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Ambient conditions can be critical to the success or failure of a coatings project. It has generally been assumed by the industry that a sling psychrometer is more accurate in determining Relative Humidity and Dew Point than electronic sensors.
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Inorganic zinc-rich coatings (IOZ’s) are often considered the gold standard for corrosion protection in atmospheric environments. Frequently, zinc epoxy coatings are considered second best among the most effective coatings for corrosion protection. However, current zinc-rich coating technology is not exempt of limitations, such as poor mechanical properties of the film, rigid environmental application conditions, or the inefficient use of zinc particles for providing galvanic protection. Due to these limitations, a number of asset owners have made the decision not to use zinc-rich coatings to maintain coating systems in marine and offshore environments
As environmentally friendly coatings, inks, and adhesive systems have evolved; additives have also evolved in chemistry, structure and effectiveness. This overview strives to present these new additive technologies in three areas: surfactants, dispersants, and defoamers. The chemical nature of these additives and subsequent performance in a variety of systems will be described.
Pull-off adhesion testing of coatings is commonly used for product testing and qualification as well as quality control / quality assurance. However, initial adhesion values do not necessarily correlate with service life of coatings or their corrosion protection performance. Adhesion of several product chemistries to steel is examined in this study before and after immersion exposure. Results are presented within the context of laboratory corrosion testing in an effort to investigate the significance of adhesion testing in modern lining systems.
In this paper, I will discuss such an example of when the predicted service of the coating determines that a more dynamic method must be utilized. I will discuss testing that was conducted for immersion service where flow of water over the surface was a major consideration. The question of how well the adhesion would hold up in real life service could not be properly answered by the degree of failure in this case. I discovered that the more important consideration was the survivability of the coating if a defect were introduced.
Quality assurance of coatings on steel water pipes commonly relies on tensile pull-off measurements of the coating-steel adhesion, according to ASTM D4541. These tests are performed by adhering a metal ‘dolly’ to the coating with an adhesive, then scoring around the dolly circumference, through the coating down to the steel surface, before recording the stress necessary to pull the dolly (and coating) away from the steel pipe.
Pull-off adhesion behaviors of 15 coating systems in three groups were studied utilizing test method ASTM D4541. Three groups of coating systems included coating systems with organic or inorganic zinc-rich primers, polymeric polyurea coatings, and overcoating systems applied on an existing coating system.
This paper discusses an innovative technique employed on the 2017 AETC Corrosion Control Study conducted on 19 NASA wind tunnel facilities located at three NASA Centers: Langley, Ames and Glenn Research Centers. The technique adds structural and prioritization context to corrosion and coating assessments which yields an Overall Risk Priority (ORP) score for each inspection item.
Geothermal energy is an excellent source of renewable clean power generation, as well as for heating and cooling. Unlike other renewable energy sources, it is unaffected by local climate conditions. However, the heat exchangers used in geothermal power plants are under constant threat of scale formation and corrosion due to the harsh operational conditions to which they are exposed. Therefore, surface modifications to heat exchanger materials, for example through coatings, are necessary to improving the efficiency and durability of geothermal plant.v
The control, mitigation and prevention of corrosion in environments ranging from mildly corrosive to severe atmospheric conditions to underground exposures (such as pipelines) to chemical spill and fume exposures has long been focused on the use of thermosetting polymers such as epoxies, polyesters, vinyl esters and urethanes. For the most part these materials have worked reasonably well in applications such as structural steel and equipment coatings, architectural paints, vessel linings, concrete coatings, secondary containment linings, and floor toppings.
The demands of cementitious coatings and repair mortars have never been greater. As manufacturers, contractors, and coatings inspectors we are tasked with providing high performance solutions for new projects, or to breathe life back into failing concrete or steel. With new cement technologies, we can meet and exceed our customers’ environmental and financial expectations.
The Brazilian cost of corrosion was estimated at 3% of the GPD in 2018, that percentage is equivalent to approximately $US 49 billion, according to an ABRACO(1) journal released in 2020.1 It is estimated that from this cost $US 19 billion could have been saved through anticorrosive actions. In another research conducted by the EPRI(2) the results showed that at least 22% of corrosion costs could be avoided through adequate mitigating actions.2