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Hot dip galvanizing steel articles after fabrication is one of the most widely used methods to provide corrosion protection. As a final step in the process, the hot dip galvanized coating is inspected for compliance with specifications. Correct measurement techniques and accurate interpretation of the results are necessary to provide an acceptable hot dip galvanized coating.
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Coatings are widely used to mitigate corrosion of structural steel in aggressive humid environments. Zinc-rich primer three-coat paint systems are widely used to mitigate corrosion of steel bridges. However, the associated costs of its required maintenance are high. As part of a research program, chemically bonded phosphate ceramics (CBPC), thermal diffusion galvanizing (TDG) and metallizing coatings along with the current 3-coat systems were exposed in outdoor conditions for up to 2 years and in salt-fog exposure for up to 14,600 hours.
The performance of a Chemically Bonded Phosphate Ceramic (CBPC) coating was investigated for marine bridge application. Assessment of possible coating degradation and corrosion development was made by physical and electrochemical techniques. Passive-like conditions developed in the chloride-free solutions and formation of oxide product occurred in the chloride solutions. A large degree of oxide product formation throughout the non-scribed coating exposure surface area, consistent with the large, measured corrosion current, was indicative that the ceramic coating had poor barrier coating properties.
Measuring physical parameters such as coating thickness, surface profile, and dew point is a common task for inspectors and applicators. However, those measurements are only as accurate as the instrument that performs them. Even high-quality electronic instruments can yield incorrect measurements.
Many modern electronic gauges have the capability for transmitting or uploading data to a computer via a data port. This can mean transferring the data to a spreadsheet for customized analysis or to a data management software package for analysis using standard statistical methods. This paper describes the format of the data for a range of gauges used for the coating inspection process including surface profile determination, climatic condition monitoring and coating thickness measurement.
The techniques used to measure, design, and test Radar Absorbing Materials (RAM) are described. Absorbing additives are added to polymer materials at a range of concentrations in the laboratory, and then tested over the frequency range of interest to determine the material’s permittivity and permeability. The techniques and algorithms used to extract these values are dependent upon the material under test and the type of information required.
This paper is a case study on a 100% solids epoxy penetrating sealer being used as a tie coat between a tightly adhered latex acrylic and aliphatic polyurethane.
In the application of coating / lining systems, applied film thickness is an important aspect in the execution of the project. Specifications call for a required minimum film build, not to verify material use, but because it relates to the overall performance of the project. Knowing the applied film thickness of the coating / lining system as the job proceeds also helps determine if one has obtained sufficient material to successfully complete the application work as specified.
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.
As the author Robert M Pirsig stated, “Technology presumes there’s just one right way to do things, and there never is.” Whilst measuring coating thickness on concrete substrates is not new, the introduction of a new non-destructive thickness (NDT) gauge to measure coatings on concrete not only allows the user to evaluate the results obtained by existing instrumentation, but also provides an alternate non-destructive measuring solution - thereby increasing the industry’s confidence in the overall measurement technology.
Engineers, architects, DOTs, and other specifiers use hot dip galvanizing to provide corrosion protection to steel and iron in many industries, including transportation and highway, parking garages, bridges, structural, agricultural, petrochemical, and original equipment manufacturing. To ensure continued corrosion protection and structural integrity in these industries, it is necessary to properly inspect the galvanizing.
Corrosion is a natural phenomenon, and thus can never be completely eliminated; however, it is a misconception nothing can be done. Estimates show 25-30% of steel corrosion could be eliminated if proper corrosion protection methods were employed. Corrosion can simplistically be viewed as the tendency for the metal, after production and shaping, to revert back to its lower, more natural energy state of ore. This tendency is known as the Law of Entropy.