Professional Documents
Culture Documents
Course Handouts
Contents
Chapter Title
1 2 3 4 5 6 7 8 9 10 11 12 Introduction What is Paint? Generic Paint Types Steelwork Pre-treatment Paint Application Inspection and Control Paint Failures Antifouling Safety, Health and Environment (SHE) Corrosion Cathodic Protection
Page
2 3 8 15 19 26 33 41 47 53 59 65
Course Handouts
Page 1
1. Introduction
Why paint?
There are two main reasons for painting. For many people, the most important reason is that we want pleasant surroundings (decorative painting). In other contexts, paints are applied because it is financially very important to protect structures against corrosion. For these purposes, corrosion-protective paints are used. A good paint system will be a cost-effective method of protecting the structure: The life of the structure is extended, maintenance costs are reduced and the risk of accidents which affect people and the environment is reduced.
Jotun
Jotun is one of the world's leading suppliers of corrosion-protective paints for industry, shipping and oil-related sectors. We also supply paints for decorative purposes and powder products, based on a worldwide network of factories and companies. To support customers, we have established a wide range of services. This ensures that the customer receives the right paint products from our corrosion-inhibiting systems at optimum cost.
Course Handouts
The course handouts contain a brief introduction to the main topics of paint technology. Each section consists of an introductory section and a copy of selected overhead slides. Not all topics in the handout will necessarily be discussed on the course you follow.
Course Handouts
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2. What is Paint ?
Definition of paint and varnish
Paint is a product in liquid or powder form which contains pigments and which is applied to a substrate to form an opaque film. The film has protective and/or decorative properties and can also be given special functions as required. Paint is described as opaque if it hides the substrate completely. Varnish is a product which, when applied to a substrate, gives a solid transparent film and has protective, decorative or special properties. Varnish does not contain covering pigments and is therefore regarded as "clear paint".
Course Handouts
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Personal notes
Course Handouts
Page 4
Chapter:
Paint consist of:
What is Paint ?
The properties of a paint will be decided by the binder
Describes the type of paint/coating Bind pigments and extenders to a solid film Provides the adhesion to the substrate Provides the water, chemical, solvent and UV resistance
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Solvents evaporating
= Dispersed droplets
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Handouts
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Chapter:
Curing mechanism of two -pack paints
Solvents evaporating
What is Paint ?
The surface tolerance depends on the penetrating properties of the binder
Vinyl Chlorinated rubber Epoxy Polyurethane
= Polymer
Urethane alkyd Surface tolerant paint: Epoxy Mastic Alkyd Boiled linseed oil Raw linseed oil
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Pigments, examples
Rust preventing pigments: Red Lead Zinc Zinc Chromate Zinc phosphate Coloured pigments (hiding power / opacity): Inorganic; red, yellow, brown, black Organic, all colours Titan dioxide (white)
Extender pigments (non/limited hiding/opacity properties): Talcum Barium sulphate Microdol (dolomite)
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Flat PVC 35 - 50
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Solvents / diluents
Solvent
Solvent or diluent
Single or blended Disolves the binder completely (Forms a solution)
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Handouts
Page 6
Chapter:
Addition of thinner
Evaporation rate and solubility of a thinner will influence a paints: Drying time Film-forming properties Quality of the film
What is Paint ?
Additives
Wetting agent Anti-foam Anti-settling Anti-skin Anti sagging Catalysts UV-absorbers
etc.
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Inhibition
Moisture Absorption Ionisation of Inhibitor Reaction with Steel Surface Passive layer forms 2nd Coat 1st Coat Inhibitive Primer Steel Moisture may penetrate to reach the inhibitive primer where the reactive pigments are activated, which in turn passivate the metal substrate at the coating/metal interface.
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Zn
Steel An inorganic Zinc primer reacts to protect the steel substrate when the topcoat is damaged.
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Handouts
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Alkyd paints
Alkyd paints are made from alcohol and acid with the addition of fatty acid or oil. The addition of fatty acid and/or oil can be varied to give alkyds with different properties. Alkyd paints can only be used above water (not submerged) as the water resistance is poor. They are not used on zinc primer or galvanised steel as a chemical reaction - saponification would occur with the binder, with subsequent blistering and flaking. The drying/curing process is also temperature-dependent. This is because alkyd paints dry or cure by absorbing oxygen from the air. This is a chemical reaction and such reactions are always influenced by temperature. The degree of pre-treatment required for the substrate can vary from St 2 to Sa 2, depending on the purpose of the paint and the environment to which the paint is exposed. By modifying the alkyds for example with styrene or silicon, other properties can be achieved.
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These paints are normally two-component. The supplier provides these paints in two separate containers, one for the base and the other for the curing agent. We often refer to these as component A and component B. Before painting, the two components must be mixed. It is particularly important to mix the components in the correct ratio and to ensure good agitation. The curing process is a chemical reaction between the base and curing agent, so application and curing are temperature-dependent. It is equally important to apply the paint to the substrate before the chemical reaction has proceeded for too long after mixing of the components. We often talk of the usage time (potlife) of paints. When the potlife has elapsed, the paint becomes dry and finally completely hard and cannot be applied.
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Chapter:
Alkyd paints
Generic types
Alkyd paint
Properties
Advantages Good application
properties 1-component Good weather durability Good wetting properties Good recoatability Good levelling properties Good gloss retention Dry heat resistant up to 120 C.
Where to use
Segments
Ships Industry Newbuildings / Maintenance All exterior and interior objects Only above water St 2 to Sa 2 or shop primed
steel
Objects
Surface preparation
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Properties
Advantages Physically drying Not temperature
dependent
Where to use
Segments
Limitations Poor solvent resistance Low solid content Relatively poor wetting
properties
Ships Offshore Industry Newbuildings / Maintenance Below and above water All external surfaces Blast-cleaned to Sa 2 or shop
primed steel
Objects
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Vinyl paints
Properties
Advantages
Physically drying Good chemical resistance Good water resistance Quick drying Not temperature dependent One-component
Used for:
Exterior objects above water Offshore on top of Zinc-ethylsilicate
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Properties
Advantages Higher content of
solids Higher water resistance Better wetting properties Cost advantages
Limitations
Low solid content Poor resistance against
strong solvents
Handouts
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Chapter:
Pure Epoxy paints
Generic types
Pure Epoxy paints
Properties
Advantages Limitations
Segments
Where to use
Ships Offshore Industry Newbuildings / Maintenance Chemical cargo tanks Blast-cleaned to Sa 2 or shop primed steel
Chemical curing Very good chemical resistance High alkali resistance Moderate resistance to acids Good adhesion Very low permeability High mechanical strength Dry heat resistant up to 120 C
Objects
Surface preparation
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Epoksy - acrylic
Properties
Advantages:
Chemically curing More flexible Excellent water resistance Better wetting properties Dry heat resistant up to 90 C
Properties
Positive
Very good weather
10
Limitations:
Dark colour Temp. dependent 2-component Recoating interval Bleeding when overcoated Coal Tar is carcinogenic
Limitations
2-pack Overcoating time
resistance Very good gloss retention Very good chemical resistance Very good solvent resistance Cures down to 0 C Potlife (24 timer)
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Where to use
Segments Ships Offshore Industry Newbuildings / Maintenance Above water Indoor and outdoor Top coat on Epoxy, Epoxy Mastic, Polyester glass flake
Properties
Advantages
Chemically curing Surface tolerant Light colours Very good water resistance Very good wetting properties Good chemical resistance High solid content High build (Thick coats) Winter curing agent Dry heat resistant up to 90 C
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Limitations
Chalking Temperature dependent Not to be applied on
thick coats of physically drying paints Minimum DFT 150 m by airless spray
Objects
Surface preparation
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Handouts
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Chapter:
Epoxy Mastic paints
Generic types
Experience When using Epoxy paints
Correct mixing ratio Good mixing Potlife Induction time Correct pre-treatment Correct film thickness Adequate ventilation
Where to use
Segments
Ships Offshore Industry Newbuildings / Maintenance Ballast tanks and Cargo tanks All exterior and interior surfaces,
above and below water
Objects
Surface preparation
St 2 to Sa 2 or Water jetted,
Magnesium descaled or shop primed steel
Temperature dependent curing Avoid high humidity Minimum and maximum curing times Time for fully cured Use epoxy thinner Health and epoxy
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Polyurethane paints
Polyurethane paints
Properties
Advantages Limitations
Segments
Where to use
Ships Offshore Industry Newbuildings / Maintenance All exterior substrates above
water (Also internal at times) Surface preparation
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Very good weather resistance Excellent gloss durability Very good chemical resistance Very good solvent resistance Cures down to 0 C
Objects
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Zinc Epoxy
Properties
Advantages
Chemically curing Good corrosion protection Good adhesion Require min. Sa 2 Good mechanical strength May be recoated with all types of paint, except Alkyd Dry heat resistant up to 120 C
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Where to use
Segments
Limitations
Temperature dependent 2-component Film thickness: 25 - 50 m Not acid- and alkaline resistant (Resistant between pH 5-9)
Ships Offshore Industry Newbuildings / Maintenance All exterior and interior objects
above and below water (as holding primer for underwater use 20-30 microns).
Objects
Surface preparation
Blast-cleaning to minimum Sa 2
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Handouts
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Chapter:
Zinc Ethylsilicate paints
Generic types
Zinc Ethylsilicate paints
Properties
Advantages
Very good solvent resistance Very high heath resistance
(max 400 Very high mechanical strength Very good adhesion to blast cleaned steel Relatively good recoatability
oC)
Where to use
Segments
Limitations
Requires humidity for
curing
Ships Offshore Industry Newbuildings / Maintenance All exterior objects above the
waterline.
Objects
Blast-cleaning to minimum Sa 2
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Waterborne acrylics
Properties
Pure aluminium silicone:
Resistant up to approximately 600C
Remember:
To be applied on Sa 2 Overcoating only on fully cured Zinc silicate
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Advantages Good corrosion protection Reduce the emission of solvents Low VOC content Flash point above 100 C Water as thinner / cleaner Good water resistance Good UV - resistance Good adhesion to other generic type of paints No risk of saponification
Due to water-soluble
groups, more sensitive to aqueous solutions (more blistering/earlier corrosion) Slower drying compared to solvent based types at high relative humidity Need good ventilation Need good pre-treatment Less chemical resistance
Limitations
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Waterborne epoxy
Waterborne paints
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Good corrosion protection Reduced emission of solvents Low VOC content Flash point above 100 C Water as thinner / cleaner Good water resistance Cures down to 5 C Good adhesion to steel, galvanized steel, Aluminium and concrete Good sprayability
Recommended conditions during application and drying Application and drying possible Application not recommended
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Handouts
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Chapter:
Glassflake Reinforced Polyester
For protection of steel and, in certain cases, Aluminium and concrete. The glass-flakes are 3-5 microns thick and 400 microns across. Potlife : Approximately 45 minutes. Curing time: Approximately 3 hours. Thickness 600 - 1500 microns per coat.
Generic types
Glassflake Reinforced Polyester
Properties
Advantages Limitations
Quick curing Variable curing time Application with airless Excellent mechanical strength Glass-flakes reduce shrinkage, increases mechanical strength and water resistance. resistance
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Properties
Advantages Limitations
Cures down to 10 C
(normal airless spray)
Excellent mechanical
strength
Glass-flake reinforced Vinylester coating for protection of steel and concrete in aggressive environments.
of 50-100 microns Very good adhesion Bad curing may be experienced Very good water resistance. on Zinc primers and galvanised surfaces. Very good chemical resistance
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resistance Very good chemical resistance Very good solvent resistance Can be applied by normal airless spray Glassflakes improve abrasion resistance
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4. Steelwork
Before a structure is painted, a number of operations must be performed on the substrate. The initial work required is generally known as "steelwork". Steelwork is a very important part of the surface treatment and must be carried out before cleaning and priming of the steel. Good steelwork will ensure that the life time of the paint system meets expectations. In practice, it is impossible to achieve a long life time for a paint system if the steelwork is omitted or poorly performed. The requirements for preparation will always be part of the paint specification. A steel structure should be designed so that all parts of the structure are accessible for cleaning, pre-treatment and painting. It is particularly important to ensure that these requirements are taken into account at the newbuilding / construction stage. Designers often forget that structures require maintenance. Steelwork involves the following stages before cleaning and priming: 1. 2. 3. 4. 5. 6. All sharp edges are rounded to a radius of at least 2 mm by grinding. All welding beads and slag are grinded off. Surface defects such as lamination etc. are removed by grinding. Undercutting in the weld is repaired before priming. Rough manual welds to be grinded. Gas-cut edges are to be grinded before priming.
To avoid contamination and damage to the coating, steelwork should be performed in the welding shop and not in the paintshop. Production times will also be reduced if sharp edges in notches, manholes etc. are rounded before welding work is performed. All welds should be inspected and if necessary repaired before cleaning is carried out. The welds must be free from weaknesses such as undercut, hole, craters and welding splashes. Notched, drainage holes etc. should have a radius of at least 50 mm to ensure good priming and correct paint application.
Personal notes
Course Handouts
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Chapter:
Pre-blasting preparation involves the following activities
Rounding or smoothing of: Sharp edges Corners Welds Grinding of: Laminations Flame cut edges Weld spatter Notches minimum diameter: 30 mm Inspected and approved before cleaning
See ISO 8501 Visual assessment of surface cleanliness
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Steel work
Steel preparation
B A
Weld spatter
B
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Pre-blasting preparation
Grinding of sharp edges, welds etc. Disc sander and disc grinder
Sander for removing mill scale, paint and rust Grinder for heavy grinding, such as edges and weld beads
Steel
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Chapter:
Manholes in a tank
Section manholes Well grinded edges
Steel work
Severe corrosion due to a combination of several effects
Sharp edges Rough welds (not grinded) Missing stripe coating
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Steel preparation
Weld spatter
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Disc grinding of weld beads, sharp edges etc. by means of a disc grinder.
Other types of discs are available. Some of them will reduce the amount of sparks.
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Chapter:
Pre-blasting preparation
Steel work
Unacceptable weld. Too rough and full of pinholes / pores
Weld spatters close to weld Rewelding and grinding must be carried out
prior to reblasting and painting
Undercut
Undercuts exceeding classification ruling should be repaired by welding and grinding.
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Paint on a very poor weld. Pinholes and holidays visible after second stripe coating
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Corrosion initiates
after a short period of time on weak areas: Sharp edges, crevices and spot welds
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5. Pre-treatment
After the steelwork on the steel structure has been completed, inspected and approved, pretreatment can begin. The purpose of preparation is to ensure that the substrate is suitable for application of the paint, i.e. the steel is sufficiently clean and rough. Contaminants such as oil, grease and salts for example cannot be removed by blast-cleaning. Before preparation begins, the steel must be properly cleaned. Cleaning removes contamination and impurities such as oil, grease, salt, dust and dirt. Salts from a marine atmosphere which are deposited on the structure, and welding fumes from manual welding are examples of salts which should be washed off before preparation. Salts can cause osmotic blistering and oil will reduce the adhesion of the paint. Salts must be removed with plenty of fresh water. Oil and grease cannot be removed with water alone; strong alkali washing agents and solvents must be used. Once the substrate is clean, pre-treatment can begin. There are countless methods which can be used, all of which have advantages and disadvantages. Here is a brief list of some methods: Blast-cleaning. To ensure maximum paint adhesion, a rough surface is required. In view of this, blast-cleaning is the best preparation method. Blast-cleaning removes old paint, rust and scales and gives a clean rough surface. Possible blast-cleaning methods are dry blast-cleaning, slurry blast-cleaning (addition of water) and wet blast-cleaning (water with addition of abrasives). Dry blast-cleaning gives a clean dry surface and the required roughness but causes considerable dust which contaminates the immediate environment. Slurry and wet blastcleaning give a rough, clean surface without dust, but create flash rust. It has been found that much of the abrasives remain on the substrate after blast-cleaning. Such contaminants may on some alloys cause a risk of corrosion at these points. For preparation of stainless steel, aluminium and galvanised steel, it is important to use non-metallic abrasives. Ultra high-pressure water cleaning. This preparation method is becoming increasingly common. The method consists of removing contamination, corrosion products and old paint by applying water to the substrate under extremely high water pressure (up to 2500 bar). The method has two essential advantages: no cloud of blasting dust is created to contaminate the immediate environment as in traditional blast-cleaning, and water-soluble salts are removed from the substrate. It is important to use clean water so that the substrate is not contaminated by the water used. The method gives a clean surface but will not give any extra roughness to steel. The original roughness of the steel is retained where intact paint is removed, but the corrosion pattern on corroded areas will be considered as roughness where corrosion has occurred. One disadvantage with water cleaning is that the tendency to form flash rust on the steel will increase as moisture is added to the substrate. The degree of flash rust depends on the relative humidity, the temperature of the steel and atmosphere, and the cleanliness of the surface. Mechanical cleaning. Use of mechanical cleaning tools such as steel brushes, grinding equipment or machining, does not achieve the same degree of cleanliness and roughness as blast-cleaning and the adhesion between the substrate and the paint system will therefore be reduced. Needle guns for example often cause excessive roughness or break-up of the substrate.
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Electrolytical descaling. There is a special preparation method where magnesium strips are used to remove rust. This has proved particularly useful in severely corroded ballast tanks on sailing ships where thick rust layers can be removed at sea. However, the procedure requires a knowledge of how to calculate the number of anodes needed, installation of the anodes, treatment periods and cleaning after the procedure. Such treatment should therefore be carried out in collaboration with Jotun. The method to be used will be described in the paint specification and is primarily selected on the basis of: Purpose of the structure Exposure conditions Required life time Restrictions related to environmental requirements and safety. One essential element of the entire pre-treatment process is care when performing the work. Today, the inspection is performed with reference to various standards. The most common standards are ISO 8501 which gives a visual description of the appearance of a steel surface both before and after blast-cleaning and wire brushing. For water-blasting/water-jetting, separate standards have been prepared by ISO and SSPC/NACE.
Personal notes
Course Handouts
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Chapter:
Surface treatment may include the following operations
Steel work (Pre-blasting preparation) Removal of: Rust and mill scale Salt Grease, oil, dirt Old / unwanted paint Flattening of glossy paint Special pre-treatment of new aluminium
and galvanised surfaces
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Pretreatment
Work to be carried out in the cleaning shop
Remove prior to pre-treatment:
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Degreasing side bottom with emulsifying detergent to remove oil, grease etc.
Should always be carried out before blast-cleaning The detergents must be removed by Low pressure
water cleaning, LPWC (Around 250 - 300 bar)
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Blisters close to weld, probably due to welding smoke remaining on the the steel
Welding smoke is resoluble in water and will
create osmotic blistering
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Chapter:
Pre-treatment
Pretreatment
Rotary impact or scarifying tools
Equipment with rotating abrasive head
Evaluation of methods
Blast cleaning Power grinding Power wire-brushing Manual wire- brushing. Needle hammer Power chiseling Manual scraping
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Ideal Not as good as blast cleaning, but best alternative. Great risk of unwanted polishing. Not recommended. Very poor. Usable, but risk of unwanted rough surface, Good in combination with other methods Usable in combination with other methods.
8
Peening flaps (Roto-Peen) - Creates a surface profile, 25 to 75 microns Rotary hammers - cutters Nylon non-woven abrasive wheels
Rotary impact tools is the best choice for removing coatings
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Steel substrate treated by hand and mechanical power tool cleaning equipment
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Pre-treatment
Surface remains dry Good anchor pattern for paint No pre-rusting profile
Does not remove salt Does not remove oil Creates dust
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Handouts
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Chapter:
Blast cleaning
Pretreatment
Blast - cleaning
Nozzle
Nozzleholder Air
Pressure at Nozzle
Pressure at Nozzle 5,6 kg/cm = 66% productivity Pressure at Nozzle 4,2 kg/cm = 50% productivity
Rubber hose
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Blast Cleaning
Nozzle opening
Remaining Removed
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Blast cleaning
Steel
Area with reduced adhesion Corroded and blast cleaned
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Handouts
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Chapter:
Blast cleaning
Pretreatment
Blast cleaning
Star cracks
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Corrosion has taken place Almost the total area has been spot blasted
Spot blasting in this way result in many loose
edges that needs to be feathered
Loose edges resulting from spotblasting carried out some time ago
Edges has not been feathered prior to application of the paint The edges are weak points in the paint film Corrosion attack initiates on such areas
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Surface has not been well cleaned Over painting grit or foreign matters
Weak point in paint film Entrapped air Less adhesion Corrosion will develop rapidly
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Handouts
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Chapter:
Slurry and wet blasting Benefits and limitations
Advantages Disadvantages
Pretreatment
Water-jetting Advantages
Salt level on steel surface drastically reduced. No dust produced. No grit cost (water is usually cheaper).
Grit blasting uses 55 kg/m, costing 63,-/ton = 3,46/m. Ultra High Pressure Water Jetting, UHPWJ needs 130 l/m, costing 0,80/ton = 0,10/m). Close working of other trades possible. Abrasives can be introduced if improved surface profile is required. Lower noise level than with grit blasting.
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Pre-treatment of Aluminium
Degreasing and washing Sweep blasting with non-metallic abrasive
or
Degreasing and washing Sweep blasting with non-metallic abrasive Abrading through other means, e.g.
mechanical tools, emery paper etc
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6. Paint Application
It is important to understand that paint is a semi-finished product. Only once the paint has been applied to a structure will the real properties of the paint system become apparent. How well a system works largely depends on the skill of the painter. The protective properties of a paint can be significantly reduced if the paint is applied incorrectly.
Application technique
To apply the paint to achieve the optimum properties, it is important to select the right application tool and method. Generally application tools are selected according to the size of the object, complexity, accessibility, type of paint and environmental aspects. Painting always begins with "stripe coating". Stripe coating means applying an extra coat of paint on areas where experience has shown that it is difficult to achieve the specified film thickness by spray. Typical areas which should be stripe coated are sharp edges, notches, welds (particularly manual welds) and areas which are difficult to reach with a spray gun. This is a very important job but it is often skipped or done badly as it is a time-consuming process. Stripe coating on bare steel should always be carried out with a round or oval brush and not a roller. The aim is to ensure good wetting of the substrate. Stripe coating should also be used between each coat. A stripe coat can be applied with a roller on the previous coat where suitable. The film thickness achieved using brushes or rollers is normally in the range of 35 - 40 m. Airless spraying is the most effective and cost-saving application method. It is possible to paint large areas in the minimum of time and paint can be applied in greater and more even film thicknesses per coat than with a brush and roller. The application technique and experience of the painter are very important for achieving a good result. This includes factors such as the right distance between the gun and object (normally 30 to 60 cm), the right angle to the object (normally 90 degrees), good overlapping (approx. 50% overlap) and sensitivity in use of the trigger. When spraying, the paint is applied at as low a pressure as possible to achieve an even spread. Too high a pressure leads to dry spraying and a lot of dust.
of the correct (specified) thinners is important as adding the wrong thinner can cause poor results in terms of corrosion protection. When applying two-component paints, the mixing process itself is also important. Use mechanical agitators and not stirrers. Good agitation or mixing of the two components and the correct mixing ratio are important. Follow the instructions on the technical data sheet for the product. Plural component spray (two-component spray) are also available for applying special two-component paints, where the components are mixed in the correct ratio in the unit itself.
Health
The painter is exposed to solvents and various other components in the paint. Make sure that approved protective equipment is used and that ventilation is adequate. Personal notes
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Airless spray: Good Paint brush: Good Roller: Poor, particularly for the first coat
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Application by roller
Benefits
Good wetting of the substrate Forces the paint into the surface Better than roller on the first coat Good on areas with poor accessibility Gives low film thickness, many coats required Creates an uneven film Application speed is slow
Application speed is faster than with paint brush Good on areas with poor accessibility Poor wetting of the substrate Never use for the first coat May incorporate air and pinholes Gives low film thickness, many coats required
in the paint film
Limitations
Limitations
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Where difficult access with spray Profiles Inside edges Holes, notches Corners, angles Sharp edges Manual welding seams
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Paint application.
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Release trigger
End stroke
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Overspray or dry-spray
Dry-spray will develop at the edges of a wide spray fan. This may give a rough film and pinholes
Outside area of effective spraying: Low impact Poor flow of paint Result: Dry-spray
Result:
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Uneven paint film Dry-spraying will occur The loss factor will be high The roughness will increase
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Contamination of
the environment High loss factor Poor corrosion protection Waste of money
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Over spray
Heavy
Light
Source: Corr. Control Principles and Metodes, Sect. 7, Ameron Inc., Monterey Park, Ca.)
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Area with thick paint film Application directly into the corner gives an uneven film thickness, but may still be satisfactory for many types of service
(Source: Industrial Maintenance Painting, National Association of Corrosion Engineers; Houston TX, p. 88, 1973.)
4 5
1
(Source: Industrial Maintenance Painting, National Association of Corrosion Engineers; Houston TX, p 88, 1973)
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Several mm thick
paint
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For all activities, the inspector should verify and document that the work complies with the specification and has been performed professionally, and that the paint supplier's instructions for use of the product have been followed.
Steelwork
Activities which are normally included in the preparation are described in chapter 4. The inspector should verify that the steelwork has been performed according to specification or ISO 12944-3. In particular, this includes the rounding of edges, grinding of welds, removal of weld spatters and grinding of laminations.
Pre-treatment
The inspector must check and ensure that the structure is free from oil, grease and salt and that the washing procedure has been followed. Visual assessments shall be made of the degree of rust on the steel before preparation and the condition of the structure after preparation. Standards ISO 8501-1 or ISO 8501-2 (for repair work) apply. Before and during pretreatment, the atmospheric conditions are checked according to ISO 8502-4. Other checks to be performed usually include inspection for invisible contamination on the surface such as salts (ISO 9502-6 and 9), dust (ISO 8502-3) and specified roughness (ISO 8503). All data and records shall be entered in a daily log.
Application of paint
The inspector's task during application of the paint is to ensure that all work proceeds in the specified manner. This includes all work operations from opening of the paint tin to the application of the final coat. It is important to have a good overview of all technical documentation. Check technical data sheets and check for use of the right thinners, the right curing agent for the base, mechanical agitators and a good mix when using two-component paints. Check the specified pre-reaction time if given in the technical data sheet. Check that stripe coating has been performed properly before application of the full coat by spraying. Ensure that the painter carries out careful checks with using wet film gauge so that the specified wet film thickness is applied. The atmospheric conditions should be monitored during the painting work. Ensure adequate ventilation to remove solvents. All data and records must be entered in a daily log.
Jotun Paint School Course Handouts Page 33
Drying / curing
After drying / curing, the dry film thickness is checked (ISO 2808). Pay particular attention to areas where access with an airless spray gun is difficult, and ensure that the dry film thickness lies within the specified limits. Check that the overpainting intervals are observed for the paints, and that the surface is clean before overpainting. After a structure is painted, the total film thickness should be checked. Individual specifications also require adhesion testing for example to ISO 4624, or holiday detection to ASTM G62-85. It is very important to have good test routines and enter all data and records in a daily log.
Personal notes
Course Handouts
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Chapter:
What is QA - QC ?
QA = Quality Assurance (A documented management system) QC = Quality Control (Inspection and testing routines)
the specifications
of the inspection Inspect all structures to be painted Ensure that all specified requirements are met Document the results from the inspections In case of non-conformance: Issue written reports
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Daily logs
Steel temperature Air temperature % Relative Humidity Dew point Object no. and name Exact specification Pre-treatment, specified and actually conducted.
Relevant standards Relevant TDS and MSDS Methods involved in cleaning, pre-treatment
and paint application
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Rounding of sharp edges. Smoothing of rough welding seams. Removal / grinding of weld spatter Cracks and pittings. Surface faults like laminates etc. ISO 12944 - 3 , or ISO 8501 - 3
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Cleaning
and beads.
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Chapter:
Surface preparation
Visual assessment of surface cleanliness after blast cleaning, hand or power tool cleaning or flame cleaning Rust grades and preparation grades of uncoated steel Photographic examples of steel when blast cleaned with different abrasives
Cleanliness (salt, oil, grease and dust/dirt) Evaluation of present condition (rust grade) Surface preparation (e.g. blast cleaning) Cleanliness of prepared surface (salts, oil, grease, dust and dirt) Climatic conditions (temperature, relative humidity etc.)
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ISO 8501 - 2
ISO 8501 - 2
Standard for deciding preparation grades
Surface preparation
As for ISO 8501-1, but: For steel where previous coating has been removed locally, not completely.
PSa : Localised blast cleaning (grades 2, 2 and 3) PSt : Localised hand and power tool cleaning (grades 2 and 3)
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ISO 8502
Assessment of surface cleanliness (1 of 2)
Part 1 Field test for soluble iron corrosion products Part 2 Laboratory determination of chloride on cleaned surfaces. Part 3 Assessment of dust on steel surfaces prepared for painting (pressure- sensitive tape method) Part 4 Guidance on the estimation of the probability of condensation prior to paint application. Part 5 Measurement of chloride on steel surfaces prepared for painting. Ion detector tube method.
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ISO 8502
Assessment of surface cleanliness (2 of 2)
Part 6 Extraction of soluble contaminants for analysis. The Bresle method.
*
Part 9 Conductometric measurements of soluble salts .
*
* Part 7, 8 and 10 are not prepared
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Chapter:
Surface temperature of the structure must be minimum 3 C above the dew point of the surrounding atmosphere
Ambient temperature will influence: shelf life pot life viscosity/sprayability steel temperature Steel temperature will affect: speed of cure degree of cure recoating interval service life of the coating
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ISO 8502 - 6
Field method for measuring soluble salts by conductivity ( S) of solutions containing water soluble salts
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Chapter:
ISO 8503 Surface roughness
Example of a reference
comparator Surface profile comparator comprising four segments. Grit (G) Shot (S) Check if the profile is according to specification and the paint manufacturers recommendation
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Record name of coating and batch no. Ensure proper mixing of 2-pack paints Ensure use of the correct thinner Measuring the wet film thickness (WFT) Number of coats as given in the specification Cleanliness between coats (salts, dust, oil etc.) Drying time / recoating intervals Control of equipment: Pressure, nozzle etc. Climatic conditions (Ventilation, Air and steel temperature and the relative humidity)
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ISO 2808 - 97
Conditions during
application
Typical recommended
system Storage Handling Packing control Health and safety Details in MSDS
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Application data Methods, mixing, potlife Surface preparation Different methods given
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ISO 2808 - 97
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Chapter:
WFT x % VS 100
250 m
Epoxy mastic
50 % 250 x 50 100 = 125 m
Polyurethane topcoat
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How much paint should we order ? calculation of paint consumption with loss
A loss of 40 % means that only 60 % will be applied on the surface
Steel
Specified thickness Uneven steel surface Paint will fill the valleys Dead volume
100
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ISO 2808 - 97
Temperature and humidity) Curing / drying of the film Dry film thickness (DFT) Adhesion Holiday detection (if required)
Electromagnetic instruments Calibration on a smooth steel surface min. 1,2 mm thick For DFT measurement, not less than 25 and preferably
above 50 microns
Number of readings, as a guide: 1 reference area: At least 3 readings evenly 2 reference areas for every square meter for flat plates 4 reference areas for every length for a web 2 reference areas every metre length for a flange 2 reference areas every metre length for a pipe
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Chapter:
Cross-cut test
Cutting tool Single bladed knife or Multi-blade cutting tool with 6 cutting edges spaced 1 mm or 2 mm apart Spacing of cuts 0 - 60 microns: 0 - 60 microns: 60 - 120 microns: 121 - 250 microns:
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There are two test methods The method to select depends on the DFT
Method A: DFT above 125 microns Method B: DFT below 125 microns (Above 125 if wider cuts are used) Method A: X - cut. Tape test Method B: Cross - cut. Tape test
1 mm spacing, hard substrates 2 mm spacing, soft substrates 3 mm spacing, hard/soft substrates 3 mm spacing, hard/soft substrates
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ISO 4624
ASTM G 62 - 85 Method A
Test dollies glued onto the coating Adhesive: Cyano-acrylate or solvent free epoxy Remove adhesive and coating around the dollies Pull off test-dollies vertical to the surface Read adhesion value and report the type of fracture
Fractures:
Adhesion failure - fracture between coats or substrate and 1. coat Cohesion failure - fracture within a coat
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ASTM G 62 Method B
ISO 12944
High voltage: 900 - 20.000 V Used to detect pinholes, voids and areas with thin paint films This is a destructive test.
General introduction. Classification of environments. Design considerations. Types of surface and surface preparation. Protective paint systems. Laboratory performance test methods. Execution and supervision of paint work. Development of specifications for new work and maintenance.
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8. Paint Failures
As we have already said, paint supplied in containers is a semi-finished product. The finished product only exists once the paint has been applied to the structure in a complete paint system. This is where we see how good the protection is. The most important and most common paint failures occur as a result of poor or insufficient steelwork, preparation or application. Some of these faults are revealed during or shortly after application but some only appear after a certain period in service. The most common failures during and just after application are: Insufficient film thickness Sags / runs Dry spraying Pinholes Amine sweating
Insufficient film thickness is often the result of non-systematic application and inadequate checks with a wet film gauge. Sags / runs occur when the paint is applied too thickly or too much thinner has been added to the paint. This is probably because the specification has not been followed. Occasionally, faults are also found in the paint. The inspector must note the production number in the daily log. Sags / runs should be repaired immediately with a brush. Dry spraying is normally a result of poor application or difficult weather conditions. The most common application fault is too great a distance between the spray gun and the structure. High temperature combined with low relative humidity will also contribute to dry spraying as the solvents evaporate en route from the gun to the object. Strong wind or strong ventilation also contributes to an increased risk of dry spraying. Pinholes often occur on porous substrates, for example zinc silicate. On these substrates, it is important to apply a thin layer of paint, normally called a tie coat or by using the mist coat full coat technique. Pinholes are also found if there is too strong ventilation during application. Amine sweating can occur on epoxy paints during curing in particularly humid environments. The phenomenon results in a sticky surface, occasionally visible as white stains. These must be removed before overpainting using rags and tepid water (thinners for some paints). The risk of amine sweating is reduced by observing the specified induction time after mixing the two-component paint and ensuring good atmospheric conditions during application and curing. The most common paint faults after exposure are: Blistering Rust penetration Cracking Flaking Chalking
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Such faults can be assessed using standard ISO 4628. Blistering is normally an adhesion-related problem and is due to poor cleaning before application of the paint. The most common cause of blistering is the application of the paint to a substrate contaminated with salt (osmotic blistering). After blisters have formed, they burst and the underlying unprotected material begins to rust if rust formation has not already started. Osmotic blistering occurs on exposure under water or in areas with heavy condensation. In particular, the salts sodium chloride and ferric chloride, and welding smoke, cause blistering. Other causes of blistering can be dust or grit on the surface (reduces adhesion), voids between the steel and the paint or trapped air in the paint film. Blistering is evaluated according to ISO 4628-2. Rusting occurs after a blister in the paint film bursts. The failure will occur most quickly where the paint film is too thin. Particularly susceptible areas are sharp edges, rough welds and places which are difficult to access for application. If rusting occurs after a very short time without prior blistering, there will be an opening through to bare steel, i.e. a pinhole. Rust penetrationevaluated according to ISO 4628-3. Cracking occurs after a certain ageing of the coating. The causes can be: The top coat is harder than the coats underneath Excessively thick system combined with temperature variations Excessively fast curing of two-component systems Excessively thick zinc silicate gives "mud cracking".
There are various degrees of cracking. Cracks can either form in the top coat only or throughout. The time before the fault occurs can vary. Mud cracking occurs immediately after application but cracking occurs only after a certain time. Cracking is evaluated according to ISO 4628-4. Flaking is normally the result of a poorly cleaned substrate (oil, grease) or the paint being applied onto condensation or surfaces with amine sweating. Paint will frequently flake off from areas with blistering or cracking and occurs where adhesion is poorest. Flaking is evaluated according to ISO 4628-5. Chalking is an ageing problem. The binder is degraded by UV radiation from the sun and the pigments appear as dust on the surface. The paint's ability to resist chalking will vary according to the binder used. Epoxy will chalk in sunlight after just a few months whereas polyurethane will retain its gloss for many years. Chalking is evaluated according to ISO 4628-6. Personal notes
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Chapter:
Most common paint failures
Holidays, too low DFT Sags and runs Orange peel Dry spraying Overspray Pinholes, popping Fish-eyes Wrinkling / lifting
Paint Failures
Sags and runs
Appearance
Sweating (Amine) Blushing Poor drying / curing Blisters Rust penetration Cracking Flaking Chalking Discolouration/bleeding
2
Too high Wet film thickness Too much thinner added to the paint Airless spray gun too close to surface
Repair
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Orange peel
Appearance Caused by
Dry spray
Appearance Porous, sandpaper like surface of the paint Caused by Poor atomisation of the paint Spray gun too far away from the object High air temperature and low relative humidity: Too fast
evaporation of the solvents
Paint surface is rough, like an orange peel Poor flow / levelling properties of the paint
(Paint too thick or too low temperature)
Poor atomisation of the paint Too fast evaporation of the thinner Airless spray gun too close to surface
Repair
Repair
Strong wind during application Inorganic Zinc: Re-blast and apply new paint Physically drying paints: Apply thinner on the painted
surface and apply a new coat
Improve application technique Use correct thinner Grind surface and apply new paint
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Pinholes
Appearance Tiny holes through one or more coats, or even down to the substrate, as if perforated by a needle Caused by Dry spraying Entrapped solvents or air Porosity of previous coat Incorrect application technique or viscosity of the paint Repair Grind top layer of the paint Recoat
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Pinholes / popping
Appearance Solvents or air try to evaporate through the upper part of the film, which has already nearly dried, leaving small bubbles /craters on the surface Very porous substrate (e.g. Zinc silicate primer) Entrapped solvents or air in the paint film Usually in connection with too high film thickness, too long application distance or too strong ventilation.
Caused by
Repair
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Chapter:
Fisheyes
Appearance Spots of paint on the surface with no wetting of the surface around the spots. Appearance of a fisheye. Caused by Paint applied on oil, silicone or other contaminants Painted on incompatible paint (Glossy paint giving poor wetting) Repair Grind top layer of the paint Recoat
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Paint Failures
Wrinkling
Appearance Small wrinkles through or partly through the paint film Caused by Skin drying of the paint film, which is usually applied too thick Repair Grind top layer of the paint Recoat
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Lifting
Appearance Small wrinkles through the paint film Caused by Softening and raising or swelling of a previous coat by the application of an additional coat Normally when overcoating Alkyd Lifting often caused because the solvents in the new coat is too strong for the previous coat Repair Remove the paint Recoat
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ISO 4628
Condensation on cold steel surfaces at high humidity Air pollution, sulphur dioxide (SO2) and ammonia
forming ammonium sulphate on the paint film.
Fast thinners
Repair
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Chapter:
ISO 4628 - 2
Paint Failures
ISO 4628 / 3 Designation of degree of rusting
Rating Designate the degree of rust formation by reference to the pictorial standards
Degree Area rusted %
0 0,05 0,5 1 8 40/50 Ri 0 Ri 1 Ri 2 Ri 3 Ri 4
Degree of blistering
Blisters of size 5
Density 2
Density 3
Density 4
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Density 5
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Ri 5
ISO 4628 / 3
Pinpoint rusting
Appearance
Points of rust
Caused by
Holidays due to overspray, dry spraying etc. Too high substrate roughness
Repair
ISO 4628 - 4
Evaluation of cracking
Quantity 1 2 3 4 5
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Chapter:
ISO 4628 / 5 Designation of degree of flaking
Test report
The test report shall contain at least the following information: a) b) c) d) e) the type and identification of the product tested a reference to this International Standard (ISO 4628/5) the numerical rating of the quantity of flaking the numerical rating of the size of flaking the depth of flaking (a or b), for example: flaking 3 (S2) a
Paint Failures
ISO 4628 - 5
Evaluation of flaking.
Quantity 1 2 3 4 5
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Chalking
Appearance Almost like dust on top of the coat
Appearance Caused by
Bleeding
Discolouration of a paint, particularly in
topcoats
Repair
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Pigments and extenders exposed on the paint surface, due to Exposure to sun / UV light Degradation of the binder Weathering of the paint Insufficient mixing of the paint
Repair
Note: Bleeding may continue through additional coats unless source is removed
Mud-cracking
Appearance Cracks occurring during the drying process of the paint Appearance of the surface of cracked mud Caused by Particularly for inorganic Zinc applied at a too high film thickness Repair Re-blast to Sa 2 or grind off Apply the inorganic Zinc
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9. Antifouling
All surfaces exposed to seawater will be "attacked" by marine organisms. When these organisms attach and grow, they cause a significant increase in surface roughness. On a ship's hull, this results in greater friction resistance and hence increased fuel consumption. It is therefore extremely important to prevent marine fouling when assessing a ship's fuel economy. The types of organisms and their growth rates vary with the temperature of the seawater, salinity and the light intensity in the sea. Plant organisms are normally diatoms or green/brown algae, whereas the most common animal organisms are Cirripedia (barnacles), bryozoa and hydroids. The most common way of preventing the fouling of marine structures is to apply a preventative coating or antifouling as we often call it. This contains one or more toxins (biocides) which are normally sufficient to make the antifouling effective against most organisms. Antifouling paint can be divided into three categories: conventional, long life and selfpolishing antifouling paints. 1. Conventional antifouling paints also known as "soluble matrix" antifouling paint, have been in use for many years. The main binder is resin, a natural product which dissolves very slowly in seawater. The Resin is brittle but although these formulations contain various additives, this type of antifouling often takes the form of a very weak film and the paint can only be applied in relatively low film thickness. The effective protection against fouling varies from 12 to 18 months. 2. Long life antifouling paints are also known as "insoluble matrix". The binder is not completely insoluble in seawater. The active components (biocides) and resin are released but the binder remains on the structure as a porous frame. The porous film left after the biocides have been released forms a weak substrate for a new coat of paint. It is therefore recommended that a sealer coat be applied at each dry docking to create a better substrate for the new antifouling. One risk with this type of antifouling is that year after year, coat after coat, many layers of paint are built up. This build up of layers can cause the paint to break away from the surface or from earlier coats, which increases the roughness of the hull. This condition is called "sandwich coating" and, after fouling, is the main cause of increased roughness on a ship's hull. Long-term antifouling paints are effective for about 24 months. 3. Self-polishing antifouling paints hydrating type are based on a mixture of watersoluble and water-sensitive binders. These react with seawater to form a soft layer which dissolves relatively easily in water. This type of antifouling was first developed when the need arose for tin-free antifouling paints. The effective life is about 36 months. In today's market, conventional, long-term and self-polishing hydrating antifouling paints are largely tin-free. 4. Self-polishing antifouling paints hydrolysing type contain a binder which is initially insoluble in seawater. When the paint film is exposed to seawater, a thin layer on the surface of the film absorbs water and a chemical reaction occurs between the binder and the water (hydrolysis). This is the main difference compared with other antifouling paints. The reaction product is water-soluble and will slowly dissolve or be washed away. Thus fresh, new
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antifouling paint is constantly being exposed. This results in a linear/predictable rate of biocide release which ensures a highly effective antifouling action. This type of antifouling is available both tin-free and with tin. Both variants can give effective protection for up to 60 months. One very important reason for using self-polishing antifouling paints is to avoid the "sandwich coating", which often occurs when using conventional or long-term antifouling paints. With a self-polishing antifouling paint, the surface will not become porous and it is not normally necessary to use sealers. When a ship is in dock, the hull is rinsed with fresh water to remove slime and other contamination, and the new antifouling paint is then applied directly onto the old paint film. Self-polishing antifouling paints are often based on copper with tin and/or other biocides. Those based on tin are restricted in most countries due to the environmental effects in the sea and will be prohibited from use within a few years. Copper-based products are more "environmentally friendly".
Personal notes
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Chapter:
What is fouling ?
(1 of 2)
Antifoulings
What is fouling ?
(2 of 2)
There is an estimated 4 - 5000 fouling species and these can be classified into: Fouling is the settlement and growth of marine plants and animals on manmade structures in the sea
Microfouling
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On a marine structure
Increased drag Structural failures Heavier load on the structure
Fouling leads to an increase in fuel consumption of up to 40%, due to the increase in drag resistance A clean ship sails faster and with less energy Fouling will eventually damage the primer system
Pump failures
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Selection of Antifoulings
Legislation / Environment Type of ship Speed Trade / Voyage factor Dry-docking interval: Conventional antifoulings: TBT-containing antifoulings (tributyltin): TBT-free, self polishing antifoulings:
Hull roughness
Roughness can be divided in two main groups
Permanent roughness welding seams, valve openings, bulging plates etc. Temporary roughness flaking, dry spray, cracking, sagging, fouling etc.
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Chapter:
Frictional resistance depends on:
The speed of the ship The area of the underwater hull The shape of the hull The roughness of the hull
Hull roughness is the only one of these factors which can be varied to a significant degree
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Antifoulings
Antifoulings and hull economy
Calculation example: Panamax vessel
Antifouling 7,000 litres at a cost of $ 40,000 - $ 50,000 10% saving represents $ 4,000 - $ 5,000 Fuel cost 10,000 HP at $ 100 / ton, sailing 250 days a year Would save 5% or $ 100,000 in the same period
Application faults
Typical application faults that increase roughness: Overspray Sagging Dry spray Paint spatter Poor application has a greater ill effect on the drag of a hull than wear and tear
Antifouling challenges
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Development of Antifoulings
Influencing factors the past thirty years:
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Chapter:
The composition of Antifoulings
Binder Biocide Extenders Pigments Solvents Additives
Antifoulings
Conventional Antifoulings
Soluble matrix paints Rosin as a binder Approximately 12 months protection Binders dissolves in water and biocide is released Often called: Tropic, Super Tropic etc. NOTE: Danger of cracking and flaking Needs to be quickly immersed in water
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Long-life Antifouling
Insoluble matrix paints Only biocides are released Effective protection is up to 24 months Leaves weak substrate for subsequent coat Sealer coat normally required Binder: CR, Vinyl (possible to add small amount of colophonium) Often called Sargasso etc.
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Chapter:
Release rate for Anti-foulings Anti-foulings
Comparison of release rate of biocide for different A/F-types
Release rate (g/cm2 / day)
40
Antifoulings
Why is hydrolysis so important ?
Because:
Conventional A/F
30
30
10
Linear erosion rate assures long term antifouling property No skeletal layers means good adhesion Continual smoothing of the surface ensures good fuel efficiency Hard film maintains its good appearance
Time, years
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The application of all anti-fouling systems containing TBT The application of all anti-fouling systems containing TBT should be prohibited throughout the world by 1.1.2003 should be prohibited throughout the world by 1.1.2003 A complete prohibition on the presence of TBT antiA complete prohibition on the presence of TBT antifouling systems on ships hulls to be in place by 1.1.2008 fouling systems on ships hulls to be in place by 1.1.2008
Meets the draft IMO regulations for 2003 and 2008 Matches tin-containing selfpolishing performance With performance that exceeds what has gone before With a track record of success in newbuilding and drydocking
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Steel hull
Newly applied
Must be free from Copper Must perform at speeds up to 50 knots Preferably selfpolishing
Can also be used on steel hulls:
Steel hull
After exposure in the sea
When port calls are frequent When service distances are short For laid up ships
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Safety Safety aspects are particularly important in connection with the use of solvent-based paints. Solvents are flammable and in the right environment and under unfavourable conditions can cause both fire and explosion. Be aware that solvents are heavier than air and will sink down to areas which lie below the painting work. In general, the following aspects should be checked in connection with painting work. Plan the work and co-ordinate this with other activities in the area. Inspect the area where the work is to be performed. Shut off the areas affected. Remember areas which are lower than that where the painting is to be performed. Check the equipment to be used, including safety and protective equipment. Closed rooms must be declared gas-free before work begins. Take extra safety precautions when painting in tanks and confined areas: Adequate ventilation, explosion-proof working lights and equipment, an assistant with a line and adequate breaks in fresh air.
Health Surface treatment represents a health risk. The risk can however be reduced to a minimum if the operators and people in the vicinity of areas where such work is in progress proceed as follows: Read the safety instructions and SHE documentation for the product (safety data sheet) Follow the instructions given. In particular: use adequate approved protective equipment e.g. fresh air masks, gloves, protective goggles and anti-static footwear/clothing. The most serious health risks are associated with the following:
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Solvents Irritation of the skin, eyes and respiratory organs Can be absorbed through the skin. Degrease the skin. Can cause eczema Negative effects on the liver, kidneys, respiratory organs, blood, central nervous system and reproductive organs Can cause headaches, dizziness and fatigue Epoxy Irritation of eyes and skin Causes skin allergy For sensitive persons: epoxy allergy can be life-long Isocyanates Irritation of eyes, skin and respiratory organs Causes allergy to the skin and respiratory organs For sensitive people: allergies can be life-long At high temperature: toxic gases such as free isocyanates can be emitted Heavy metals: Dust and vapours Metals harmful to health are mainly: chromium (IV), lead, iron, cadmium, cobalt, copper, zinc and nickel. The organs which can be affected (examples of symptoms/effects): Respiratory organs (metal fever) Skin (eczema) Blood cells (anaemia) Nervous system (fatigue) Heart (irregular pulse) Kidneys (reduced function) Bone structure (accumulation) Dust Dust is a factor which must be taken into account both during pre-treatment and spray application. Dust is inhaled through the nose and mouth and can cause lung damage (dust disease, silicosis) and irritation of the eyes. Dust on the skin can also cause irritation depending on what the substance contains. Noise Noise is primarily linked with steelwork and preparation. Many tools produce noise levels over 100 decibels. A lower limit for the use of ear protectors is often set at around 80 decibels. Personal notes
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Chapter:
Many risks are involved when working with paints
Safety Explosion and Fire Health Manufacturing and Surface treatment Environment Emission to air (VOC) Emission to water (Maintenance) Emission to soil (Waste handling)
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SHE
Safety hazard: Solvents
Solvents are heavier than air A fire may start in lower
areas or compartments
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Read the Safety Data Sheet and follow the given precautions and advices Check the surrounding areas for nearby activities, particularly welding, machining etc. (remember lower levels) Ensure proper ventilation and check the direction where solvents may move Always use approved and sufficient personal protection equipment of approved type
to the bottom Start application from the bottom and up Always use non-sparking tools Use antistatic clothing with hood Use masks with air supply Use boots and gloves Never smoke Safety lines or use naked flames ! Sufficient rest periods
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Chapter:
Symbols Fire and explosion hazards
These symbols can be found in Safety Data Sheets and on the paint tin label E O F+ F
SHE
Symbols Health hazards
These symbols can be found in Safety Data Sheets and on the paint tin label T+ T C Xn Xi
Explosive
Oxidizing
Extremely flammable
Highly flammable
Very Toxic
Toxic
Corrosive
Harmful
Irritant
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Mastic
Tar Epoxy
65 %
Alkyd
50 %
CR
40 %
Vol. % Solids 82 %
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Keep all containers / tins closed The work can be exhausting: Take sufficient rests Keep the work place tidy during the work
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Chapter:
General precautions for surface treatment (3 of 3)
After work
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SHE
Filter types
Dust P1: Lowest degree of protection P2: Medium degree of protection P3: Highest degree of protection Gas from organic solvents A1 Lowest degree of protection A2 Medium degree of protection A3 Highest degree of protection
Close all Containers / tins Clean the equipment properly Store unused paint and thinners safely (Paint store) Throw waste in designated containers. (Hazardous waste) Clean the personal protection equipment and store it properly to avoid contamination Clean yourself with water and cleaning cream
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Chapter:
Health hazards when working with Epoxies. Epoxies.
Hazards : Eczema and allergic reactions on the skin Liquid Epoxies with low molecular weigths (below 700) are most likely to give an allergic reaction An allergic reaction to Epoxy is irreversible. Hyper-sensitive persons must stay away from epoxies. Protective measures Protective clothes covering the whole body and gloves Proper cleaning with water, soap and cleaning cream Use disposable overalls
SHE
Health hazards when working with tar containing paints. paints.
Hazards The main hazard with tar containing paints is the risk for developing cancer, especially when exposed to strong sunlight Long term exposure to vapours may damage internal organs, cause heritable genetic defects and birth defects Short term exposure to fume and vapours may cause irritation to nose, throat and eyes Splashes to skin causes irritation Protective measures Protective mask to avoid breathing vapours Protective clothes covering the whole body and gloves
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Health hazards when working with paints containing heavy metals. metals.
Some times used in pigments, additives or driers. Hazards (Metal fumes,dust from hot work) Zinc. Dust and fumes: Zinc fever, chills, coughing, irritation Copper. Fumes: Metal fever and chills Lead. Dust and fumes. Damage blood cells, Anemi, skeleton, reduced fertility and central nervous system Chromium. Dust and fumes: Sensitisation, cancer Nickel / Cobalt. Sensitisation General Protective measures Protective mask to avoid breathing of vapours Protective clothes covering the whole body, boots and gloves
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11. Corrosion
What is corrosion?
To give materials satisfactory protection against corrosion, it is important to understand what corrosion is. Only once we know when, how and why a material corrodes (rusts) can we specify the right material and give the material a cost-effective protection. Corrosion is defined as "a materials reaction with the surrounding environment during the formation of corrosion products". From this definition, it is clear that it is not enough to know the properties of the material, we also need knowledge of the exposure environment. This means that we need to know how corrosive the environment surrounding the material is. To illustrate the different material properties, consider the following example: gold will not corrode in seawater and therefore we call this an inert material in this environment. Zinc however is far from inert. Similarly a particular material will have a totally different longevity in two different environments: unprotected steel corrodes quickly in seawater but will be almost everlasting in a dry indoor atmosphere.
Corrosion types
There are many different forms of corrosion. Although we will not discuss all of them, we should briefly mention the two most common types on steel structures: galvanic corrosion, general corrosion and crevice corrosion. Galvanic corrosion occurs when two different alloys are connected together in an electrical circuit, as described for corrosion cells. In such a circuit, it is always the most negative metal which corrodes. This metal is called the base metal or the anode in the circuit. The noble
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metal or cathode will actually acquire a certain degree of protection (see cathodic protection). Typical examples of galvanic corrosion are aluminium which corrodes when connected to steel or a cast iron valve which is connected to an aluminium-brass pipe. In principle, general corrosion is very similar to galvanic corrosion except that the corrosion process occurs on one metal only. The galvanic cell occurs when either various alloy elements or contaminants are present in the metal or the metal surface is uneven. The corrosion will occur on the most base elements on the alloy surface. Crevice corrosion is a type of corrosion which is mostly found on passive materials such as stainless steels. The attack takes place in narrow gaps or crevices. Critical crevices for initiation of corrosion are between plates, pores in welds, between gasket and flange in pipe systems, under various types of settlements (marine mud) and contamination (paint splashes). The reason for the attacks is that the environment inside the crevice is different from the environment outside. A corrosion cell will be formed between the two areas. A ondition that will increase the risk of attack even furter is the presens of aggressive ions such as chlorides found in seawater. Once initiated the crevice corrosion attack may propagate at a very high speed and cause rust penetration within a surprisingly short period of time. Personal notes
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Chapter:
Definition of Corrosion
Corrosion is a reaction between Material and Surrounding environment under formation of corrosion products
Corrosion
Production and degradation of steel
Reaction between the material and the surrounding environment takes place Plates, pipes, profiles, etc.
g gy in er tur En fac u an M
Raw material Iron ore
The presence of water / humidity and Oxygen is a pre-requisite for corrosion of steel
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The water molecules penetrate the paint Due to osmotic forces blisters are formed
Paint Steel
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A galvanic cell
2e-
Zn = Zn + 2 e
2+
Anode: Zinc
O2
O2 + H2 O + 2e - = 2OH -
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Chapter:
Corrosion speed differ when exposed to the same environment
In a strong alcaline environment Aluminium and Zinc will corrode rapidly, while steel will be passive
Aluminium Zinc Steel
Corrosion
Galvanic potentials in seawater
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Steel in Seawater
Potential versus Zinc & Ag/Ag Cl ref. electrodes
Ag / Ag Cl
Potentials in volt
Rapid corrosion
Zinc
Cu / CuSO4
- 0.55
+ 0.50
- 0.60
Structure
General corrosion
- 0.80
+ 0.25
- 0.85
-1.05
+ 0.0
-1.10
- 1.30
- 0.25
- 1.35
Sea water
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Reference electrode
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pH-scale
Acidic
Temperature Salinity Oxygen content Water velocity Acidity (See below) Type of electrolyte ( e.g. cargo or chemicals) Content of contaminants / pollution that
promotes corrosion Micro-organisms.
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Neutral
Alcaline
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Chapter:
Parametres influencing the corrosion speed. Atmospheric corrosion
Humidity Temperature Concentration of salts Amount of air pollution,
including acid rain, soot and dust particles
Corrosion
Apart from using paint and CP: How to protect against corrosion ?
Corrosion protection can be achieved in many ways
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Good design Avoid corrosion traps Improved accessibility - maintenance Proper materials selection Insulate between dissimilar materials Change the surrounding environment Remove water / humidity Apply metallic coatings Use corrosion inhibitors (closed systems)
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Uniform corrosion Uneven corrosion (deep pits) Galvanic corrosion Stress corrosion cracking
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Knowledge is required for selecting the correct material for a given application
Erosion corrosion
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Chapter:
Steel with mill scale
Outdoor exposure The mill scale cracks Corrosion will develop on the steel Mill scale is more noble than steel Mill scale Corrosion
Corrosion
Crevice corrosion occurs under paint spillage or plates
Crevice corrosion occurs in narrow gaps where the oxygen concentration is lower than on the freely exposed part of the material
Seawater
Ingress of seawater Plate Paint
Stainless Steel
Steel Steel
Corroded areas
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Pitting corrosion
Pitting corrosion is a localised attack on a material normally protected by a passive film The passive film may be destroyed mechanically or by aggressive ions in an electrolyte Severe corrosion may take place beneath the passive layer Passive layer
Corroded area
Electrolyte (Seawater)
Pitting corrosion
Anode
Cathode
Stainless steel Seen from above Cross section
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Corrosion fatigue
Corrosion Fatigue is a combined effect of an aggressive environment and dynamic loads on a structure Load
Quay
- +
Fatigue only
To earth Corrosion
Corrosion fatigue
Seawater
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knowledge of some important parameters. The most important ones are the area to be protected, the type of material to be protected, the type of anode to be used, the lifetime of the system and the area of the structure which has been painted. A painted structure requires fewer anodes than an unpainted one. Finally: cathodic protection can be achieved by a forced voltage system. These systems supply DC current to the steel in the same way as anodes.
Personal notes
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Chapter:
Corrosion of a metal or alloy
Cathodic Protection
How to protect a structure
Corrosion Protection can be achieved by : Sacrificial Anode Cathodic Protection System Impressed Current Cathodic Protection System
Fe Fe
2+
+ 2e
Both systems supply electrons to the structure. The structure will become more negative and metal dissolution will be prevented
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Objects to be protected:
Offshore platforms Fixed/floating Concrete/steel Subsea installations Templates/manifolds/
modules. Subsea pipelines
The principle of cathodic protection. protection. potentials vs. different reference electrodes vs.
Cu / Zn + 500 +400 +300 +200 +100 0 CuSO4 - 600 - 700 - 800
Mixed potential
- 900 - 1000 - 1100
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Chapter:
Cathodic Protection Steel protected by a sacrificial anode
Cathodic Protection
Corrosion potentials in seawater
Zinc, Ag/Ag Cl and Cu/CuSO4 Reference electrodes Zinc, Cu/CuSO
Ag / Ag Cl
Potentials in volt
Rapid corrosion
Zinc
Cu / CuSO4
- 0.55
+ 0.50
- 0.60
- 1.30
- 0.25
- 1.35
Cathode
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Anode
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10 -600 -650 +500 +450 -700 +400 -750 +350 - 800 +300
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Protective
Design criteria
Design lifetime Coating system and condition Protection potential Anode capacity Electrolyte resistivity Environmental conditions/impacts
B. Steel surface Painted / not painted Steel temperature Coating system, if any Condition of coating system
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Chapter:
Sacrificial anode material selection
Anode material selection Chemical composition Electrochemical performance - Anode potential - Stable current - Consumption Anode corrosion pattern Price Class requirements
Cathodic Protection
Comparison of cathodic protection systems general advantages: advantages:
Sacrificial anode systems Simple, reliable and free from in-service operator surveillance System installation is simple Low installation cost for short term protection Impressed current systems
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Response to varying
operating conditions is limited.
In-service operator
surveillance required.
Vulnerable to component
failure or loss of power.
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20
40
60
80
100
120
140
160
180
Anodes
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ICCP
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Chapter:
Principle : Effect of using CP
Corrosion Curves depend on - Coating condition - CP-design Corrosion
CP and coating at newbuilding
Cathodic Protection
Corrosion in broken blister Passivation by CP
Without Cathodic Protection Seawater Rust
Paint
Steel
Paint
Time
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Steel
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Calcareous layer
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Cathodic protection
ICCP - Impressed Current SACP - Sacrificial Anodes EAF - Electrolytic Antifouling System for
seawater systems (CUPROBAN)
Web frame
Seawater Anode
Water level
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