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CorrosionManagement | September/October 2009COMPANYNEWSDENSO VOID FILLER PROTECTS JETTY CRANESA recent joint venture contract completed forthe Ministry of Defence by Morgan Est AMECwas the construction of the Valiant floatingjetty for servicing Astute Class submarines atFaslane. The jetty was towed to Faslane fromthe construction site at Port Glasgow.The 200 metre long, 28 metre wide, Valiantjetty is equipped with eight Service LogisticDerricks (cranes). In order to give maximumanti-corrosion protection to the mountingbases that fix the cranes to the jetty, all voidsaround the bolts were filled with Winn &Coales’ Denso Void Filler. In total, 750 litresof Denso Void Filler was used on the jetty.Denso Void Filler is based on a microcrystallinepetrolatum containing corrosion inhibitors andmoisture repellents. It forms a permanentlyflexible medium for the encapsulation andprotection of bearings, tendons, stay cablesetc. It has been used on a variety of majorcivil engineering projects, including bothSevern Bridges.The Valiant floating jetty on tow to Faslane. The eight Service Logistic Derricks arepainted yellow.APPLYING DENSO PROTECTION INA CONFINED SPACEA challenging contract recently completedby Advanced Engineering Solutions ofCramlingham, Northumberland, was theapplication of a Denso protection systemto water pipelines enclosed within a 300mbrick tunnel. The work was carried out forNorthumbrian Water as part of its ongoingprogramme of upgrading its potable watersupply system.Constructed in the 1920s, the tunnel is in aremote part of Northumbrian Water’s area.The first problem to be met by AdvancedEngineering Solutions was to transport thepipeline protection materials across roughboggy terrain approximately one mile fromthe nearest road.Entry to the tunnel was via a manhole at eitherof the 300 metre tunnel carrying sectionsof the two 18 inch diameter pipelines. Thematerials therefore had to be manhandled forup to 150 metres from either end within thistunnel. Additionally, as it was confined spacethe protection materials could not containany hazardous substances such as solvents.The Winn & Coales Denso system chosenconsisted of Denso Paste, followed by DensoHi-Tack Tape and Denso Self Adhesive PVC.Prior to application the AES confined spacespecialist team cleaned the pipe surfacesfrom any loose residues of the formerbitument wash coating and wire-brushedareas showing signs of surface corrosion.AES personnel applying Denso Hi-Tack Tapein the confined space of the NorthumbrianWater tunnel.14
CorrosionManagement | September/October 2009COMPANYNEWSRJ Herbert Opts for Metal Sprayingwith MetallisationRJ Herbert Engineering has opted for metalspraying, using Metallisation equipment,as an alternative to hot dip galvanising, toimprove customer service, reduce costs andsave time.The decision to opt for metal sprayingwas made following a request from aBelgian customer, a potato processing andpackaging line export company, to protectthe walkways and handrails of the potatoprocessor equipment. Herbert is a Britishmanufacturer of handling equipment forthe vegetable industry and environmentalwaste and recycling industries. Its clientbase includes European fresh produce packhouses, major international processors aswell as many well-established growers andindustrial companies.With constant use of the walkways andhandrails running alongside the process andpackaging equipment, as well as cleaning andpressure washing, a sturdy surface protectionis crucial to the longevity of the equipment.The customer specified a zinc coating shouldbe applied prior to a powder coating finishusing either hot dip galvanising or metalspraying. Herbert had extensive experienceof galvanising, but was unhappy with thedownsides of this process, in this instance, anddecided to explore metal spraying options.The reasons behind Herbert looking atmetal spraying, as an alternative to hot dipgalvanising, were based on the logisticalcost and lead times associated with the offsite process. Herbert needed to find an inhousealternative that had equal, or better,corrosion preventative properties. Havinglooked at all the processes available it wasdecided that not only did metal sprayingmeet this criteria, but also meant that therewas no post spraying operations such as redrillingholes or cleaning of metal drips. Thepre-spraying process was also simplified,as no special preparation, such as designedfor heat distortion and holes for hot airexpansion, was required. The main factors forthe acquisition of the metal spray equipment,were that the process is now done on site, notransport costs, no sub-contractor lead time,less product build time and no post sprayoperations are required.Ken North, Operations Director at RJHerbert Engineering, says: “Our decision toopt for metal spraying, as an alternative tohot dip galvanising, was made much easieronce we made contact with Metallisation.We knew that metal spraying could be anideal alternative for us, but Metallisation’sunderstanding of what we were trying to dowas ideal. We are so pleased with the metalspray equipment we have purchased fromMetallisation. The outstanding results of thepotato processing plant has encouraged usto offer the enhanced corrosion protectionas an option to other customers across ourfull product range. So we are very happy allround.”In addition, Herbert use wet paint as well aspowder coatings and hope to use the newmetal spray process for these applications too.It’s hoping to reap the benefits of improvedadhesion of paint to metal spray withoutthe need to etch primers, as they currentlydo when painting on to galvanised steel.The thickness of the metal sprayed coatingswill vary depending on the environment inwhich the sprayed item is located and on thecustomers’ specific requirements.The operator has found it easy to use and ishappy to work with the system. Herbert alsopurchased a 20m supplies package, whichallows its operators to locate the spray unitoutside the spray room and provides flexibleaccess around the items they are sprayingwithout having to stop to move equipment.Metallisation provided an onsite trainingcourse to maximise the efficiency of theequipment and ensure operators are totallyfamiliar with the system. Herbert also optedfor the Metallisation, Metserve preventativemaintenance contract, which provides twovisits per annum by a Metallisation serviceengineer to keep the system in excellentworking order.Herbert spray zinc at this time but is currentlyconsidering spraying with aluminium forcertain applications. Future considerationsinclude offering a robust, non-slip metalsprayed coating on walkways, stairs andinspection areas, to its clients.Established in the UK in 1922, Metallisation issynonymous with metal spraying to a diverserange of industries around the world. Metalspraying is a technology, which protects andgreatly extends the life of a wide variety ofstructures, equipment and vessels, in themost hostile environments and in situationswhere protective surface coatings are vital forlongevity. The variety of metallised coatingsis vast, but can be broken down into two maincategories. These include anti-corrosion andengineering coatings.For more information on Metallisation, pleasecall Stuart Milton, Sales and MarketingManager, on 01384 252 464 or visitwww.metallisation.com.15
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