Steelwork Corrosion Control

✍ Scribed by D.a. Bayliss

• Publisher: Spon Press
• Year: 1990
• Tongue: English
• Leaves: 267
• Edition: Rev Sub
• Category: Library

✦ Synopsis

Basic guide to the principles involved and methods of achieving sound steel protection.

✦ Table of Contents

Book Cover......Page 1
Half-Title......Page 2
Title......Page 3
Copyright......Page 4
Preface......Page 5
Contents......Page 6
CHAPTER 1 Introduction......Page 15
2.1 CORROSION. THE BASIC PROCESS......Page 17
2.2 THE ELECTROCHEMICAL NATURE OF CORROSION......Page 18
2.3.1 Potential......Page 19
2.4 CORROSION IN AIR......Page 20
2.5 CORROSION IN WATER......Page 22
2.5.4 Corrosion Rates of Steel in Water......Page 23
2.7 BACTERIAL CORROSION......Page 24
FURTHER READING......Page 25
3.1 STEEL SURFACE CONTAMINANTS AND CONDITIONS......Page 26
3.1.2 Millscale......Page 27
3.1.3.2 Water-Soluble Contaminants......Page 29
3.1.5 Surface Defects and Welds......Page 31
3.2.1.1 Liquid Solvent Cleaning......Page 32
3.2.2 Hand—and Power-Tool Cleaning......Page 33
3.2.3 Abrasive Blast-Cleaning......Page 34
3.2.3.1 Air Blast-Cleaning......Page 35
3.2.3.3 Centrifugal Blast-Cleaning......Page 36
3.2.3.4 Wet Blasting......Page 37
3.2.3.5 Abrasives for Cleaning Steel......Page 40
3.2.4 Innovative Methods......Page 44
3.2.5 Flame Cleaning......Page 45
3.2.6.1 Inhibitors......Page 46
REFERENCES......Page 47
4.1 GENERAL REQUIREMENTS......Page 49
4.2 THE NATURE OF PAINT......Page 50
4.3 PROTECTION BY PAINT FILMS......Page 51
4.3.2 Inhibitive Pigments......Page 52
4.3.3 Barrier Coatings......Page 53
4.4.1 Adhesion......Page 54
4.4.4 Abrasion Resistance......Page 55
4.4.7 Ageing of Paint Films......Page 56
4.6.1 Oxidation Type......Page 57
4.6.2.1 Chlorinated Rubber......Page 58
4.6.3.1 Epoxy......Page 59
4.6.3.3 Other Binders......Page 60
4.7.1 Inhibitive Pigments......Page 61
4.7.2 Other Pigments......Page 62
4.9.1 Oil-based and oleo-resinous paints (oxidation drying)......Page 63
4.9.2.1 Chlorinated-Rubber Paints......Page 66
4.9.2.4 Bituminous Coatings......Page 67
4.9.3.1 Epoxies......Page 68
4.9.3.2 Coal-Tar Epoxies......Page 69
4.9.3.5 Moisture-Curing Urethanes......Page 70
4.9.4.2 Inorganic Zinc-Rich Paints......Page 71
4.9.6 Heat-Resistant Coatings......Page 72
REFERENCES......Page 74
FURTHER READING......Page 75
5.1.1 Brush Application......Page 76
5.1.2 Roller Application......Page 77
5.1.3 Airspray Application......Page 78
5.1.4 Airless Spraying......Page 79
5.1.5 Heated Spray Units......Page 80
5.1.6 Application of Two-Component Paints by Spray......Page 81
5.1.7 Electrostatic Spray......Page 82
5.1.9 Comparison of Application Methods......Page 83
5.2.1 Pre- or Post-Fabrication......Page 84
5.2.3.1 Temperature......Page 85
5.2.3.3 Ventilation......Page 86
5.3 THE PAINTER......Page 87
5.4 PAINT MANUFACTURERS’ DATA SHEETS......Page 88
REFERENCES......Page 89
6.1.1.2 External Tank Bottom Corrosion......Page 90
6.1.2.1 Organic Coatings......Page 91
6.1.2.2 Cementitious......Page 92
6.1.3.3 Ventilation......Page 93
6.2 POWDER COATINGS......Page 94
6.2.1 Application Methods......Page 95
6.3 COIL COATINGS......Page 96
6.4 WRAPPING TAPES......Page 98
6.6 PIPELINES......Page 99
6.6.1.1 Coat and Wrap......Page 100
6.6.1.2 Fusion-Bonded Epoxy Coatings......Page 101
6.6.2 Buried Pipelines......Page 102
REFERENCES......Page 103
7.1.1 Hot-Dipping......Page 105
7.1.1.3 Reactions Occurring in Hot-Dip Galvanising......Page 106
7.1.1.6 Design of Fabrications for Hot-Dip Galvanising......Page 107
7.1.2 Sprayed Coatings......Page 109
7.1.3 Coatings Produced by Diffusion......Page 110
7.1.5 Other Application Methods......Page 111
7.2 CORROSION PROTECTION BY METAL COATINGS......Page 112
7.3 ADDITIONAL PROTECTION TO METAL COATINGS......Page 113
7.4 CORROSION DATA FOR METAL COATINGS......Page 114
7.4.1.1 Atmospheric......Page 115
7.5 THE SELECTION OF METAL COATINGS......Page 116
7.8 WET STORAGE STAIN......Page 118
REFERENCES......Page 119
8.1 STANDARDS AND SPECIFICATIONS......Page 120
8.2 THE PURPOSE AND DRAFTING OF A SPECIFICATION......Page 121
8.4 PREPARATION OF A COATING SPECIFICATION......Page 122
8.5 SPECIFICATION REQUIREMENTS......Page 123
8.5.2.3 Surface Cleanliness......Page 124
8.5.2.6 Maintenance Work......Page 125
8.5.3 Coating System......Page 126
8.5.5 Coating Application......Page 127
8.5.6 Treatments of Special Areas......Page 128
8.5.7 Handling, Transport and Storage......Page 129
8.5.9 Inspection and Quality Control......Page 131
REFERENCES......Page 132
9.1 INTRODUCTION......Page 133
9.3 THE APPROACH TO QUALITY CONTROL......Page 134
9.4.1 Training and Certification of Inspectors......Page 136
9.5 METHODS OF INSPECTION OF PAINT COATINGS......Page 137
9.5.1.2 Visual Cleanliness......Page 138
9.5.1.3 Surface Contaminants......Page 139
9.5.1.4 Surface Profile......Page 144
9.5.1.6 Blast-Cleaning Operations and Equipment......Page 146
9.5.1.7 Abrasives......Page 147
9.5.3.1 Storage and Preparation of Paint......Page 148
9.5.3.4 Measurement of Ambient Conditions......Page 149
9.5.3.6 Measurement of Paint Film Thickness......Page 151
9.5.3.7 Detection of discontinuities in coatings......Page 154
9.5.3.8 Adhesion......Page 155
9.6.1 Hot-Dip Galvanising......Page 156
9.7 INSPECTION INSTRUMENTS......Page 157
9.8 REPORTS AND RECORDS......Page 158
REFERENCES......Page 160
10.2 MATERIALS......Page 162
10.3 BIMETALLIC CORROSION......Page 163
10.4 ACCESS FOR INSPECTION AND MAINTENANCE......Page 164
10.5 CREVICES......Page 165
10.6 GROUND-LEVEL CORROSION......Page 166
10.7 ENTRAPMENT OF MOISTURE AND CONDENSATION......Page 167
10.8 GEOMETRY AND SHAPE......Page 168
10.10 FABRICATION AND CONSTRUCTION......Page 170
FURTHER READING......Page 171
11.1 INTRODUCTION......Page 172
11.2 THE GENERAL APPROACH TO MAINTENANCE PAINTING......Page 173
11.3 PLANNING MAINTENANCE......Page 174
11.4.1 Survey Procedures......Page 175
11.4.1.1 Planning the Survey......Page 176
11.4.1.2 Inspection and Testing......Page 177
11.4.1.4 Health and Safety during Survey......Page 179
11.5 MAINTENANCE PROCEDURES......Page 180
11.5.1 Surface Preparation Prior to Re-Painting......Page 181
11.6 ENVIRONMENTAL CONDITIONS DURING REPAINTING......Page 182
REFERENCE......Page 183
12.1.1 Basic Principles......Page 184
12.1.5 Choice of Method for Cathodic Protection......Page 185
12.1.6 Practical Applications of Cathodic Protection......Page 186
12.2 CONDITIONING OF THE ENVIRONMENT......Page 187
12.2.2 Treatment of Aqueous Solutions......Page 188
12.3.2 Low-Alloy Weathering Steels......Page 189
FURTHER READING......Page 191
13.2 SURFACE PREPARATION......Page 193
13.3 COATING MATERIALS......Page 194
13.6 TYPES OF COATING DEFECTS......Page 195
13.6.4 Blistering......Page 196
13.6.6 Chalking......Page 197
13.6.9 Cracking......Page 198
13.6.13 Lifting or Pulling Up......Page 199
13.6.19 Skin Curing......Page 200
13.6.24 Wrinkling......Page 201
REFERENCE......Page 202
14.1 INTRODUCTION......Page 203
14.2 FACTORS INFLUENCING THE SELECTION OF COATING SYSTEMS......Page 204
14.3 SELECTION OF COATINGS FOR SPECIFIC ENVIRONMENTS......Page 205
14.4.1 Paints......Page 207
14.4.2 Metal Coatings......Page 210
14.5 COSTS OF PROTECTIVE SYSTEMS......Page 211
14.5.1.1 Surface Preparation......Page 212
14.5.2 Initial Costs of Protective Systems......Page 213
FURTHER READING......Page 214
15.1 GENERAL STEELWORK EXPOSED TO THE ATMOSPHERE......Page 215
15.1.2 Buildings......Page 216
15.2 OFFSHORE STRUCTURES......Page 217
15.2.3 Splash Zone......Page 218
15.3.3 Underwater Plating......Page 219
15.3.7 Steel Decks......Page 220
15.4 CHEMICAL PLANTS......Page 221
15.6 SEWAGE SYSTEMS......Page 222
15.8 JETTIES AND HARBOURS......Page 223
15.9.1.3 Basic Chemistry of Concrete......Page 224
15.9.2.2 Carbonation......Page 225
15.9.3 Types of Failure with Reinforced Concrete......Page 226
15.9.4.2 Cathodic Protection......Page 227
REFERENCES......Page 228
16.1 INTRODUCTION......Page 229
16.2 TEST REQUIREMENTS......Page 230
16.3 LABORATORY TESTING OF PAINT FILMS......Page 231
16.3.2 Adhesion Tests......Page 232
16.3.3 Abrasion Resistance......Page 233
16.3.4 Physical State of the Film......Page 234
16.3.5 Film Thickness......Page 235
16.5.1 Artificial Weathering......Page 236
16.5.2 Salt-Spray Tests......Page 237
16.5.5 Other Laboratory Tests......Page 238
16.6 INSTRUMENTS FOR SPECIALISED ANALYSIS......Page 239
16.7.1 Type of Specimen to be Used for the Tests......Page 240
16.7.2 The Coating......Page 241
16.7.4.1 Climatic Conditions......Page 242
16.7.5 Monitoring of Test Sites......Page 244
16.7.7 Conduct of Field Tests......Page 245
16.8 SERVICE TRIALS......Page 246
16.10 FORMULATING THE TEST PROGRAMME......Page 247
REFERENCES......Page 248
British Standard 3900. Group D: Optical Tests on Paint Films......Page 249
British Standard 3900. Group H: Evaluation of Paint and Varnish Defects......Page 250
17.2.1 Open-Nozzle Blast-Cleaning......Page 251
17.2.3 Flame Cleaning......Page 252
17.3.2.3 Explosive Hazard......Page 253
17.3.2.6 Solvent Vapour Density......Page 254
17.3.2.13 Toxicity......Page 255
17.3.2.14 Instrumentation......Page 256
REFERENCES......Page 257
Index......Page 259