Blast Cleaning Standards: Cutting through the ... - aca conference

Blast Cleaning Standards: Cutting through the Confusion?
Rob Francis, R A Francis Consulting Services, Ashburton, Australia
Abstract
The cleanliness of a prepared surface is perhaps the most important factor determining
a the durability of a subsequent protective coating system. Standards for surface
cleanliness have been available for over fifty years, but there is still confusion
regarding definitions, relation between pictorial and written standards and how the
standards developed in North America (Joint SSPC/NACE standards) relate to the
ISO standards used in the rest of the world. Moreover, with the arrival of power tools
that can produce a level of surface cleanliness similar if not equal to levels achievable
by abrasive blasting, it is worth reviewing these standards. This paper looks at the
various standards and levels of blast cleaning, what they really describe and how they
differ from one another. Computer image analysis is used to assess cleanliness levels
of the near white (very thorough) level and finds that the ISO and Joint standard
levels overlap. Finally, an attempt has been made to simplify and standardise
cleanliness levels, incorporating current standards.

The Application of Plasma Electrolyte Oxidation (PEO) to the Production of Corrosion
Resistant Coatings on Magnesium Alloys: A Review
R. O. Hussein, X. Nie and D. O. Northwood*
Magnesium alloys are widely used in the automotive, aerospace, electronics and sports/leisure
equipment industries because of their excellent physical and mechanical properties including low
density and high strength –to-weight ratio. However, magnesium is a highly reactive metal and
requires surface modification using protective coatings to obtain adequate environmental
resistance to corrosion and wear. Several techniques have been used for the surface engineering
of Mg alloys including anodizing, conversion coatings, electrochemical plating, physical vapor
deposition (PVD) coatings and organic coatings. Plasma electrolyte oxidation (PEO), which
evolved from the conventional anodizing process, has emerged as one of the most effective ways
of improving corrosion resistance. As is the case for all surface engineering technologies, the
successful development of PEO coatings is dependent on adequate substrate pretreatment
together with choice, and control, of electrolyte composition and process parameters. In this
paper we will review the effects of processing parameters (DC, AC, current density, voltage,
current mode, duration, temperature) magnesium alloy substrate and chemical composition of
electrolyte on the coating morphology and composition, and ultimately the corrosion resistance
of coated Mg-alloys. The review will also examine some new developments which involve the
codeposition of materials such as polymers, within the PEO layers to produce composite coatings
with much improved corrosion resistance.

The Effect of Cationic Surfactants on Corrosion Resistance and Adhesion of
Coating on Mild Steel Cleaned by Sulfamic Acid Solution
M. Motamedi 1 , M. Mahdavian 2 , A.R. Tehrani Bagha 3 , S. Mahvidi 1
Institute for Color Science and Technology, Tehran, Iran 1 , Sahand University of
Technology, Tabriz, Iran 2 & Chalmers University of Technology, Goteborg, Sweden 3
Presenter email address: sadegh.mahvidi@gmail.com
Abstract
In this research, the effect of cationic surfactants - dodecyltrimethylammonium bromide (DTAB)
and its gemini counterpart with a spacer containing 4 carbon atoms (12-4-12) – on corrosion
resistance and adhesion of polyurethane coating on mild steel surface acidwashed by 1M
sulfamic acid solutions was studied by salt spray, pull off and cross cut methods. Acid cleaning
solutions are consisting of 1M sulfamic acid solution without surfactant inhibitor (blank
solution), 1M sulfamic acid containing 1mM DTAB and acid solution containing 0.5 mM 12-4-
12. Surface Prepared mild steel panels was exposed to test solutions for 30 sec, afterwards
washed by distilled water immediately and then dried completely. Then, polyurethane coating
was sprayed to specimens. Results after 140 hr exposure to salt spray conditions prove that
cationic surfactant presence in sulfamic acid cleaning solution causes less corrosion damages and
adhesion failure of coating on acidwashed mild steel surface. In fact, cationic surfactants can
leads to decrease of water affinity to mild steel surface due to polarity decline of acidwashed
surface because of less surface energy, which leading to corrosion resistance increment of
coating and less coating disbanding from metal surface. In addition, surface free energy of mild
steel samples immersed in test solutions was determined by sessile drop method which
demonstrating surface energy decline of mild steel samples immersed in acid solutions
containing cationic monomeric and gemini surfactants. Furthermore, morphology of mild steel
samples exposed to acid solutions was inspected by scanning electron microscopy (SEM).
Keywords: corrosion, cationic surfactants, sulfamic acid, surface energy, mild steel

Silane Coating for the Corrosion Protection of a Magnesium Alloy,
ZE41
P. Chakraborty Banerjee 1,2 , R.K. Singh Raman 1,3 , Y. Durandet 2,4 , G. McAdam 5
1 Department of Chemical Engineering, Monash University, Clayton, VIC-3800
2 CAST Cooperative Research Centre, Hawthorn VIC-3122
3 Departments of Mechanical and Aerospace Engineering, Monash University,
Clayton, VIC-3800
4 Industrial Research Institute Swinburne (IRIS), Swinburne University of
Technology, Hawthorn, VIC-3122
5 Defence Science and Technology Organisation, Fishermans Bend, VIC-3207
Presenter email address: parama.banerjee@monash.edu
Magnesium alloys are the lightest structural metallic materials with excellent
mechanical properties. Their high strength to weight ratio makes them very attractive
to the automotive and aerospace industries. However the use of magnesium alloys is
restricted due to their poor corrosion resistance. Hence, for industrial applications,
chemical surface treatments are often required. Surface treatments based on chromate
conversion coatings have been successfully used for corrosion protection and paint
adhesion, but concerns about the carcinogenic nature of Cr(VI) ions that are
subsequently released into environment have recently led to the development of
alternative coatings. Chemical surface treatments based on silanes are emerging as an
attractive environmentally friendly alternative for improving the corrosion resistance
of the metallic substrates, as well as for enhancing the compatibility of the metal
surface with paint systems.
In the present study, n-octadecyl-trimethoxy silane was applied to a magnesium alloy
ZE41. The specimens were subjected to a pre-treatment in 3 M sodium hydroxide
solution to produce a uniform layer of magnesium hydroxide which facilitates the
formation of a compact silane film. The chemical nature of the silane film was
analysed using ATR-FTIR and XPS. The corrosion resistances of the coated and
uncoated specimens in 0.1 M sodium chloride solution were characterized by
potentiodynamic polarization and electrochemical impedance spectroscopy (EIS).
Three orders of magnitude improvement in corrosion resistance was achieved on
application of the silane to the alloy’s surface.

Efficiency of Hydrophobic Impregnation – Site Results
Michel Donadio – Technical Manager Refurbishment
Mobile phone: +41 799 46 33 39 Office phone: +41 58 436 23 86
Sika Services AG, Speckstrasse 22, CH 8330 Pfäffikon, Switzerland
donadio.michel@ch.sika.com,
Abstract:
Deep penetrating hydrophobic impregnation can contribute to increase the service life of civil engineering
structures by providing an efficient barrier against penetration of all soluble aggressive elements such as chlorides
or sulphates.
Returns of experience from site are numerous and show the durability of this treatment.
However, low active content product or low consumption result in the products remaining at the surface of the
concrete, hence loosing its performances when subject to weathering.
Therefore, the appropriate product shall be selected according to the particularity of each project; preliminary tests
shall be conducted to determine the consumption required to achieve a targeted penetration depth. As example, for
a reinforced concrete bridge in central Europe, the product to be used shall conform with the class II (penetration
>10 mm) and satisfy the freeze and thaw cycles with de-icing salts tests of EN 1504-2.
Melbourne Conference ACA Corrosion & Prevention 2012

ABSTRACT FOR PRESENTATION AT ACA CONFERENCE IN MELBOURNE
(This presentation will be accompanied by a short slide
with illustrations of the examples mentioned).
Title: “ENERGY EFFICIENCY AND CAPITAL SAVINGS:
SUSTAINABLE CORROSION MANAGEMENT”
Writer: Ray Van Haven
Presenter: Ray Van Haven
Managing Director Blygold Oceania.
Theme: Protective Coatings – Corrosion Management it can be said, is part of the
nuts and bolts of what a facility manager does. It is what prevents deterioration of
the infrastructure for the many years of the buildings required life. How do we do this
efficiently, economically and to acceptable standards? Which protective coatings are
effective?
___________________________________________________________________
Abstract:
Advanced corrosion management will have to include HVAC equipment as this
accounts for 40 to 70% of a buildings energy usage.
Corrosion has massive consequences in terms of efficiency and energy use / waste
over the lifespan of the HVAC equipment. This will be illustrated with various
examples and analysis.
Various methods are available to counter this problem. There are methods applied
in the production process of the coils, after assembly of coils and in situ.
An overview will be presented regarding the available solutions and the pros and
cons of them in the HVAC environment, their impact on conductivity and energy use
and how to protect most effectively.

Control of Corrosion of Mg alloys using
biocompatible ionic liquid in Simulated Body Fluid
Yafei Zhang 1 , Bruce Hinton 1, 2 , Gordon Wallace 3 , Xiao Liu 3 and Maria Forsyth 1
ARC Australian Centre of Excellence in Electromaterials Science (ACES)
1. Deakin University, Burwood, VIC, Australia, 2. Monash University, Clayton, VIC,
3. University of Wollongong, NSW, Australia
Abstract The use of magnesium alloys as metallic implant materials for biodegradable coronary artery stents is of growing
interest. Controlling the corrosion rate of magnesium alloys in the body is critical in the development of biodegradable
magnesium alloys stents. This paper discusses the preliminary finding regarding the ability of ionic liquid (IL) trihexyl
(tetradecyl) phosphonium bis-2, 4,4 trimethylpentyl-phosphoniate [P 66614 ][( i C 8 ) 2 PO 2 ] to protect magnesium alloy AZ31 from
corrosion. Cycotoxic test shows this IL is relatively low toxic. Both Potentiodynamic Polarization (PP) tests and
Electrochemical Impedance Spectroscopy (EIS) tests suggest that this IL can increase the corrosion resistance of AZ31 in
simulated body fluid (SBF). The surface of AZ31 was pickled by acid HNO 3 and H 3 PO 4 before IL pretreatment, in order
to homogenize the surface and increase the formation of IL film on AZ31.

Seeing Is Believing.
A Visual Method of Corrosion Management using Protective Coatings
Jim Mackay, International Protective Coatings, Sydney, Australia
jim.mackay@akzonobel.com
Corrosion costs billions of dollars every year in downtime, and in steel and concrete
replacement.
How do we determine what areas of a plant or facility should be treated for corrosion, and
when is the most appropriate time?
This paper will discuss how all parties, from Asset Owner to Consultant to Plant Engineers to
Contractors gain a greater understanding of the challenges associated with bringing a plant
online and forming a predictive economical maintenance plan to increase the longevity of
assets.
Using a novel approach of Computer Aided Flow charts we will explore how microenvironments
require unique treatment, specifically in:
The Mining Market categories of extraction, processing and transportation
The Waste Water Treatment Market categories of new construction and maintenance
and repair.
The Oil and Gas Markets categories of upstream and downstream
These tools allow all members of the contract chain to accurately visualise the specific plant
areas and work together to improve corrosion protection.
Speaker Biography:
Jim has been involved in the selling, specifying, application and Protective Coatings for over thirty
years. In his present role he controls over 300 ‘Interplan’ corrosion surveys and maintenance
schedules in Australia, New Zealand and Asia. He is a NACE Coating Inspector and has
presented at AOG, ACA and ICOMS conferences.

Electroless Ni-P-PTFE-Al 2 O 3 Hybrid Nanocomposite Coating for Corrosion
Resistance
Ankita Sharma 1 , A.K.Singh 2
1, 2 Department of Paper Technology
I.I.T. - Roorkee, Saharanpur Campus, Saharanpur, India
ankitadpt@gmail.com
Abstract
For surface treatment on various substrate electroless nickel (EN) plating process is an effective
technique. To enhance hardness as well as low friction coefficient along with corrosion and wear
resistance, hybrid composites is to be incorporated with hard and soft particles. Reinforcement of
the nanoparticles provides the respective advantages for the wide applications. In this paper
electroless Ni-P, and Ni-P matrix with polytetraflouroethelene (PTFE) and alumina (Al 2 O 3 ) nano
particles were developed on mild steel substrate. The scanning electron microscopy (SEM),
energy dispersive analysis of X-Ray (EDAX) and X-ray diffractrometer (XRD) were used in
order to investigate the morphologies, chemical composition, and phase structure of the
developed coating respectively. Co-deposition of alumina and PTFE particles with Ni–P coating
changes topography and surface morphology of deposits from smooth state in Ni–P coating to
non-smooth state containing nodular appearance in Ni-P-PTFE-Al 2 O 3 composite coating. The
microhardness of the coating was investigated by using Vicker’s hardness tester. The corrosion
resistance was measured by using electrochemical and immersion test in 3.5% NaCl solution.
The results were compared with the previous study on electroless Ni-P-PTFE and Ni-P-Al 2 O 3
coating. The results indicate the deposited coating have a moderate hardness between electroless
Ni-P-PTFE and Ni-P-Al 2 O 3 coating. The synergistic effects of PTFE and Al 2 O 3 on the corrosion
properties of the coatings are discussed.

Corrosion Resistant Manganese Phosphate Conversion Coatings for
Magnesium Alloys
X-B Chen 1 , N Birbilis 1 T Abbott 2 & M Easton 1
CAST Co-operative Research Centre, Department of Materials Engineering,
Monash University 1 , Calyton, Australia
& Advanced Magnesium Technologies 2 , Sydney , Australia
Presenter email address: xiaobo.chen@monash.edu
Abstract
In this study, a simple chrome-free method to grow manganese phosphate conversion
coatings upon magnesium alloy AZ91D for corrosion protection was developed. The
morphology of the conversion-coated layer was observed using scanning electron
microscopy; the crystal structure and the composition was analysed and determined
using X-ray diffraction and X-ray photoelectron spectroscopy. Corrosion performance
was evaluated by the measurement of polarisation behaviour and salt spray testing.
XRD indicated that the conversion coating is an amorphous structure. The XPS
results indicated that the coated layer contained products of MgO, Mg(OH) 2 ,
MgAl 2 O 4 , Al 2 O 3 , Al(OH) 3 , and Mn 2 O 3 – resulting in a complex surface chemistry.
Such a surface coating was able to impart considerable corrosion protection to the
AZ91D substrate, and the results of a round robin of tests (with varying coating
formulations) are presented, along with electrochemical polarisation test results to
describe mechanistic aspects.
Key words: Manganese phosphate, Magnesium, Conversion coating, Corrosion,
Surface Engineering

Coatings Inspection – How good is good enough? An Inspector’s viewpoint
Tony Ridgers 1
Akzo Nobel Pty Limited, International Protective Coatings
Australia
Presenter email address: Tony.Ridgers@akzonobel.com
Abstract
Coatings inspectors are very capable and qualified in carrying out their duties and are
ultimately faced with having to make a “go – no go” call on the final quality of the
applied surface finish providing correct selection of system used. There is no grey
area, especially in critical applications which include; immersion applications such as
tank linings, chemical storage/protection, high temperature and passive fire
protection.
ACA and NACE Coatings Inspectors undergo a very comprehensive and rigorous
training regime which not only includes how to use specific inspection equipment but
the interpretation of the results obtained from such equipment and the reporting of
such results.
A Coatings Inspector has the experience to interpret coatings specifications together
with the intent of the manufacturers data and their relationship to the applied finish
A Coatings Inspectors role is the final audit of the physical protection of a surface
from its operating environment by the protective layer or coating whether it is a liquid
applied protective coating, HDG, tile, rubber, glass or passive fire protection, after all,
it is this layer the client has paid for in protecting his asset from degradation
The delegates attending the conference will be given the opportunity to travel along
the inspection trail and see some practical issues facing the Coatings Inspector.
Speaker Biography:
Tony has extensive experience in the protective coatings industry for 34 years with 11
years “hands on” as an owner/operator of an abrasive blasting and coatings operation
(both yard and field) covering the areas of industrial, pulp and paper, marine, high
value infrastructure, mining, power generation, up stream oil and gas. This business
was also heavily involved in protection of concrete in aggressive environments with
the use of spray, trowel and hand layup protective coatings.
Tony has ACA coatings inspection certification, is an ACA Corrosion Technologist
and holds NACE Level 3 Coatings Inspector certification.

Inhomogeneity of organic coatings and its effect of protection
Sina S. Jamali 1 , Douglas J. Mills 2
1 Intelligent Polymer Research Institute, AIIM Facility, Innovation Campus, University
of Wollongong, NSW Australia 2522
2 School of Science and Technology, University of Northampton, St George’s Avenue
Northampton, NN2 6JD, UK
Presenter email address: Sina.Jamali198@uowmail.edu.au
Summary
An important aspect of polymeric coatings from the protection point of view is their
inhomogeneous nature. Phenomena such as lack of cross-linking, inappropriate pigmentation,
quick solvent evaporation etc may introduce local micro defects. The diffusion rate at these
micro defects is proportional to the ionic concentration of the solution at which the coating is
immersed and therefore they have been known as “D” or direct type areas. On the other hand
is the highly resistive “I” type area where the ionic resistance increases with increasing the
ionic concentration of environment. It has been revealed that corrosion proceeds through the
ionic conduction pathways within the coating layer when the metal is protected by an organic
coating. Traditionally it is believed that a certain level of adhesion is a fundamental
requirement to avoid anodic and cathodic areas connecting underneath the coating. Therefore
the ionic resistance and specifically D type areas play an important role to determine the anticorrosive
properties of paint.
In the present study a set of organic coatings in the form of detached coatings has been
examined using DC technique to determine the D/I type ratio. The significance of thickness
and curing condition on D area formation has been also investigated. Consequently coatings
were applied on steel panel and the corrosion behaviour was looked at in the long term. Also
the adhesion strength of coatings was examined by pull-off method. Results indicate that the
protection efficiency of coating is mainly governed by D/I type ratio but is relatively
insensitive to the adhesion strength. A theory of how the permselectivity of coating
influences the protectiveness will be advanced.

April 23, 2012
Abstract Submission for the Nov 2012 ACA Corrosion & Prevention Conference in Melbourne
David Beamish – President
DeFelsko Corporation
802 Proctor Ave.
Ogdensburg, NY 13669-2205 USA
Tel: +1-315-393-4450 Fax: +1-315-393-8471
dbeamish@defelsko.com
Developments in Coating Thickness Gauges and Paperless QA
(Under the recommended topic “Protective Coatings”)
Summary:
This paper describes recent improvements to thickness measuring devices that simplify the task of
obtaining accurate results in a timely manner. It will review recent, significant changes to two international
documents, ASTM D7091 and SSPC-PA 2, and will explain developments in software and gauge design
that now makes paperless QA with cloud computing a reality for all protective and industrial coating
applications.
Abstract:
Regular film thickness measurement helps control material costs, manage application efficiency, maintain
finish quality and ensure compliance with contract specifications. Paint manufacturers recommend target
ranges to achieve optimum performance characteristics and clients expect these parameters to be met.
Every owner, specification writer, applicator and inspector should know what equipment is available and
know how to use it. This paper will begin by describing common types of hand-held, non-destructive
magnetic, eddy current and ultrasonic instruments. It will also describe their latest design and operational
features, and how stored readings can be easily transferred to data management software.
Two common industry standards will then be reviewed. ASTM D7091 describes proper methods for
obtaining measurements on both ferrous and non-ferrous metal substrates. Building on that, SSPC-PA 2
defines a procedure to determine if film thickness over an extended area conforms to specified min/max
levels. Significant changes to both documents were published this year. Equivalent ISO documents 2808
and 19840, and AS 1580 and 3894.3 will be reviewed.
Manually logging individual thickness measurements with pen and paper is time consuming and error
prone. Testing instruments that store measurement results simplifies this task. Coupling this with simple
analysis and reporting software results in a paperless QA (quality assurance) system that automates the
inspection process to reduce time and costs.
Recent developments in both software and gauge design make Paperless QA a reality for all protective
and industrial coating applications. The trend today is towards simple, web-based software
communicating with instruments that have built-in flash memory (mass storage) and the ability to
wirelessly upload measurement data to the cloud for archiving and sharing with any web enabled device
anywhere in the world.
DAVID BEAMISH is President of DeFelsko Corporation, a New York-based manufacturer of hand-held coating test instruments sold
worldwide. He is a Registered Professional Engineer and has more than 25 years’ experience in the design, manufacture, and
marketing of these testing instruments in a variety of international industries including industrial painting, quality inspection, and
manufacturing. He conducts training seminars and is a member of various organizations including NACE, SSPC, ASTM and ISO.

Dehumidification and Temperature Control during Surface
Preparation, Application and Curing for Coatings/ Linings
B Battle Dehumidification Technologies LP Houston Texas USA
bbattle@rentdh.com
Abstract
This paper presentation is based on the Joint Technical Committee Report titled
Dehumidification and Temperature Control during Surface Preparation, Application
and Curing for Coatings/ Linings of Steel Tanks, Vessels, and Other Enclosed Spaces.
NACE 6A192 (2000 Revision) SSPC-TR 3 Publication No. SSPC 01-07 Item No.
24083.
The purpose of this paper is to provide an in depth assessment and review of the
content of the Joint Technical Committee Report and present it to Australian
Corrosion and Surface Preparation and Coating industry members and associates to
ensure a thorough understanding of the content and how this can be applied for the
benefit of future corrosion control in Australia.
The use of dehumidification and temperature control has become more common
during coating/lining operations and much has been learned about ways to optimise its
use to achieve maximum benefits at minimum cost. This technical committee report
presents current information about why and how dehumidification and temperature
control are being used to achieve higher-quality coating/lining projects. It is intended
to be a resource for engineers and coating consultants who write specifications for
coating projects involving tanks or enclosed spaces.
This report was originally prepared by NACE Task Group T-6A-60 on The Need for
Dehumidification Equipment in the Application of Linings. This revision was
prepared by NACE Task Group 003 on Dehumidification. This Task Group is
administered by NACE Specific Technology Group (STG) 80 on Intersociety Joint
Coatings Activities, and is sponsored by STG 03 on Protective Coatings and Linings
– Immersion/Buried. The Task Group also has representation from SSPC Group
Committee C.2 on Surface Preparation. This report is published by NACE
International under the auspices of STG 80, and by SSPC.
The content of the report that this paper will review includes a Glossary of terms,
Methods of Dehumidification, Sizing Equipment, Impact of Contaminants and
Relative Humidity, Dew Point Differential and Surface RH, Uses of Dehumidification
and Temperature Control Equipment, Psychrometric Chart, Inspection
Instrumentation, and Corrosion Mechanisms.

Thermal Metal Spray: Successes, Failures and Lessons Learned
Willie L Mandeno
Opus International Consultants Ltd, Wellington, New Zealand
Presenter email address: willie.mandeno@opus.co.nz
Abstract
Thermal sprayed metal (TSM) includes proven long term protective coating systems
using zinc, aluminium and their alloys for steelwork in a marine environment;
however specifiers have been slow to adopt these in Australia. This paper reviews the
technology then looks at several projects in New Zealand and overseas, some where a
failure has occurred, and discusses these and the lessons that should be learned. It
concludes with recommendations as to how coating specifications could be improved
so that TSM’s potential long life performance can be achieved.