Corrosion Control

Corrosion Control Methods

Better Design
Better Selection of Materials
Corrosion Control by Coatings
Corrosion Control by Inhibitors
Corrosion Control by Cathodic Protection
Corrosion Control by Anodic Protection
Factors affecting the service Life
Better Design
Weld Design
 Avoid
Crevices
Avoid Erosion Corrosion
 Better Material Selection
Material Selection Criteria
Lowest Corrosion rate
Also falls within the project cost

If there is choice to select between steel and SS,

you can better select SS
But if the choice is to select only steel, then one
has to make thorough investigations of various
steels and find the best for application based
upon the chemistry of the steel
Protection by Coatings
 Protection by Coatings
Classification of Coatings
Metallic / Ceramic/Organic
Room Temperature Application/ High
Temperature Application
Zn ( Galvanization), Cr, Sn, Ni, Cd
Aluminising, Al-Cr, Nitriding, carborizing
 Method of Application
Hot Dip Method
Slurry method
Electroplating/Electroless Plating
Liquid route ( Cyanide bath)/Sol-gel
PVD/CVD
Thermal Spray / Laser
Coatings by Spray paint spray
 Paint Coatings
Though appears simplest method of
Corrosion Control, actually not so in
practice.
It is an art as well as science.
Requires good knowledge of paint
formulations, paint selection, application
skill, suitable surface preparation method &
experience and inspection methods.
 Why paint Coatings ?
Aesthetics
Corrosion Protection
Both
 Paint System
Surface Preparation
Primer
Intermediate layer
Top layer
A technician is required to properly carry out
above jobs.
An inspector / supervisor is required to
continually monitor the requirement as per
specifications.
 Main Properties of a Coating
The coating material should be an effective
electrical insulator
It can be applied with no breaks
The coating must be strong enough to resist
the impact of sharp objects.
It constitutes initially a perfect film which
remains so with time.
 Surface Preparation
Surface Cleaning
Conversion Coatings
Blasting
Dry
Hydroblasting
 Paint Application
Brush
Rollers
Air Spray
Airless Spray
 Coating Composition

Binder ( Resin)
Solvent
Pigment
Additives
 Pigments
Several Functions as part of Coating
Provide colour & Opacity
TiO2, C or lamp black
Reinforce the film structurally
Iron oxides
Corrosion resistance
Zn ( Galvanically)
Talc & mica act as extenders, reduce permeability
through film as plate like particles block
permeation.
Lead chromate as inhibitive pigment
 Role of Pigment

Pigment

Inhibitive
Barrier Coating Primer Organic Rich
Coatings

Inorganic rich coating

 Organic Zinc Rich Coatings
They utilize an organic resin rather than an inorganic
silicate binder for film formation.
They protect steel galvanically as well as by barrier
protection but do not provide a high level of galvanic
protection as do inorganic Zn rich coatings.
They are formed by simple solvent evaporation or by
chemical reaction of components.
Film properties of these coatings are similar to that of free
zinc organic coatings.
Organic Zn Coatings do not require high level surface
cleanliness while inorganic Zn coating require the best
cleaned surface.
 Inorganic Zn-rich Primer

Organic Zn-rich primers

 Additives
Trace or small quantities of these help in
modifying various properties:
Phenylmurcury, Zinc, Cuprous compounds act
as mild inhibitors
Co and Mn Napthanates - help in drying
ZnO - protection of resin from heat and Sun
 What is required from a Paint
Coating
Good Adhesion
Flexibility
Impact Resistance
Resistance to environment
Chemical
Moisture
Sunlight / Rains
 Types of Coatings
Conventional
Lacquers, solutions of synthetic resins ( vinyl chloride,
rubber and acrylic)
Water emulsion (latex) Coatings ( acrylics and Vinyls)
Oil based coatings
Epoxy Coatings
Coal tar Epoxy coatings
Poly-urethanes
Polyester and Vinyl ester coatings
Organic Zn rich Coatings
Special
Solvent Less Coatings
Fiber Reinforced coatings
 Lacquers
Lacquers are solutions of natural resins ( Shellac or bituminous materials) or
synthetic resins ( vinyls, chlorinated rubber and acrylics).
Upon application, solvent evaporates and the resin deposits unchanged.
Films have good water and chemical resistance but poor solvent and heat
resistance.
Require abrasive blast cleaning.
Applied in Multiple coats and easy to topcoats for repair.
Have Good gloss Retention and resistance to weathering.

Advantages
Rapid Drying & Recoating
Good General Chemical Resistance
Good in water immersion
Good gloss Retention
Good Durability
Limitaions
High in VOC
Poor Solvent Resistance
Low film build up
Blasted surface is necessary
Occasional poor adherence
 Water Emulsion Latex
Latex coatings are being successfully used to coat
wood and masonry structures.
Relatively porous nature of structure allows water
vapour to pass through them.
Advantages Limitations
Reduced level of VOC Limited Durability
Easy to apply, topcoat & repair Poor chemical resistance
Fast to dry for recoating Poor wetting of surface
Excellent Flexibility Poor immersion service
Low Cost Best cure above 50 C.
 Oil Based Coatings
Coatings based upon drying oil ( linseed oil, tung, soyabean,
fish oil).
Cure by reaction with oxygen.
Though complete dry less than in one day, complete curing
takes much longer.
Alkyd coatings use resin formed by the reaction of polyhydric
alcohols ( glycerin) and polybasic acid ( phthalic acid) followed
by modification with drying oils. These cure much faster than
unmodified alkyds..
Silicon alkyd coatings were developed by modifying alkyd resin
with silicon ( 30%) to provide greater gloss retention.
Epoxy ester coatings are another modification of drying oils to
improve performance, particularly chemical resistance.
Uralkyd coatings are formed with polyurethane. These coatings
are hard.
 Epoxy Coatings
The Most Common two component thermosetting product.
An epoxy resin is based on a reaction product of phenols,
commonly bisphenol F or Cresol with epichloridehydrin.
Available in solvent free, with solvent or water containing
formulations.
The two components are called base and the curing agent. Latter
is used to polymerise the epoxy resin which has major influence
on the mechanical and chemical resistance properties. The most
common curing agents are aliphatic amines, ketamines and
polyamides.
Epoxy coatings bond well to the abrasive cleaned steel and clean
concrete.Their films are hard and relatively inflexible. They
chalk in sunlight.
 Epoxy Coatings
We make the prepolymer using bisphenol A and
epichlorohydrin

Bisphenol A Epichlorohydrin

Diepoxy molecule
 Polyurethane Coatings

R-N = C = O + OH--R = R- NH- C - O -R

Very important Class of Coatings

Urethanes are perhaps the most common
materials used in our day to day life.
Soft, flexible to rigid materials are
availbale.
 Polyester and Vinyl ester Coatings
Unsaturated polyester and vinyl ester thermosetting resins are used as
base for a useful group for a high performance corrosion resistant lining
for steel, concrete and other surfaces
Polyesters and vinyls contain unsaturated groups which are reacted with
unsaturated monomers such as styrene.The combination of resin and
monomer forms a relatively low viscosity material to which when added
some catalysts such as peroxides accelerate curing.
A great skill is required to ensure proper propotionating and mixing
Limited pot life
Blast surface required when used as primer.
More expensive than epoxies.
To the final lining product, one can add reinforcements and fillers to
minimise the effect of shrinkage and enhance properties such as lowering
coefficient of friction and increasing tensile strength and decrease
permeation.
Polyesters and vinyls are applied in large thicknesses from 500 um to 5
mm.
 Natural and Synthetic
Rubber Linings
Natural and synthetic rubber linings are used in such industries as
steel, chemical, paper, plating, mining, agriculture and power
The physical properties of these steel linings allow them to
protect steel from erosion, corrosion, abrasion and chemical
attack.
These linings are applied to various types of equipments such as
flue gas desulphurisation systems, pipe, tanks, railway tank cars,
rolls and pulleys.
Typical thickness of Rubber linings are from 3.2 mm to 6.4 mm.
Surface should be blast cleaned SA21/2 with a profile of 40-50
um.
The surface before linings must be primed with suitable primer.
 - CH - CH2-
Epoxy
Chlorinated rubber

Polyester Coating
--- CH -- CH --

O = C - OCH2 - - CH3
Acrylate
Vinyl Acetate
Urethane
R-N = C = O + OH--R R- NH- C - O -R
 Paint Application
1. Brush or Rollars
2. Spray
Air Spray
Airless Spray
Electrostatic Spray
Airless, Theory of Operation
Airless spray atomization 2000+ psi fluid pressure
- hydraulic force through
a cats eye shaped orifice
2000+ psi fluid pressure
Fastest and heaviest spray
Transfer efficiency = 50 - 60%
finish and is measured in
liters per minutes
Transfer efficiency =
50-60%
Protective coatings

Click to see spray

36
 Transfer Efficiency

Transfer efficiency (TE) = (paint deposited on a part)/(total paint

sprayed)
TE = (Wp/Ws) x 100%
Wp = Weight of wet coating on the part
Ws = Weight of liquid coating sprayed
Electrostatic Technology
 High Performance Coatings
1. One those which are functional specific
2. Can be applied in highly aggressive
environment.
3. Have high Corrosion resistance
4. High Erosion & abrasion resistance
5. Can dry very fast
6. Can give large thickness in one coat
 Solventless Systems
Can achieve very high thickness in
one coat
Can have Drying time of a few
minutes
Life can further enhanced by
addition of glassfalkes
 Fibreglass Reinforced Linings
Fibergalss-reinforced plastic (FRP) linings are unstaurated
polyester and vinyl ester thermosetting resin linings into
which fibre glass are incorporated to optimize the lining
performance.
They are commonly used to control the internal corrosion
of above ground petroleum storage tank bottoms.
The main reinforcement used with polyester and vinyl ester
resin liner are E glass mat and 250 um glass veil ( very thin
fibre glass mat) which has electrical properties, strength
and durability appropriate for most applications.
C glass mat is chemical resistant, e.g. resistant to most
acids. A 3000g/m2 is sometimes used instead of choopede
strand mat.
 Moisture Penetration

Glass Flakes

Coating

Substrate
Substrate
 Offshore
Structures

Glass Flake Reinforced

Polyester Coating to achieve
750um in one coat
 Application
Underwater:
Brushes - Using vigorous
circular motion.

Underwater pump with

round brush - using
vigorous circular
motion
 Once we have made diepoxy prepolymers, we tie
them all together by adding a diamine.
 How Epoxies Work
The well known adhesion of epoxies is due to the
strong polar bonds it forms with the surfaces it comes
in contact with.
On dry surfaces the bond between the surface and the
epoxy displaces the air, which is a fluid.
The same is true underwater. As on dry surfaces, the
polar bond attraction is strong enough to displace the
fluid, in this case the water, and produce an strong
bond even underwater.
Thus, painting underwater is, in theory, no different
that painting above the water. The cross linking
reaction of epoxies should be independent of the
surrounding environment.
 POWDER COATINGS
Type I Thermoplastic - are high molecular weight products
that melt, flow and form a film without change in their
chemical composition. Because they are difficult to grind
they are often applied in fluidized beds and used in thick
films. : polyethylene, polypropylene, PVC, nylon.
Type 2 Thermosets - are lower molecular weight polymers
that cross link during heat curing to form higher molecular
weight. They can be ground finer and thus applied in thinner
films 25-200 um. They chalk in presence of UV light.
FBE is one of the best known thermoset Coatings used in
large applications for external and internal pipelines
corrosion protection.
Application methods : Fluidized bed, electrostatic spray, hot
flocking and thermal spray.
 Fluoroelastomeric Coatings
Fluoroelastomeric coatings are among the most expensive and
highest performance coating materials in present Day.
Application, surface finishing, material mixing are of paramount
importance
Fluoroelastomeric coatings are chemical resistant coatings that can
withstand elevated temperatures and attack by acids and alkalies,
hydrocarbons, gases and solvents and many harsh industrial
chemicals.
They are generally two component catalysed systems that cure at
room temperature.
Physical properties can be controlled by varying the amount of
catalysts.
They are commonly used as heat and acid resistant linings in power
station flues and duct work. And also in tanks, sumps, ditches,
hazardous waste dikes and immersion zones.
Fluoropolymer Bonds are Less Likely to Break

The C-F bond is one of the strongest known

(PVDF shown below)
Fluorine Content of PVDF
Chemical Spot Test

PVDF
Polyester
 Tapes & Wrappers
TAPES are finally prepared coating material ready to apply
onsite.
They may be either thermoplastic or felt impregnated with
petrolatum or petroleum wax.
Success of tapes depends upon the application. The most
important problem is the improper overlapping that causes
gaps where shielding corrosion may take place.
The most common application of tapes is for immediate
repair of underground pipelines.
One of the failure areas of tapes is in above ground araes
such as soil to air pipe transition zones
Experienced tape applicators or especially with machine
wrapping one can eliminate failure problems.
 Thermal Spray Coatings
The most latest and easy to apply and
provide much longer life.
Flame spray, Arc Spray, Detonation Gun or
Plasma Spray guns are used.
They are also called hybrid systems with
internal metal coating with a top seal
coating of epoxy or PU.
Life of such coatings is 25- 50 years.
Various Thermal Spray Systems
Flame Arc

HVOF Plasma
 Actual Application

Flame Spray

Thermal Spray by Robots

 Summary
Paint Coating is one of the most effective and known
methods of corrosion protection at the surface.
To get an excellent corrosion protection, several factors
which include, proper surface preparation, correct
application technique, suitable environmental
conditions, inspection during surface preparation and
application are required.
Paint selection is very important. Depending upon the
environment, a suitable system is selected.
Most modern paint coating systems such as
Floroelastomers, glass flake systems are used for
selective applications are now readily available.