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This paper presents an in-sight to the standard “ISO 12944 – Corrosion Protection of Steel Structures by Protective Paint Systems”, from the angle of prevention of premature coating-failure, but also how the standard can be used to help analyze premature coating-failures (if and when a coating-project was done as per ISO 12944).
A major fire in a Reactor Effluent Air Cooler (REAC) of the Hydrocracker Unit (HCU). Visual inspection was made on the failed portion. Metallurgical investigation, macrostructural and microstructural analysis, Scanning Electron Microscopy, and Energy Dispersive x-ray Spectroscopy was conducted on the failed air cooler.
An accurate and comprehensive coating failure analysis often hinges not only on the quality of the field investigation and the laboratory analysis but also on effective communication between the field analyst and the forensic laboratory. Several steps can be taken during a field investigation to ensure that samples of coating removed for laboratory analysis fairly represent the condition of the coatings and give the forensic laboratory the best possible chance of discovering the root cause of the coating failure.
The Bureau of Reclamation’s Materials Engineering Research Laboratory has been evaluating polyurethane pipe linings for severe immersion exposure, specifically for outlet works and penstock linings. Polyurethanes have several advantages over other coatings, such as application temperature range, faster cure times in cold temperatures, rapid return to service, coat large surface area rapidly, low viscosity (i.e., accommodates pumping over longer distances), and greater impact resistance.
The tensile pull-off test, as in ASTM 4541, in which a round metal ‘dolly’ is glued to a coating then pulled off is a very common method for measuring adhesion of a coating to its substrate. This technique is very well known to produce joint failures that are not at the intended coating steel interface but may initiate within the coating, within the glue or at the glue-coating interface.
Structures are made of different substrates and materials. In order to protect these structures from the impact of corrosion, virtually everything is coated with some combination of paints, lacquers, epoxies, and thermoplastics. Inspecting structures requires multiple types of tests including measuring the thickness of a wide variety of protective coatings. This paper will discuss flexible measurement devices and how the utilization of various probes provides the best measurement results for specific applications.
Stainless steel is selected for use in the municipal waterworks industry because of its inherent corrosion resistance properties. Designers oftentimes overlook the associated problems with coupling stainless steel with carbon steel metals. When these materials are electrically connected and placed into aqueous environments (immersion service) accelerated corrosion of the anodic carbon steel metal is initiated.
These case studies are presented demonstrating the cost savings and performance of one-coat direct-to-metal (DTM) and two-coat polyaspartic exterior coatings of three industrial maintenance applications involving hopper railcars, bridges, and an exposed steel beam superstructure. In each example, the rapid cure time of the polyaspartic coating provided increased productivity to complement its documented high performance.
While real time outdoor weathering exposures in benchmark climates, such as South Florida, are highly recommended for determining coating performance and service lifetimes, the lengthy test times required are often problematic. Therefore, outdoor and laboratory artificial accelerated weathering testing has become a mainstay in coatings testing, particularly in the product development phase.