONS OCCURRING IN HOT- DIP GALVANISING......Page 183
7.1.1.5 DESIGN OF FABRICATIONS FOR HOT- DIP GALVANISING......Page 184
7.1.2 SPRAYED COATINGS......Page 185
7.1.3 COATINGS PRODUCED BY DIFFUSION......Page 188
7.1.4 ELECTRODEPOSITED COATINGS......Page 189
7.2 CORROSION MECHANISM OF METALLIC COATINGS......Page 190
7.3 PAINTING OF METALLIC COATINGS......Page 193
7.4 PERFORMANCE OF METALLIC COATINGS......Page 195
7.4.1.1 ATMOSPHERIC......Page 196
7.4.3 PERFORMANCE OF CADMIUM COATINGS......Page 198
7.5 COMPARISON BETWEEN METALLIC AND PAINT COATINGS......Page 199
7.6 CHOICE OF TYPE OF METALLIC COATING......Page 201
7.8 WET STORAGE STAIN......Page 202
7.10.2 METAL SPRAYING......Page 203
REFERENCES......Page 205
CHAPTER 8: WRITING EFFECTIVE SPECIFICATIONS......Page 206
8.1 SCOPE OF THE SPECIFICATION......Page 207
8.1.2 DOCUMENTS......Page 208
8.1.4 SURFACE PREPARATION......Page 209
8.1.6 CONTROL OF COATING MATERIALS AND SAMPLES......Page 210
8.1.7 COATING APPLICATION......Page 211
8.1.9 TREATMENTS OF SPECIAL AREAS......Page 213
8.1.10 HANDLING, TRANSPORT AND STORAGE......Page 215
8.1.12 INSPECTION AND QUALITY CONTROL......Page 218
8.2 INTERNATIONAL STANDARDS......Page 219
9.1 INTRODUCTION......Page 221
9.2 INSPECTION REQUIREMENTS......Page 223
9.3 THE APPROACH TO QUALITY CONTROL......Page 224
9.4 REQUIREMENTS FOR AN INSPECTOR......Page 226
9.4.1 TRAINING AND CERTIFICATION OF INSPECTORS......Page 227
9.5.1.2 VISUAL CLEANLINESS......Page 229
9.5.1.3 SURFACE CONTAMINANTS......Page 232
9.5.1.4 SURFACE PROFILE......Page 238
9.5.1.6 BLAST- CLEANING OPERATIONS AND EQUIPMENT......Page 241
9.5.1.7 ABRASIVES......Page 244
9.5.3 COATING APPLICATION......Page 246
9.5.3.2 PAINT APPLICATION EQUIPMENT......Page 247
9.5.3.3 GENERAL CONDITIONS IN THE SHOP AND ON THE SITE......Page 248
9.5.3.4 MEASUREMENT OF AMBIENT CONDITIONS......Page 249
9.5.3.5 MEASUREMENT OF STEEL TEMPERATURE......Page 251
9.5.3.6 MEASUREMENT OF PAINT FILM THICKNESS......Page 252
9.5.3.7 DETECTION OF DISCONTINUITIES IN COATINGS......Page 259
9.5.3.8 ADHESION......Page 263
9.5.3.9 TESTS FOR CURE......Page 265
9.6 INSPECTION OF METAL COATINGS......Page 266
9.6.2 SPRAYED METAL COATINGS......Page 267
9.7 INSPECTION INSTRUMENTS......Page 268
9.8 REPORTS AND RECORDS......Page 270
REFERENCES......Page 273
CHAPTER 10: DESIGNING FOR CORROSION CONTROL......Page 275
10.2 MATERIALS......Page 276
10.3 BIMETALLIC CORROSION......Page 277
10.4 ACCESS FOR INSPECTION AND MAINTENANCE......Page 279
10.5 CREVICES......Page 281
10.6 GROUND- LEVEL CORROSION......Page 285
10.7 ENTRAPMENT OF MOISTURE AND CONDENSATION......Page 287
10.8 GEOMETRY AND SHAPE......Page 288
10.9 TANKS......Page 289
10.10 FABRICATION AND CONSTRUCTION......Page 290
FURTHER READING......Page 291
11.1 INTRODUCTION......Page 292
11.2 THE GENERAL APPROACH TO MAINTENANCE PAINTING......Page 294
11.3 PLANNING MAINTENANCE......Page 295
11.4 INSPECTIONS AND SURVEYS FOR MAINTENANCE......Page 297
11.4.1.1 PLANNING THE SURVEY......Page 298
11.4.1.2 INSPECTION AND TESTING......Page 300
11.4.1.4 RECORDING OF SURVEY......Page 304
11.4.1.6 COMMENTS ON SURVEYS......Page 305
11.5.1 SURFACE PREPARATION PRIOR TO REPAINTING......Page 306
11.5.2 PAINTING......Page 308
11.6 ENVIRONMENTAL CONDITIONS DURING REPAINTING......Page 310
REFERENCES......Page 312
12.1 CATHODIC PROTECTION......Page 313
12.1.2 THE APPLICATION OF CATHODIC PROTECTION......Page 314
12.1.5 CHOICE OF METHOD FOR CATHODIC PROTECTION......Page 315
12.1.6 PRACTICAL APPLICATIONS OF CATHODIC PROTECTION......Page 316
12.2 CONDITIONING OF THE ENVIRONMENT......Page 318
12.2.1 TREATMENT OF THE AIR......Page 319
12.3 ALLOY STEELS......Page 320
12.3.1.1 CORROSION CHARACTERISTICS OF STAINLESS STEELS......Page 321
12.3.2 LOW- ALLOY WEATHERING STEELS......Page 322
REFERENCES......Page 323
13.1 INTRODUCTION......Page 324
13.2 SURFACE PREPARATION......Page 325
13.4 COATING APPLICATION......Page 327
13.6.1 ADHESION LOSS ( FLAKING, PEELING, ETC.)......Page 330
13.6.2 BACTERIAL OR FUNGAL ATTACK......Page 331
13.6.4 BLISTERING......Page 332
13.6.6 CHALKING......Page 334
13.6.9 CRACKING......Page 335
13.6.10 COMPLETE OR PARTIAL FAILURE TO CURE OF TWO- PART MATERIALS......Page 336
13.6.14 ORANGE PEEL......Page 337
13.6.18 SAPONIFICATION......Page 338
13.6.21 THICKNESS FAULTS......Page 339
13.6.23 UNDERCUTTING......Page 340
REFERENCES......Page 341
14.1 INTRODUCTION......Page 342
14.2 FACTORS INFLUENCING THE SELECTION OF COATING SYSTEMS......Page 344
14.3 SELECTION OF COATINGS FOR SPECIFIC ENVIRONMENTS......Page 345
14.4 TYPES OF COATINGS......Page 347
14.5 COSTS OF PROTECTIVE SYSTEMS......Page 348
14.5.1 CALCULATING THE COSTS OF ALTERNATIVE PROTECTIVE SYSTEMS......Page 349
14.5.1.1 SURFACE PREPARATION......Page 350
14.5.1.3 COATING MATERIALS......Page 351
14.5.1.5 OTHER ASPECTS OF COATING ECONOMICS......Page 352
14.5.2 INITIAL COSTS OF PROTECTIVE SYSTEMS......Page 354
FURTHER READING......Page 355
15.1 GENERAL STEELWORK EXPOSED TO THE ATMOSPHERE......Page 356
15.1.1 BRIDGES......Page 357
15.1.2 BUILDINGS......Page 359
15.2 OFFSHORE STRUCTURES......Page 360
15.2.1 ATMOSPHERIC ZONE......Page 361
15.2.3 SPLASH ZONE......Page 362
15.3.2 AREAS TO BE PROTECTED......Page 363
15.3.4 ANTI- FOULING PAINTS......Page 364
15.3.6 TOPSIDES AND SUPERSTRUCTURES......Page 365
15.3.9 CARGO AND BALLAST TANKS......Page 366
15.4 CHEMICAL PLANTS......Page 367
15.6 SEWAGE SYSTEMS......Page 369
15.7 SHEET PILING......Page 370
15.8 JETTIES AND HARBOURS......Page 371
15.9.1.1 CEMENT......Page 372
15.9.1.4 PROPERTIES OF REINFORCED CONCRETE......Page 373
15.9.2.2 CARBONATION......Page 374
15.9.2.3 CHLORIDES......Page 375
15.9.3 TYPES OF FAILURE WITH REINFORCED CONCRETE......Page 376
15.9.4.1 COATINGS......Page 377
15.9.4.2 CATHODIC PROTECTION......Page 378
REFERENCES......Page 379
16.1 INTRODUCTION......Page 380
16.2 TEST REQUIREMENTS......Page 382
16.3 LABORATORY TESTING OF PAINT FILMS......Page 385
16.3.1 DETERMINATION OF DRYING TIME......Page 386
16.3.3 HIDING POWER......Page 387
16.3.4 ADHESION TESTS......Page 388
16.3.5 ABRASION RESISTANCE......Page 389
16.3.6 PHYSICAL STATE OF THE FILM......Page 391
16.3.7 FILM THICKNESS......Page 393
16.4 TESTING OF PAINTS......Page 394
16.5.1 ARTIFICIAL WEATHERING......Page 395
16.5.2 SALT- SPRAY TESTS......Page 396
16.6 INSTRUMENTS FOR SPECIALISED ANALYSIS......Page 398
16.7 FIELD TESTS......Page 399
16.7.2 THE COATING......Page 401
16.7.3 EXPOSURE OF SPECIMENS......Page 402
16.7.4.1 CLIMATIC CONDITIONS......Page 405
16.7.5 MONITORING OF TEST SITES......Page 406
16.7.6.1 SULPHUR DIOXIDE......Page 407
16.7.7 CONDUCT OF FIELD TESTS......Page 408
16.8 SERVICE TRIALS......Page 410
16.9 TESTS IN WATER AND SOIL......Page 411
16.11 REPORTING THE RESULTS OF TESTS......Page 412
REFERENCES......Page 413