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IN THIS ISSUE SEPTEMBER 2017
VOL. 56, NO. 9

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

28 42
SPECIAL FEATURES

28 Protecting Concrete Infrastructure from Corrosion

Wesley Fawaz

60 9th Annual Company Showcase

CATHODIC PROTECTION
34 Coupons for Cathodic Protection Evaluation
of Mixed-Metal Piping Systems
Douglas E. Gilroy About the Cover
The Arthur Ravenel Jr. Bridge, which spans the Cooper
River in Charleston, South Carolina, is the third longest
cable-stayed bridge in the Western Hemisphere with a
COATINGS & LININGS main span of 1,546 ft (471 m). The largest local contract
secured 250,000 m3 (326,988 yd3) of concrete for the
38 Plasma Electrolytic Oxidation Coatings for Aluminum Alloys
Y. Zhang, W. Fan, H.Q. Du, and Y.W. Zhao structure. Concrete is the most widely used construction
material in the world. According to www.concretehelper.
42 Hydrogen Sulfide Tube Failure in a Seawater Heat Exchanger
Hanan Farhat and Roy Johnsen
com, about 10 billion tons (9,072 billion kg) of concrete are
produced every year. In this issue of MP, several articles
discuss concrete structure corrosion and how to mitigate
47 Coatings & Linings Essentials
degradation of the reinforcing steel that gives concrete
higher tensile strength. Alkaline conditions in concrete form
a passive film on the surface of the steel reinforcement
that prevents or minimizes corrosion. Reduction of the pH
CHEMICAL TREATMENT caused by the ingress of chlorides or carbonation causes
the passive film to degrade and allows the reinforcement
52 Electrochemical Approach for Screening Concrete Corrosion
Inhibitors
to corrode in the presence of oxygen and moisture. A key
way to minimize corrosion is to design for durability and
I-Wen Huang, Fred Goodwin, and Frank Apicella employ the most appropriate prevention technologies and
techniques available.

MATERIALS SELECTION & DESIGN

56 Rust Layer Characterization of a Buried Drinking Water Pipe
Zhanjun Guo and Zhiliang Chen

2 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

WHATEVER IT IS,
WE CAN PROTECT IT.
SPECIFY LORESCO.
®

IT WORKS!

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Certified to
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Loresco International
421 J.M. Tatum Industrial Park Drive
Hattiesburg, MS 39401
Website: www.Loresco.com
Email: info@loresco.com
Phone: (601) 544-7490
Fax: (601) 544-7531
IN THIS ISSUE SEPTEMBER 2017
VOL. 56, NO. 9

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

6 17 47
DEPARTMENTS

6 Up Front

8 What’s Online @ www.materialsperformance.com

Coming Next Month:
10 From the Editor’s Desk

CORROSION 2018 The MP Blog

11
Advance Program 14 Material Matters
14. Study Evaluates Chloride Limits for Structural Reinforced Concrete
17. Florida Tests Cathodic Protection Solutions on High-Resistance Concrete

MP (Materials Performance) is published monthly by NACE International

20 Company News

(ISSN 0094-1492; USPS No. 333-860). Mailing address and editorial

offices: 15835 Park Ten Place, Houston, TX 77084; tel: +1 281-228-6200. 24 Product Showcase

Internet address: www.nace.org. Preferred periodicals nonprofit postage

paid at Houston, TX and additional mailing offices. Canada Post: Publications 76 Building Business Connections
76. Corrosion Engineering Directory
Mail Agreement
MP (Materials #40612608.
Performance) Canada Returns
is published monthly by to NACE
be sent to IMEX,
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(ISSN
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+1 281-228-
or in part,
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is forbid-
80 Corrosion Basics
80. Corrosion Inhibitors
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4 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

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UP FRONT
Seawater Reactions
Strengthened Ancient
Concrete
Samples from this ancient Roman pier in
Italy were studied with x-rays at Berkeley
Lab. Photo by J.P. Oleson.
A new look inside 2,000-year-old concrete—
made from volcanic ash, calcium oxide
(CaO) (also known as lime), and seawater—
is helping explain the chemistry that has
allowed ancient structures to withstand the
test of time. The research is also inspiring a
hunt for the original recipe so that modern
concrete manufacturers can do as the
Romans did.
Researchers at the U.S. Department of
Energy’s (DOE) Lawrence Berkeley National
Laboratory (Berkeley Lab) (Berkeley, Cali-
fornia) used x-rays to study samples of
Roman concrete from an ancient pier and
breakwater sites. Their earlier work found
that crystals of aluminous tobermorite, a
layered mineral, could play a key role in
strengthening concrete. Now, this study is
piecing together how and where it formed—
namely, in the centers of partially dissolved
relict lime clasts.
They believe the work could lead to con-
crete manufacturing techniques with less
environmental impact than modern Port-
land cement processes. Also, researchers
suggest a reformulated recipe for Roman
concrete could be tested for applications on
ocean-facing structures such as seawalls,
and could help safeguard hazardous wastes.
According to Marie Jackson, a professor
with University of Utah (Salt Lake City,
Utah) who led the study, the CaO likely
reacted with volcanic ash when it was
exposed to seawater. “Contrary to the prin-
ciples of modern cement-based concrete,
the Romans created a rock-like concrete
that thrives in open chemical exchange with
seawater,” Jackson says.
6 SEPTEMBER 2017 MATERIALS PERFORMANCE
The work was supported by the U.S.
DOE’s Office of Science (Washington, DC)
and the National Science Foundation
(Arlington, Virginia).
For more information, visit www.lbl.gov.
‘Seawater-Drinking’ Battery
Could Power Underwater
Surveys
Batteries that “drink” seawater are being
developed to power underwater vehicles.
Photo courtesy of MIT.
Massachusetts Institute of Technology
(MIT) (Cambridge, Massachusetts) spinout
Open Water Power (OWP) is developing an
aluminum-water power system that it says
is safer, cheaper, and more durable for
unpiloted underwater vehicles (UUVs) than
lithium-ion batteries.
While many UUVs use lithium-based
batteries, OWP says these batteries are
flammable, have limited energy density, and
must be encased in expensive metal pres-
sure vessels. In contrast, their system con-
sists of an alloyed aluminum anode, a cath-
ode alloyed with several elements (primarily
nickel), and an alkaline electrolyte posi-
tioned between electrodes.
When these UUVs are placed in the
ocean, seawater is pulled into the battery
and splits at the cathode into hydroxide
anions and hydrogen gas. The hydroxide
anions interact with the aluminum anode,
creating aluminum hydroxide and releasing
electrons. Those electrons travel back
toward the cathode, donating energy to a cir-
cuit along the way to begin the cycle anew.
Both the aluminum hydroxide and hydrogen
gas are jettisoned as harmless waste.
Components are only activated when
the battery is flooded with water. Once the
aluminum anode corrodes, it can be replaced
at low cost.
With their system, OWP says UUVs can
launch from shore and without a need for
service ships. To that end, the group is work-
ing with the U.S. Navy (Washington, DC) to
replace batteries in acoustic sensors
designed to detect enemy submarines. In
mid-2017, a pilot was launched to use the
UUVs for surveys. Currently, these UUVs can
travel ~100 nautical miles (185 km), but OWP
believes it can raise the distance to ~1,000
nautical miles (1,852 km).
For more information, visit news.mit.edu.
High-Tech Sensing Illuminates
Concrete Stress Testing
The coating can create a candle-like “flame,”
that highlights shear stress distribution in a
concrete beam. Photo courtesy of the
University of Leeds.
Scientists at the University of Leeds (Leeds,
United Kingdom) and the University of Qatar
(Doha, Qatar) discovered a new way to mea-
sure the strength of modern concrete com-
posites and the points when it could fracture.
Their approach involves applying a light-
refracting coating, designed to display stress
positions, to the surface of concrete beam
samples. The epoxy coating is birefringent,
which means it can split light waves in differ-
ent directions in proportion to any stress.
The light reflects back to a photonic cam-
era. The camera takes a picture showing
where the stress levels are most extreme,
before cracks or fractures occur. While the
coating is not new, this project is the first
time it has been used to measure shear strain
on opaque materials rather than transparent
materials. With the process, the researchers
believe they can prove that concrete made
from non-traditional ingredients—such as
waste plastic products—can sustain service
loads without fracturing.
For more information, visit www.leeds.
ac.uk.
—Ben DuBose
NACE INTERNATIONAL: VOL. 56, NO. 9
 ABLE ·
EAT
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·
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ST

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· FA

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A C C U R AT E

Halve your DFT inspection

times using the Elcometer 456
Coating Thickness Gauge
with the Ultra/Scan Probe.

sales@elcometer.com
USA & Canada: (800) 521-0635 elcometer.com
WHAT’S ONLINE @ www.materialsperformance.com
Discussed this
Month
Following are just a few of the articles featured
this month on www.materialsperformance.com.

Features
Analysis of Materials for Highly
Corrosive Environments
Extra consideration is given to the coatings used
to protect sections of horizontal directional
drilling-installed pipe from corrosion; however,
the systems currently being employed may be
insufficient. (This is a Science in Action feature
with links to CoatingsPro articles.)

New Collaborative Research Project

Targets Surface Degradation
Researchers from BP and several prominent
European universities were awarded a contract to
investigate the processes that cause surface
degradation and to develop new mitigation
strategies.

Editor’s Choice
New Tantalum Alloy Resists Highly
Corrosive Environments
The results of recently completed trials show that
adding low levels of ruthenium improve the
corrosion and hydrogen enrichment resistance of
a titanium alloy in acid media.

Researchers Eye Advanced Sensors

to Monitor Buried Infrastructure
These novel advanced sensors were attached to a
hazard-resilient plastic pipeline installed
underground and tested through a simulated
fault rupture.

For even more corrosion news, visit

www.materialsperformance.com to read
MP articles that are exclusively on the web.

8 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 Leaders in Corrosion Prevention

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FROM THE EDITOR’S DESK

Helping www.materialsperformance.com

Concrete EDITORIAL
MANAGING EDITOR-IN-CHIEF
EDITOR
Gretchen A. Jacobson
Kathy Riggs Larsen

Stand the TECHNICAL EDITORS Norman J. Moriber

Jack Tinnea,
Tinnea Associates, LLC

Test of Time TECHNICAL EDITOR EMERITUS

STAFF WRITER
PRODUCT MANAGER,
John H. Fitzgerald III, FNACE
Ben DuBose
Husna Miskinyar
ELECTRONIC MEDIA

I
t’s very likely that each of us will be year-long study, the researchers tested
influenced by several concrete struc- samples from more than 500 concrete mix- GRAPHICS
ELECTRONIC PUBLISHING Teri J. Gilley
tures during our day, whether it is a tures. A description of the work and the COORDINATOR
water main pipeline delivering pota- results can be found in the Material Mat- GRAPHICS DESIGNER Michele S. Jennings
ble water for our morning coffee, a high- ters article that starts on p. 14.
way bridge helping us travel to work, a Corrosion inhibitors in concrete can ADMINISTRATION
CHIEF EXECUTIVE OFFICER Robert (Bob) H. Chalker
parking garage sheltering our motor vehi- mitigate the effect of chlorides on the con-
GROUP PUBLISHER William (Bill) Wageneck
cle, or an office building protecting us crete’s reinforcing steel. The technical
ASSOCIATE PUBLISHER Eliina Lizarraga
from the weather. Concrete is the most- article on p. 52 introduces a new method-
used manmade material on the planet and ology for assessing the inhibiting capabil- ADVERTISING
SALES MANAGER Diane Gross
its use dates back for centuries. Many ity of corrosion inhibitors designed to form
diane.gross@nace.org,
ancient concrete structures are still in a passive protective film on reinforcing +1 281-228-6446
existence today, such as the concrete dome steel in concrete. Several electrochemical SALES DEVELOPMENT Tiffany Krevics
of Rome’s Pantheon that was built around tests are combined to monitor the perfor- REPRESENTATIVE tiffany.krevics@nace.org,
126 AD. mance of candidate corrosion inhibitors in +1 281-228-6411
Almost every aspect of modern life is a short time frame as a screening review SALES SPECIALIST Kaci Lamb
supported by concrete—electrical energy before conducting long-term testing. kaci.lamb@nace.org,
from hydroelectric dams; pilings for Another corrosion mitigation strategy +1 281-228-6459
bridges, wharves, and jetties; conveyance for protecting the reinforcing steel in con- KEY ACCOUNT EXECUTIVE Eric Freer
structures for water and sewerage; anchor- crete is cathodic protection (CP), which is eric.freer@nace.org,
+1 281-228-6292
ages for electrical transmission and cell often used to protect concrete immersed
ACCOUNT EXECUTIVES Jody Lovsness
towers; and containment structures for in water. The Material Matters article on jody.lovsness@nace.org,
nuclear waste. Over the years, many p. 17 describes a case study conducted by +1 281-228-6257
improvements have been developed to the Florida Department of Transportation Leslie Whiteman
enhance concrete’s mechanical properties that compares the performance of two leslie.whiteman@nace.org,
and longevity, and structures made of con- types of galvanic CP test systems for +1 281-228-6248
crete can have a long service life. Still, bridge piers located in seawater. One uses MEDIA ADVERTISING Brenda Nitz
modern-era concrete is not immune to a zinc mesh anode integrated into a fiber- COORDINATOR brenda.nitz@nace.org,
+1 281-228-6219
degradation, particularly from corrosion, reinforced polymer jacket and the other
REGIONAL ADVERTISING SALES The Kingwill Co.
and it can be a challenge for owners and utilizes zinc anodes encapsulated in an REPRESENTATIVES Chicago/Cleveland/
operators to maintain the integrity of their activated mortar. New York/U.S. West Coast Area–
assets as concrete infrastructure ages. Since the early Romans started build- jim@kingwillco.com,
Keeping concrete infrastructure func- ing their concrete structures around 2,000 +1 847-537-9196
tional and safe while meeting demands to years ago, the concrete industry has pro- NACE International Contact Information
extend its service life is essential. Corro- gressed tremendously. By monitoring con- Tel: +1 281-228-6200 Fax: +1 281-228-6300
sion of reinforcing steel in concrete can be crete infrastructure, using proven corro- Email: Firstservice@nace.org Web site: www.nace.org
caused by chloride ions that enter the con- sion-control technologies, and making EDITORIAL ADVISORY BOARD
crete from salt-laden environments. Com- timely repairs when necessary, today’s Zahid Amjad, FNACE Walsh University
ponents used in the concrete mixture can structures should also stand the test of Susan Borenstein General Dynamics Electric Boat
also contain chlorides, which means the time. Raul A. Castillo Consultant
structural concrete can have a chloride Irvin Cotton Arthur Freedman Associates, Inc.
David D. He Corrpro
presence from the day it is cast. A joint
Jerry Holton Specialty Polymer Coatings USA, Inc.
research project was established to evalu- W. Brian Holtsbaum Corsult Associates (1980), Ltd.
ate the initial total chloride content of var- Russ Kane iCorrosion, LLC
ious concrete mixtures vs. the measured Kathy Riggs Larsen Ernest Klechka CITGO Petroleum Corp.
water-soluble chloride content in aged, Editor Kurt Lawson Mears Group, Inc.
Lee Machemer Jonas, Inc.
hardened steel-reinforced concrete. In this kathy.larsen@nace.org
John S. Smart III John Smart Consulting Engineer

10 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 THE BLOG

The following are excerpts from the

NACE International Corrosion Network
(NCN) and NACE Coatings Network.
grade distilled water is ~8 µS; to get lower
it is necessary to use double-distilled or
deionized water. Any offset introduced by
A: Chloride contamination of CSE
shifts the potential in the nega-
tive direction. For example, 5 ppt of Cl–
These are email-based discussion groups using good-quality condensate or com- produce a variation of ca. –17 mV in the
for corrosion professionals, with more mercial grade distilled is usually less than reference potential, and 10 ppt produce a
than 3,000 participants. a millivolt.
Continued on page 13
The excerpts are selected for their
potential interest to a large number
of NACE members. They are edited for
clarity and length. Authors are kept
anonymous for publication.
Please be advised that the items are
not peer-reviewed, and opinions and
suggestions are entirely those of the
inquirers and respondents. NACE does
not guarantee the accuracy of the techni-
cal solutions discussed. MP welcomes
additional responses to these items. They
may be edited for clarity.
For information on how to subscribe
to these free list servers, click on the
“Corrosion Central” link and then “Online
Corrosion Community List Servers” on the
NACE web site: www.nace.org.

Water for Copper/Copper

Sulfate Electrodes
Q: Is it advisable to use drinking
mineral water mixed with
copper sulfate (CuSO 4) crystals as an
electrolyte inside the tube of a Cu/CuSO 4
electrode (CSE) to make a saturated
solution?

A: Definitely not! You should use

only distilled or demineralized
water for the make-up solution. Using any
other types of water will lead to signifi-
cant errors in the potential.

A: Distilled water must be used, and

it should be saturated with CuSO 4
crystals. Do not add any other substance
to the solution or the integrity of the CSE
will be compromised.

A:
be used.
I have heard it said that water
drops from an air conditioner can

A: If you had to do this, then mea-

sure the conductivity of the con-
densate. When an air conditioner or de-
humidifier is run after it has not been on
for a while, the condensate will be unsuit-
able because it has washed accumulated
dust and salts from the coils. Once it has
been used for several weeks, the conden-
sate conductivity will typically be <12 µS,
which is quite adequate for reference
electrodes. Much of the commercial-

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 11

 January 23-26, 2018 | Las Vegas, Nevada, USA

Visit www.concrete.org
to register
Learn more about
ACI’s publications,
education, and
certification.

Other features:
• Talk to industry experts
• Dedicated contractor’s section
• Membership discounts
• Recursos en español

+1.248.848.3800 | www.concrete.org | |
THE BLOG
Continued from page 11

shift of ca. –100 mV. Refer to “Factors

Affecting the Accuracy of Reference
Electrodes” by F. Ansuini and J. Dimond, Mentors Make a Difference
November 1994 MP, p. 14.

Intergranular Cracking of
Find a mentor. Be a mentor.
Low CS Stack Casing
www.nace.org/BeAMentor
Q: The stack casing of fired heaters
in a catalytic reformer unit has
been cracking. The fired heaters burn fuel
oil, fuel gas, and natural gas. The stack
casing is a welded structure of ¼-in
(6.3-mm) thick low carbon steel (CS)
(A285 Grade A, 0.05%C/60 HRB). The cas-
ings have cracked in the refractory-lined
regions. Cracks occurred within 2 in
(51 mm) of welds, mostly parallel to but
some through the welds and some in the
heat-affected zones. The cracking initi-
ated on the inside surface and propagated
through the plate thickness to the outside
surface. The cracking is almost com-
pletely intergranular, some extensively
branched. I am looking for possible corro-
dents responsible for the intergranular
stress corrosion cracking (IGSCC). The
only thing I can think of is ammonium
nitrate in acidic condensates, with the
ammonium coming from the air intake.
The stack casing material that failed
has 0.05% C, which was reported to be
sensitive to IGSCC of CS in nitrate (e.g.,
CORROSION 2007 paper no. 485). How-
ever, few have reported on nitrate crack-
ing in fired heaters and boilers. I wonder
if this is because nitrogen oxides (NO x)
are so prevalent in combustion products.
Do you have any suggestions or simi-
lar experiences with fired heater/stack
casing cracking?

A: If the cracking is occurring in the

refractory-lined regions, wouldn’t
it be difficult for acidic gases or conden-
sates to penetrate through to the underly-
ing steel? I suggest contamination of the
refractory during fabrication is a possible
cause; this should be examined by com-
parative analysis. Are there other stack
casings or casing histories where this
type of cracking has not occurred?

A: I had a similar problem in the

Middle East. Most of the furnace
stacks in one refinery cracked. It was
blamed on nitrates, as I remember.

A: Would it be possible to insulate

the exterior of the stack to keep
the temperature of the steel above the
dew point and prevent condensation of
NO x?

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 13

MATERIAL MATTERS
Study Evaluates Chloride Limits for
Structural Reinforced Concrete
D
isintegrating and deteriorat-
ing concrete is a key issue for
structures worldwide. A
major contributing factor is
the presence of chloride ions in the con-
crete, which causes the reinforcing steel
inside to corrode. Recently, a research
project1 on chloride limits for reinforced
concrete was completed by the National
Ready Mixed Concrete Association
(NRMCA) (Silver Spring, Maryland) in
collaboration with NACE International
member Neal Berke, FNACE, vice presi-
14 SEPTEMBER 2017 MATERIALS PERFORMANCE
dent of Tourney Consulting Group, LLC
(Kalamazoo, Michigan). The research,
conducted at NRMCA and Tourney labo-
ratories, established a relationship
between the initial calculated total chlo-
ride content of the concrete’s constituents
and the measured water-soluble chloride
content in aged, hardened concrete.
According to the researchers, con-
crete’s highly alkaline environment pro-
tects the reinforcing steel from corro-
sion. When chlorides concentrate on the
steel reinforcement, however, its protec-
tive passive layer breaks down and corro-
sion starts. Rust forms, which takes up
more space than the original steel, and
causes the concrete cover to crack and
spall. While external chloride ions from
the environment (e.g., seawater and deic-
ing salts) migrate through concrete over
time and eventually reach the reinforcing
steel, internal chlorides that originate
from materials used to produce the
concrete are present when the concrete
is cast.
ACI 318-142 prescribes limits on inter-
nal water-soluble chlorides for concrete,
which are determined based on the
weight of Portland cement in the con-
crete. The reason for the chloride limits,
explains Karthik Obla, vice president,
technical services with NRMCA, is to pro-
tect the reinforcing steel against corro-
sion initiation. According to NRMCA, 3
corrosion initiates when the concentra-
tion of chlorides exceeds a threshold con-
centration at the reinforcing steel.
Although these chloride concentration
values can vary, they are typically in the
range of 0.05 to 0.1% of the weight of the
concrete—~2 to 4 lb/yd 3 (1.2 to 2.4 kg/ m 3),
or ~0.4 to 0.8% of the weight of cement
(based on the assumption of ~500 lb/yd 3
[297 kg/m3] of cement).
Chloride limits set by ACI 318-14 tar-
get various atmospheric exposures. For
exposure class C1—concrete that is
exposed to moisture but not to external
sources of chlorides—the maximum
internal water-soluble chloride ion con-
tent (by weight of cement) in concrete is
0.3% for reinforced concrete and 0.06% for
prestressed concrete. For exposure class
C2—concrete that is exposed to moisture
as well as an external source of chlo-
rides—the maximum internal water-solu-
ble chloride ion content is 0.15% for rein-
forced concrete and 0.06% for prestressed
concrete. Typical sources of water-soluble
chloride ions include water, aggregates,
NACE INTERNATIONAL: VOL. 56, NO. 9

For chloride testing, concrete samples are cast and then ground into powder. Photo courtesy of
Karthik Obla.
cementitious materials, and admixtures.
Obla notes that concrete producers
conduct a water-soluble chloride test (per
ASTM C1218 4) on concrete specimens
that have cured between 28 and 42 days
after casting to determine if concrete
mixtures used for buildings comply with
the ACI 318-14 chloride limit. If the test
results exceed the chloride limit criterion,
he says, the concrete producer must
adjust one or more of the ingredients in
the concrete mixture and then repeat the
test. If concrete has been poured prior to
the availability of the chloride test
results, the viability of the concrete
placed may be questionable.
Not all chlorides in concrete contrib-
ute to corrosion, says Berke. Some chlo-
rides are chemically bound in the cement
matrix and supplementary cementitious
materials and cannot be extracted by
water. This means they are not available
to cause corrosion of the reinforcing steel.
Some aggregates also contain chlorides
that are trapped and probably unavail-
able to cause corrosion. Water-soluble
chlorides, however, are not bound and
can move through the concrete’s capillary
NACE INTERNATIONAL: VOL. 56, NO. 9
Information on corrosion
control and prevention
pores. Between 50 and 75% of the total
chloride content in concrete is estimated
to be water soluble and a contributor to
reinforcing steel corrosion. 3
With an aim to reduce the time and
cost added to a concrete job for chloride
testing, the researchers implemented the
first phase of a project to evaluate chlo-
ride limits for reinforced concrete. In this
phase, the researchers worked to estab-
lish a relationship between the total
amount of chlorides in concrete calcu-
lated from the chloride levels in the indi-
vidual concrete constituents and the level
of chlorides measured by the ASTM C1218
water-soluble chloride test.
Berke explains that total chloride con-
tent in a concrete mixture can be estab-
lished when the mixture proportions are
being developed for a concrete building
project. The total chloride content is
determined based on measured chloride
content of the individual materials used
and the proportion of these materials in
the concrete mixture. NRMCA’s Technol-
ogy in Practice (TIP) 13 3 discusses
sources of internal chlorides and calcu-
Continued on page 16 Coating Thickness Material Analysis Microhardness Material Testing
MATERIALS PERFORMANCE SEPTEMBER 2017 15
MATERIAL MATTERS
Continued from page 15
lating chloride content in concrete from
the mixture ingredients.
The researchers propose that if the
initial calculated total chloride content is
less than the chloride limit specified by
ACI 318-14, then the water-soluble chlo-
ride level measurement for the hardened
concrete will be lower than the initial cal-
culated chloride total and comply with
the building code—and water-soluble
chloride testing may be avoided. If the ini-
tial calculated total chloride content
exceeds the specified limit, the concrete
producer can then adjust the proposed
concrete mixture up front to ensure code
requirements are met rather than deal
with out-of-spec water-soluble chloride
level test results during the project.
In the year-long study, the researchers
tested more than 500 samples of concrete
mixtures, says Obla. Concrete mixtures
included numerous combinations of
ASTM C1505 Type II and Type V Portland
16 SEPTEMBER 2017 MATERIALS PERFORMANCE
cement, Class C and Class F fly ash, silica
fume, and slag cement, with varying
water/cementitious material ratios and
aggregate types. Chloride in various dos-
ages was also added to the freshly mixed
concrete. The initial total chloride con-
tent was calculated for the samples and
then verified using the acid-soluble chlo-
ride content measurement method in
accordance with ASTM C1152. 6 The
water-soluble chlorides were measured
when the samples had aged between 28
and 42 days in accordance with ASTM
C1218, as required by ACI 318-14.
Study results showed that for most of
the mixtures, the ratio of the initial cal-
culated total chloride content and the
measured acid-soluble chloride was close
to 1.0, which indicated the calculated
total chloride content and the measured
total chloride content were reasonably
consistent. Also, the measured water-
soluble chloride content was less than the
initial calculated chloride content and
the measured acid-soluble chloride con-
tent for each mixture, and <60% of the ini-
tial calculated chloride content for mix-
tures that had no chlorides added. This
supports the researchers’ proposal that if
the initial calculated total chloride con-
tent of concrete mixtures is less than the
specified limits for water-soluble chloride
content in hardened concrete, then the
concrete mixture will comply with code
requirements for chloride limits. Added
time and project costs could be avoided if
the requirement for a water-soluble chlo-
ride content test could be waived.
This phase of the research work was
funded by the RMC Research & Education
Foundation and the ACI Concrete Foun-
dation. The complete report can be down-
loaded at www.nrmca.org/lab.
References
1 K. Obla, C. Lobo, R. Hong, N. Berke, “Evalua-
tion of Chloride Limits for Reinforced Con-
crete Phase A,” RMC Research & Education
Foundation, Project 14-01, July 2017.
2 ACI 318-14, “Building Code Requirements for
Structural Concrete and Commentary ”
(Farmington Hills, MI: ACI, 2014).
3 NRMCA TIP 13, “Chloride Limits in Con-
crete” (Silver Spring, MD: NRMCA).
4 ASTM C1218/C1218M-17, “Standard Test
Method for Water-Soluble Chloride in Mor-
tar and Concrete” (West Conshohocken, PA:
ASTM, 2017).
5 ASTM C150/C150M–17, “Standard Specifica-
tion for Portland Cement” (West Consho-
hocken, PA: ASTM International, 2017).
6 ASTM C1152/C1152M-04 (2012) e1, “Stan-
dard Test Method for Acid-Soluble Chloride
in Mortar and Concrete” (West Consho-
hocken, PA: ASTM International, 2012).
—K.R. Larsen
Read
MP Online
NACE International members have free
access to MP Online, with back issues to
2005.
Access the digital issues of MP at
www.materialsperformance.com/magazine.
NACE INTERNATIONAL: VOL. 56, NO. 9
 Information on corrosion control and prevention

Florida Tests Cathodic Protection Solutions

on High-Resistance Concrete

T he ease and practicality of installa-

tion were found to be key variables in
the success of new cathodic protection
(CP) techniques applied to high-resis-
tance concrete on bridges in marine
environments, according to a recent case
study implemented by the Florida Depart-
ment of Transportation (FDOT) (Gaines-
ville, Florida).
Historically, galvanic CP systems are
recognized as an optimal strategy to mit-
igate the corrosion of steel-reinforced
concrete in marine environments,
explains NACE International member
Ivan R. Lasa, FDOT’s steel material prod-
ucts administrator and co-author of a
paper1 on the study. However, to obtain
suitable performance, structures such as
bridges must be frequently exposed to
wet conditions containing significant
amounts of chloride. Galvanic CP gener-
ates direct current (DC) as a result of the
The Type 2 CP solution involving an outer jacket and an activated mortar/grout was installed and
electrical potential difference between
tested on various bridges along the Florida coastline. Photo courtesy of FDOT.
the steel being protected—the cathode—
and the other metal to be sacrificed—the
anode. Metals like zinc, aluminum, or
magnesium are used as the anode to pro-
vide the CP current and polarize the steel.
This process is “self-powered,” Lasa notes,
and requires little to no maintenance.
One of the limitations of that system is
the low driving voltage. In other words,
the resistivity of the concrete needs to be
low enough to allow distribution of the
current to the target area, Lasa explains.
For areas constantly exposed to water,
the system works well—as the continuous
chloride contamination keeps the anode
active and concrete resistance low. Corrosion of fasteners, used for the Type 1 CP system, was commonly found near the splash zone
But for drier concrete, the resistivity is on the marine bridges examined in the study. Photo courtesy of FDOT.

so high that typical galvanic anodes either

passivate or do not have a voltage poten-
tial sufficient to drive the CP current. In
turn, impressed current CP (ICCP) sys-
tems are often preferred in drier locations.
In this method, the current flow is forced
from an external power source. The costs
of monitoring and maintenance are sub-
stantially higher for ICCP systems than
with galvanic CP systems.
Bridges such as those along the
humid, subtropical Florida coastline
require solutions for both low- and high-
resistance concrete. Many parts of the
piers holding up each bridge are con-
stantly exposed to water, while other
parts of the structure are primarily dry.
Splash and tidal zone areas can be espe-
cially problematic, based on the presence
of alternate wetting and drying cycles.
While a combination of galvanic CP and
ICCP systems can work, Lasa’s team
believes the possible use of galvanic CP
on both wet and dry areas could signifi-
cantly increase efficiencies.
Continued on page 18

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 17

MATERIAL MATTERS
Continued from page 17

To address this, FDOT’s corrosion

research laboratory decided to experi-
ment with an expanded zinc mesh anode
integrated within a fiber-reinforced poly-
mer jacket. This system has been used for
many years, but until recently, its instal-
lation was limited to wet locations—
where the anode stays active due to con-
stant moisture. Knowing a new approach
was needed to protect the reinforcing
steel bar (rebar) in drier concrete with
higher resistance, FDOT’s scientists
experimented with two different modi-
fied galvanic CP systems that incorporate
zinc anodes encapsulated in an activated
mortar.
In their study, following adequate sur-
face preparation on five different bridges,
The anode wire from all panels for connection to the steel were housed in a PVC junction box
located outside the jacket. Photo courtesy of FDOT. two types of galvanic CP systems were
installed and evaluated. The first CP sys-
tem (Type 1) utilized a cement board
outer jacket with an expanded zinc mesh
anode installed in the inner face of the
jacket. The anode was then encapsulated
in an activated mortar/grout to provide
the contact between the anode and the
concrete surface. The jackets were
installed with the mortar/grout mixed
with a proprietary activator, which was
hand troweled onto the interior face of
the jacket panel and secured to the con-
crete surface with stainless steel fasten-
ers. Marine-grade paint was then applied
to the outside of the cement board after
installation.
Meanwhile, the second CP system
(Type 2) was comprised of a fiberglass
outer jacket shell and solid zinc bar
anodes encapsulated within an activated
mortar different from that of Type 1. The
jackets were mounted to the columns or
struts using compression bands, and the
voids between the jackets and concrete
surface were filled by pumping in a
cementitious grout.
In both systems, the anode-to-steel
connections were housed in a polyvinyl
chloride (PVC) junction box located out-
side the jacket, while potential monitor-
ing access ports were installed in each
jacket. Each potential measurement loca-
tion was marked so that future measure-
ments could be taken at the same loca-
tions to observe the polarization of the
rebar.

18 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9


The measurements were recorded at
various points on each bridge over the
last few years. While the precise results
showed some variance based on the exact
geometry, location, and condition of the
bridges, the second CP system showed the
most consistent success. On one particu-
lar bridge with the Type 2 CP system, the
footing steel directly beneath the jacket
was also protected from corrosion. That
additional protection extended up to 305
mm (12 in) away from the bottom of the
protective jacket onto the footing,
according to Mohammad Islam, co-
author and also a scientist with FDOT.
“Of the two systems installed, the
Type 2 system appears to be providing the
best CP polarization, whereas the Type 1
system is providing CP for less than 50%
of the areas covered,” Lasa says. “The
lesser performance of the Type 1 system is
attributed at this time to the poor bond
between the anode and the concrete sur-
faces, which impedes a uniform flow of
ATTENTION
ENGINEERS
Design guidelines
for water and wastewater
infrastructure
Download Specs
NACE INTERNATIONAL: VOL. 56, NO. 9
Information on corrosion control and prevention
the CP current.” According to Lasa, the
crucial variable is that the second system
can be installed via pumping—whereas
the first system requires hand troweling.
“Hand trowel requires more time for
application,” says Matthew Duncan, cor-
rosion mitigation technologist at FDOT
and a co-author of the paper. “When
applying the mortar by trowel, if the oper-
ation is not done fast enough, the mortar
first applied may have already started the
setting process when the panel is put in
place. In addition, if sufficient mortar is
not placed on the panel, there may be
voids at the anode-concrete interface
when the panels are placed against the
concrete.”
“On the other hand, pumping is faster
and it completely fills the annular space
between the anode and the concrete,”
Duncan adds.
Future system installations may
include a manufacturer’s representative
to oversee the initial installation, the
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FDOT team explains. At the moment,
FDOT says neither system is completely
ready for full-scale installation as a CP
standard on their bridges. However, sig-
nificant knowledge of each system’s per-
formance and an understanding of their
current distribution mechanisms on
high-resistance concrete were acquired
through the study.
“Additional testing and subsequent
modifications to each system to improve
performance is certainly promising,
along with the development of better
installation procedures,” Lasa says.
Reference
1 I.R. Lasa, M. Islam, M. Duncan, “Galvanic Ca-
thodic Protection for High Resistance Con-
crete in Marine Environments,” CORROSION
2017, paper no. 9700 (Houston, TX: NACE
International, 2017).
—Ben DuBose
Lift Stations
Pipe Systems
19
COMPANY NEWS
Redesigned Web Site for
Concrete Corrosion Inhibitors
The site offers tips to extend the life of concrete
structures. Photo courtesy of Cortec Corp.
A redesign of the Mitigating Corrosion
Inhibitors (MCI†) web site by corrosion
control technologies group Cortec® Corp.
(St. Paul, Minnesota) offers a fresh look at
extending the service life of concrete
structures. On the web site, the company
offers its products within a vastly
improved online user experience and con-
nects visitors to industry news, learning
resources, and more. Visitors can browse
newsletters, read the latest news releases
about the products, or watch videos on the
effects of corrosion and potential protec-
tion solutions—such as the company’s
inhibitors. These inhibitors can extend the
service life of new structures by proac-
tively delaying the onset of corrosion and
keeping rates low after initiation. In reha-
bilitation projects, the application of these
inhibitors can penetrate a considerable
distance to significantly reduce the corro-
sion rate by up to 80%. The products main-
tain structural integrity, rehabilitate vul-
nerable structures, and also alleviate
environmental concerns.
New R&D Hub in Spain for
Fire Protection Coatings
Hempel A/S (Lyngby, Denmark) is invest-
ing in a new research and development
(R&D) center focused solely on passive fire
protection (PFP) coatings. Located just
outside Barcelona, Spain, the center will
open in late 2018 and employ 35 experi-
enced technicians and scientists. The
investment demonstrates a commitment
†
Trade name.
20 SEPTEMBER 2017 MATERIALS PERFORMANCE
to further developing the range of fire pro-
tection coatings, as well as expanding a
global R&D network.
Applied to structural steel in large
buildings and industrial oil and gas instal-
lations, the PFP coatings expand to form
an insulating layer of carbon char when
exposed to high temperatures. This
enables the steel to maintain its load-bear-
ing capacity for up to four hours longer
during a fire, giving people time to escape
the building and for firefighters to extin-
guish the fire. The new R&D facility
focused on PFP coatings will enable the
company to further expand its PFP prod-
uct range, including the development of
PFP coatings for hydrocarbon fires—
which are encountered in the oil and gas
industry.
“Our 15 R&D centers around the globe
all work together as one organization to
ensure that our customers get best-in-
class solutions and technical support,
whether they are global, multinational, or
local,” says CEO Henrik Andersen. “PFP
coatings are a key element in our strategy,
and the new PFP-focused R&D center will
ensure we remain at the leading edge of
this important technological area.”
U.S. Navy Honors Projects
Designed to Prevent Aircraft
Corrosion
FRCSE scientists and engineers inspect a piece
of aircraft aluminum that will go through an
advanced anodizing line to receive a corrosion-
resistant coating. Photo by Clifford Davis,
U.S. Navy.
Scientists and engineers with the U.S.
Navy’s Fleet Readiness Center Southeast
(FRCSE) ( Jacksonville, Florida) were pre-
sented with the 2016 Delores M. Etter Top
Scientists and Engineers Award for a
series of projects, including two designed
to improve corrosion resistance in aircraft
parts. The award recognizes a group of
five, including lead materials engineer
Jack Benfer, senior chemist Ruben Prado,
engineer technician Rodney Williamson,
materials engineer Peter Sheridan and
chemical engineer Luzmarie Youngers.
Two of their accomplishments came in
the development of new methods to fight
corrosion, FRCSE explains, including an
advanced anodizing line aimed at provid-
ing better protection to aircraft alumi-
num. The team also introduced a new
zinc-nickel plating line for steel aircraft
components. The “active” coating works
by releasing electrons in the event a steel
part is scratched or nicked, to keep the
component from corroding. Parts outfit-
ted with the new coating are currently
deployed on a Navy aircraft carrier to
confirm its durability.
Distribution of Elastomeric
Polyurethane Coatings
Expands to Canada
Global paints and coatings group Akzo-
Nobel (Amsterdam, The Netherlands) has
extended the existing distribution agree-
ment for its Polibrid coatings to now
include Canada. The original worldwide
distribution pact was crafted in 2016. This
expanded agreement will enable access to
the coating range throughout North Amer-
ica as part of the company’s international
brand portfolio of protective coatings and
linings. The range includes high-build,
low-odor, two-component elastomeric
polyurethane lining options designed to
protect concrete and steel in severe
immersion environments, while also being
free of volatile organic compounds
(VOCs). Fast curing times, easy applica-
tion, and flexible, crack-resistant proper-
ties make the range ideal for use in corro-
sive wastewater treatment, potable water,
and other immersion applications such as
penstocks, dam gates, manholes, and pipe-
lines, where exposure to hydrogen sulfide
(H2S) and microbiologically influenced
corrosion (MIC) is prevalent.
NACE INTERNATIONAL: VOL. 56, NO. 9
Executive Vice President include managing the group’s oil and gas nearly $1 million in overall funding allo-
Named for Oil, Gas team in Atlanta, Georgia, and Houston, cated for more than 20 institutions and
Engineering Division Texas. The company’s team entails more educational programs across North Amer-
Architecture, than 80 engineers specializing in the oil ica. The foundation funds programs across
engineering, and gas division, which also includes the the continent each year, providing hands-
planning, and sectors of natural gas, midstream, fuel, on learning opportunities in areas from
construction corrosion control, and environmental ser- robotics and thermodynamics to design
group Pond & vices. Despite an overall downturn in the and materials development. Since 2001,
Co. (Peachtree oil and gas sector, the company notes that the foundation has advanced the auto
Corners, Geor- it recently opened two new offices in industry through grants to colleges and
gia) has named Houston. universities and by providing students
Lorraine A. with technology, tools, and experiences
Green as execu- Corrosion Control Group similar to that of the professional work-
Lorraine A. Green. Photo
tive vice presi- Issues Education Grants to place The proposal process for these edu-
courtesy of Pond & Co.
dent of its oil Develop Trade Workforce cation grants is by invite only, and all pro-
and gas division. Green has more than 30 The Denso North America Foundation posals are evaluated based on technical
years of experience providing engineering (DNAF) philanthropic arm of corrosion merit, student experience, and alignment
and environmental consulting services to protection group Denso North America with industry needs.
the industry, according to the company, (Houston, Texas) recently confirmed its
which adds that her responsibilities will 2017 college and university grants, with Continued on page 22

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NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 21

COMPANY NEWS
Continued from page 21
New Web Site for
Architectural Metal Coatings
PPG (Pittsburgh, Pennsylvania) has
launched a new web site for architectural
metal coatings that features a streamlined
appearance, intuitive navigation, and
enhanced access to popular coatings spec-
ification tools. Architects, specifiers, and
22 SEPTEMBER 2017 MATERIALS PERFORMANCE
product manufacturers will find the com-
pany’s product information organized by
coatings type—coil or extrusion—as well
as by finished end-use or performance
requirement. Coil coatings are searchable
by roofing, panel, and industrial applica-
tions, while extrusion coatings are sorted
according to industry standards for resi-
dential, light commercial, and high-per-
formance coatings. The site also hosts pro-
files and data sheets for nearly two dozen
of the company’s metal coatings. A “where
to buy” section links visitors to members
of the company’s certified applicator pro-
gram network, a select group of excep-
tional extrusion coatings applicators, as
well as a list of company-approved coil
coaters around the world. Additional con-
tent includes an automated sample
request system, project case studies, and a
project photo gallery.
Corrosion Inhibitor Chemical
Earns European Regulatory
Approval
Rivertop Renewables (Missoula, Montana)
announced that its sodium glucarate
chemical has achieved registration under
the European Chemical Agency’s (ECHA)
(Helsinki, Finland) Registration, Evalua-
tion, Authorization, and Restriction of
Chemicals (REACH) regulation. REACH
registration opens the door for the com-
mercial deployment of products derived
from sodium glucarate in markets across
Europe, including its Waterline CI and
Headwaters corrosion inhibitors.
The registration confirms the health
and safety characteristics of sodium gluca-
rate for manufacturers, customers, regula-
tors, and non-governmental organizations
in Europe. Sodium glucarate, based on
glucaric acid (C6H10O8), only recently
became available in commercial quanti-
ties due to Rivertop’s oxidation technology
that transforms simple plant sugars into
renewable chemicals. The company plans
to develop additional applications for
sodium glucarate in marine corrosion and
rust removal.
—Ben DuBose
MP welcomes submissions of
Company News. Please send photos
and information to Ben DuBose, NACE
International; tel: +1 281-228-6414;
email: ben.dubose@nace.org.
NACE INTERNATIONAL: VOL. 56, NO. 9
12 – 15 November 2017 | Sydney, Australia
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Paints and coatings company PPG
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Don’t let corrosion stop you vessels since its launch. Tel: +1 312-544-
7000, web site: www.akzonobel.com.
from getting here to there... Corrosion-Inhibiting
Packaging Boxes

Cortec® Corp. (St. Paul, Minnesota) intro-

We have the solution to help you duced custom-made CorrTainer boxes at

Protect those Assets! its coated products facility in Eau Claire,

Canadian Office: 780-447-1114
Email: sales@irtrectifier.com
U.S. Office: 918-805-7587
Website: www.irtrectifier.com
Wisconsin. These boxes incorporate
vapor-phase corrosion inhibitor (VCI)
films directly into the cardboard walls for
automatic corrosion protection of the
metal parts placed and sealed inside the
box. A state-of-the-art box-making

24 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 The Latest Tools for
Fighting Corrosion

machine allows the company to make any

quantity of boxes needed, and each box MP welcomes submissions of product press releases
can be custom designed to meet the cus- and photos for Product Showcase. Please send them
tomer’s exact size requirement. The VCI to the attention of Ben DuBose, NACE International;
molecules coated on the corrugated card- tel: +1 281-228-6414; email: ben.dubose@nace.org.
board evaporate and diffuse throughout
the enclosed box, forming a protective
layer on metal parts packaged inside. The
molecular layer protects the metal surface
from interacting with corrosive elements
such as moisture and oxygen that may be
present during shipping and storage. The
nontoxic boxes are free of nitrites, phos-
phates, silicates, or banned or restricted
substances, and they are fully recyclable
and repulpable after use. Tel: 1 800-426-
7832, web site: corteccoatedproducts.com.

Water-Resistant
Calcium Silicate

Global building products manufacturer

Johns Manville (Denver, Colorado)
released Thermo-1200, a water-resistant
calcium silicate (Ca₂SiO₄) in North Amer-
ica. The product will be globally available
and replace Thermo-12 Gold, the current
high-temperature Ca₂SiO₄ product avail-
able from the company’s industrial insula-
tion group (IIG). The new product offers
the same thermal performance and corro-
sion-inhibiting properties as its predeces-
sor, but it is now also resistant to water. “It
is engineered to give contractors a little
more breathing room during installation,
because water will be on the insulation’s
surface, rather than soak into the insula-
tion,” explains Jack Bittner, senior IIG
product manager. “This will allow con-
tractors a little extra time to jacket the
insulation during the installation process,
even in moderate rainfall.” Tel: +1 303-978-
2000, web site: www.jm.com.
Continued on page 26

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 25

PRODUCT SHOWCASE
Continued from page 25
PVC-Coated Sealing Locknut
The polyvinyl chloride (PVC) coated con-
duit division of Plasti-Bond (Gilmer,
Texas) released its new PVC-Coated Seal-
ing Locknut to protect conduit systems
against water, oils, and other liquids. The
primary function of a PVC-coated conduit
system is to maximize the life of the elec-
GET BETTER PERFORMANCE
FROM THERMAL INSULATION
ULTRA-LOW RESISTS CORROSION WORKSITE SAFETY
HEAT TRANSFER UNDER INSULATION & PROTECTION
AEROLON’S ADVANTAGES
STAND OUT FROM THE REST
Aerolon® thermal insulating coating from
Tnemec has raised the level of performance for
thermal insulation. Its innovative, fluid-applied
formulation features aerogel, the world’s best
insulating solid. Equally effective in both interior
and outdoor environments, Aerolon’s many
wide-ranging benefits make it the only viable,
all-in-one solution. For more information, please
visit tnemec.com/Aerolon.
26 SEPTEMBER 2017 MATERIALS PERFORMANCE
trical system it contains and to prevent
corrosion from sabotaging the system’s
structural integrity. One of the most com-
mon exposure areas are the threads of
conduit connections into outlet boxes,
conduit bodies, and other fittings. To pre-
vent thread exposure, the company devel-
oped a simple, detachable sleeve that pro-
CONDENSATION HIGHER BUILD &
CONTROL FASTER APPLICATION
vides a consistent seal over exposed
conduit threads at the point of connec-
tion. Other features of the patent-pending
locknut include a built-in gasket, extra-
thin construction, and a simple design to
allow for easy installation and tightening
over conduit threads at joints throughout
the system. Tel: +1 903-843-5591, web site:
www.plastibond.com.
Portable Flaw Detector
for Difficult Inspections
Nondestructive testing (NDT) technolo-
gies group Olympus (Waltham, Massachu-
setts) announced the launch of its EPOCH
6LT flaw detector, designed to meet the
requirements of challenging ultrasonic
inspections. Optimized for single-handed
operation, the flaw detector combines an
ergonomic design with powerful ultra-
sonic functionality in an instrument built
for rope access and high portability appli-
cations, such as inspections of offshore oil
platforms, in-service wind turbines, avia-
tion, bridges, and structural steel. Addi-
tional key features include hands-free
operation; easy navigation; a strong resis-
tance to dust, water, and drops; optional
Wi-Fi connectivity; and corrosion soft-
ware that combines the ease of use of a
thickness gauge with the flexibility of a
flaw detector. “With a simple workflow,
technicians can spend more time on their
inspection and less time adjusting the
instrument,” the company says. “For
added efficiency, users can control the
NACE INTERNATIONAL: VOL. 56, NO. 9
 The Latest Tools for Fighting Corrosion

inspection parameters without interrupt-
ing flaw scanning.” Tel: +1 781-419-3900,
web site: www.olympus-ims.com.
Lightweight Lenses
for Face, Eye Protection
provides a fully automated Persoz or
König pendulum hardness test with no
human intervention. Users simply fit the
pendulum onto the loading pins, load the
sample, and close the door. The pendulum
automatically moves to the start position,
the sample table rises, and the test begins.
A sturdy, dustproof, and robust design
ensures a stable environment for the tests,
which leads to repeatable and consistent
results. The tester is controlled via a sim-
ple, menu-driven operation available in
multiple languages, and a batch memory
feature stores all of the testing data for
output to a computer. Tel: +44 (0)161 371
6000, web site: www.elcometer.com.

New lightweight Browguard lenses from

Allegro (Piedmont, South Carolina) pro-
vide full face and eye protection against
spatters, small particles, and nonhazard-
ous liquids. The product features a sleek
wraparound design that can be worn
comfortably with impact-resistant safety
glasses. The polycarbonate lenses are
available in clear, dark green, IR3, and IR5
models. The lenses, which do not yellow
over time, are an ideal fit for many jobs
and can provide protection in the event a
grinding wheel breaks off—or if particles
fly in a user’s direction. Meanwhile, a
hardhat adapter allows users to connect
the lens to a hardhat with flip-up move-
ment and functionality. Tel: 1 800-622-
3530, web site: www.allegrosafety.com.

Automated Pendulum
Hardness Testing for
Coatings
The new 3045
Pendulum
Hardness
Tester from
Elcometer
(Manchester,
United King-
dom) is aim-
ing to make
the measure-
ment of coat-
ing hardness
more accurate, repeatable, and reproduc-
ible than ever before. Using infrared tech-
nology, the adjustable Elcometer 3045

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 27

FEATURE ARTICLE
Protecting Concrete
Infrastructure from
Corrosion
Corrosion of Steel in Concrete Can Be
Accelerated in Harsh Environments—Such
as Coastal, Tropical, or Desert—with High
Salt Levels and/or Extreme Temperatures
Wesley Fawaz, Executive Officer, Australasian Corrosion Association
C
Corrosion continues to impose a massive cost on as-
set owners and industry. NACE International reports
the global cost of corrosion is estimated to be US$2.5
trillion, which is equivalent to 3.4% of the global
gross domestic product (as reported in 2016). By
using available corrosion control practices, it is esti-
mated that savings of between 15 and 35% of the cost
of corrosion could be realized (i.e., between US$375
and $875 billion annually) on a global basis.1
As concrete infrastructure ages, owners and oper-
ators are being challenged to find better ways to
maintain the integrity of their assets. Factors that
need to be considered include how long the asset is
expected to remain in operation and if a shorter ser-
vice life is acceptable if maintenance must be fre-
quently repeated. Corrosion prevention needs to be
cost effective as well as practical.
Monitoring the impact of corrosion on concrete
infrastructure such as storage sheds, wharves, and
bridges is a critical aspect of ensuring structural
integrity and durability performance. A key way to
minimize corrosion is to design for durability and
employ the most appropriate technologies and pre-
vention techniques available.
Corrosion of concrete-reinforcing steel is a world-
wide problem that causes a range of economic, aes-
thetic, and utilization issues. Asset owners and
28 SEPTEMBER 2017 MATERIALS PERFORMANCE
managers who operate and maintain concrete infra-
structure face different corrosion challenges depend-
ing on the industry sector in which they operate. The
concrete degradation in the football pitch-size stor-
age sheds operated by Queensland Sugar Limited
(QSL) (Brisbane, Queensland, Australia) differs from
that of the bridges maintained by VicRoads (Kew,
Victoria, Australia).
Harsh environments—especially coastal, tropical,
or desert with high salt levels and/or extreme temper-
atures—can accelerate the rate of corrosion of steel in
concrete. Usually the most exposed elements deterio-
rate first, although it can take from five to 15 years for
the effects of reinforcing steel corrosion to become
visibly noticeable.
Alkaline (high pH) conditions in concrete form a
passive film on the surface of the steel reinforcing
bars that prevents or minimizes corrosion. The pas-
sivity provided to steel reinforcement by the alkaline
environment of concrete may be lost if the pH of the
concrete pore solution falls because of carbonation or
if aggressive ions such as chlorides penetrate the con-
crete in sufficient concentration to reach the steel
reinforcement surface. Carbonation of concrete
occurs as a result of atmospheric carbon dioxide
(CO2), atmospheric sulfur oxide (SOx), and nitrogen
oxide (NOx) gases neutralizing the concrete pore
NACE INTERNATIONAL: VOL. 56, NO. 9
Monitoring concrete structures such as bridges, jetties, and piers in Australia’s coastal environments detects conditions such as chloride ingress that can speed up
corrosion of reinforcing steel.

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 29

FEATURE ARTICLE
Raw sugar is poured onto the concrete floor of
a QSL bulk sugar storage shed. Photo
courtesy of ACA.
water (lowering its pH to 9) and thereby
destroying the passive film. Leaching of cal-
cium hydroxide [Ca(OH)2] as well as
sodium hydroxide (NaOH) and potassium
hydroxide (KOH) from concrete also lowers
pH to cause corrosion of steel reinforce-
ment. Stray electrical currents, most com-
monly from electrified traction systems,
can also break down the passive film and
cause corrosion of steel-reinforced and pre-
stressed concrete elements.
As reinforcing bars rust, the corrosion
products increase the volume of the steel—
up to six times its original size—and put
increasing pressure on the surrounding
material, which slowly cracks the concrete.
Over the course of several years, the cracks
eventually appear on the surface and the
concrete starts to flake off or spall.
Inspections of the many concrete cul-
verts and low road bridges along the hun-
dreds of kilometers of country highways
in Australia have shown that their effec-
tive operational life is being reduced as
the size of interstate road trucks
increases. Many structures were designed
for vehicles half the size and weight of
modern trucks. Fred Andrews-Phaedonos,
principal engineer—concrete technology
at VicRoads, says the government road
authority has a range of assets throughout
30 SEPTEMBER 2017 MATERIALS PERFORMANCE
the state that face degradation from a
range of sources.
“Current estimates suggest that a pro-
portion of Australia’s bridges are structur-
ally or functionally deficient and require
major rehabilitation, strengthening,
improvement, or replacement to bring
them to current design standards,”
Andrews-Phaedonos says. “The iconic West
Gate Bridge carries massive loads in addi-
tion to being subject to high winds and salt
spray,” he adds.
QSL operates and maintains a range of
assets, the major ones being its storage
sheds and wharves where raw sugar is
loaded onto ships. According to David
Edelman, project engineer at QSL, the com-
pany’s massive storage sheds—some of
which are 45-m (148-ft) wide and 400-m
(1,312-ft) long—also face a slow-acting but
pervasive threat.
“Sugar makes a mildly acidic solution
that can slowly eat away at the concrete
floors and walls of the sheds,” Edelman
says. “This damage leads to a potholed,
uneven surface and breaking of the con-
crete at joints, which adds to the difficulty
of washing the floors in addition to present-
ing hazards to workers. The sugar forms a
sticky, unsafe coating that builds up over
time and makes work inside the sheds diffi-
cult, meaning the floors have to be washed
periodically.”
To minimize the damage caused by the
sugar attack, the walls and floors of the
company’s storage sheds are coated with a
sealer. Deeper holes and cracks are filled
with epoxy, and joints are maintained to
prevent sugar attacking deeper into the
slabs. In addition to this chemical attack,
the continual operation of large, front-end
loaders moving hundreds of thousands of
tons of raw sugar through the sheds and
onto conveyor belts and ship loaders dam-
ages the concrete surfaces.
Similar to VicRoads’ coastal concrete
structures, QSL’s port assets also degrade in
the aggressive maritime environment. For
QSL, this is exacerbated by its location in
the tropics as well. The wharves and associ-
ated infrastructure at Lucinda, Bundaberg,
and Cairns in Queensland are all under
threat of chloride attack in addition to
damage from tropical storms and cyclones.
“Correct interpretation of observations
and testing is essential to a correct diagno-
sis and prognosis of the problem, and thus
enable appropriate corrective measures to
be taken,” Andrews-Phaedonos says.
The traditional method of concrete
repair is to remove the cracked, delami-
nated, and spalling concrete to a depth of
20 to 30 mm behind the reinforcing bars to
fully expose the rusted material and remove
the contaminated concrete from the steel.
Once the corrosion-affected material is
taken out, the steel is either treated or
replaced and then special concrete repair
mortars are applied and the surface refin-
ished. Polymer-modified repair mortars are
a modern development that improves
adhesion and resists further ingress of con-
taminants. Coatings are commonly used in
combination with patch repairs to reduce
further entry of chlorides or CO2.
“Without a proactive
approach, the first sign of a
problem with a structure is
typically when a piece of
concrete falls off due
to corrosion.”
Edelman comments that when the QSL
jetty at Lucinda was built, an alkali-silica
reaction later developed, which caused
concrete cracking. Chlorides then pene-
trated the concrete and caused premature
corrosion of the reinforcing steel on parts of
the structure. Where parts of the structure
were highly exposed, this corrosion caused
extensive damage and elements had to be
repaired or replaced. However, in large sec-
tions of the jetty structure, the chlorides in
the concrete have not yet reached a concen-
tration where corrosion is initiated.
“The chloride concentrations have been
monitored over many years and they are
slowly increasing,” Edelman says. To coun-
ter this, QSL started applying an impregnat-
ing silane coating to the underside of the
5.7-km (3.5-mi) long jetty to prevent further
ingress of chlorides. “By putting this rela-
tively inexpensive protection in place now,
we can extend the life of the structure,”
states Edelman. “If we wait another 10 or
15 years, the chlorides levels will have
increased, corrosion will have started, and
it will be too late. The square-meter cost of
a simple protective coating like silane is as
little as one hundredth of the cost of a con-
NACE INTERNATIONAL: VOL. 56, NO. 9

Installation of the CP system at QSL’s Lucinda wharf includes drilling holes in the concrete (left) and inserting anodes (right). Photos courtesy of ACA.
crete patch repair, but it is only effective
before corrosion starts.”
Monitoring chloride levels through core
sample testing allows a proactive approach.
All asset managers should know the chlo-
ride and carbonation profile of their con-
crete, particularly if that concrete is aging
and located in coastal environments.
“Without a proactive approach, the first
sign of a problem with a structure is typi-
cally when a piece of concrete falls off due
to corrosion,” says Edelman. “At that point
it may be too late for a coating to protect
the remainder of the structure, and you
may be up for some very large repair bills.”
Several of QSL’s assets have experienced
significant corrosion and spalling of con-
crete over the years due to chloride ingress.
Traditional patch repair has been used,
with replacement of corroded reinforce-
ment in many cases, but results have been
inconsistent. “We have some patch repairs
that are pushing 30-years old and remain in
great condition,” Edelman says, “but others
NACE INTERNATIONAL: VOL. 56, NO. 9
Protecting Concrete Infrastructure from Corrosion
are beginning to crack and fail after less
than 10 years.” One of the limitations of
patch repair is that it is often necessary to
remove large quantities of sound concrete
to solve the problem, which causes exten-
sive disruption and can cost ~$3,000/m2.
One of the alternative methods of pro-
tection used on concrete, especially in
marine environments, is cathodic protec-
tion (CP). One type, impressed current CP
(ICCP), mitigates corrosion by passing a
small, permanent current through the con-
crete to the reinforcing steel. Electrical
cabling and a permanent direct current
(DC) power supply are required. Anodes are
inserted into the concrete at set spacing
and electrically attached to the positive ter-
minal of a DC power supply (transformer/
rectifier). The negative terminal is electri-
cally connected to the reinforcing steel. The
CP current passivates the steel reinforce-
ment and restores an alkaline (high pH)
environment in the concrete around the
steel reinforcement. Well-designed CP sys-
MATERIALS PERFORMANCE SEPTEMBER 2017
tems with proper installation can achieve a
30-year or longer operational life.
One of the QSL conveyor tunnels has an
ICCP system installed, and the company is
preparing to add the technology to a sec-
tion of the Lucinda jetty that is subject to
near-constant wetting from waves. “In this
section, chlorides have reached a level
where corrosion has begun and some spall-
ing has occurred,” Edelman states.
“Cathodic protection is a more cost-effec-
tive option compared to allowing the corro-
sion to continue and having to carry out
constant repairs.” He adds that there will be
long-term cost savings that help with the
total annual spend for concrete repair and
protection, which is ~$1 million across the
six terminals.
During the past 30 years, much
research has been done on replacing some
of the Portland cement used in concrete
with alternative binders such as fly ash,
blast furnace slag, silica fume, polymers,
recycled car tires, and fibers. One area of
31
FEATURE ARTICLE
research is in the field of geopolymer con-
crete that utilizes alkali-activated binding
agents. Some of this research has been
published through the Australasian Corro-
sion Association, Inc. (ACA) (Kerrimuir,
Victoria, Australia). Fly ash is a by-product
from burning coal at a power station, and
incorporating fibers into a concrete mix is
similar to the old practice of adding horse
hair to wet plaster.
The enhanced characteristics of fiber-
reinforced polymer (FRP) concrete include
increased flexural and shear capacity of
beams and slabs, says Andrews-Phaedonos.
FRP concrete is now regularly specified by
VicRoads for repairing and strengthening
works. “The material is thinner, lighter,
noncorrosive, and easier and quicker to
install,” he comments. “It also has increased
axial load, bending, shear, and confinement
capacities.”
Research into concrete additives has
provided construction companies and engi-
neering consultancies with access to infor-
NACE NEW ORLEANS SECTION
19TH ANNUAL EDUCATION WEEK
DECEMBER 4-9, 2017 • NEW ORLEANS AIRPORT HILTON
nace.org/nolaedu to register for NACE Section Local Courses
NACE NEW ORLEANS SECTION COURSES DATES
Corrosion in Oil and Gas Production (COG) December 4-6
Corrosion Under Insulation (CUI) December 4-6
Rectifier School (RS) December 4-5
Oilfield Operator Chemical School (OOCS) December 7-8
GENERAL NACE EDUCATION COURSES DATES
Basic Corrosion (BC) December 4-8
Designing For Corrosion Control (DCC) December 4-8
Corrosion in Refining Industry (CCRI) December 4-8
Protective Coatings Specialist (PCS-1 BASIC) December 4-6
Protective Coatings Specialist (PCS-2
December 7-9
ADVANCED)
Students are responsible for hotel reservations. Contact the New Orleans Airport Hilton at
+1 504-469-5000 or 1 800-445-8667 and ask for the NACE Event Rate Code: NAC. Room rate is $133/night.
For pricing and to register for NACE General Education
courses, go to nace.org/nolacourses
For information about New Orleans Section Events,
go to nace.org/nola
32 SEPTEMBER 2017 MATERIALS PERFORMANCE
mation on all the latest technologies that
yield a suite of proactive and reactive pro-
cesses and procedures to maximize the
effectiveness of reinforced and prestressed
concrete. “If you have all the appropriate
specialists involved at the design stage, it is
very possible to have a design life of 100
years or more,” says NACE International
member Warren Green, a partner and cor-
rosion engineer at Vinsi Partners Consult-
ing Engineers (North Ryde, New South Scaffolding for concrete repair works is
Wales, Australia). erected around a mooring dolphin at QSL’s
Cairns bulk sugar terminal. Photo courtesy of
By incorporating the byproducts of
ACA.
other processes into the concrete mix, it
has been possible for different types of con-
crete to qualify for “Green Star” credits—an stressed concrete panels, under factory
internationally known sustainability rating conditions, permits a far greater degree of
system that recognizes reductions in green- quality control. “Advances in admixtures
house gas emissions, resource use, and means that we can build almost anything
waste. In addition to new materials being out of concrete these days,” Green notes.
incorporated into the concrete mix, other “The Australian standards for concrete
additives have created self-compacting and work give basic guidance for normal situa-
self-leveling concrete that can save both tions, but in aggressive environments such
time and cost. Off-site construction of pre- as tropical, coastal, acid-sulfate soils, etc.,
a structure will not necessarily achieve its
design life if simply designed and con-
structed to comply with the standards,”
says Green. To complement the standards
(e.g., AS 51002) and support designing for
maximum durability in specific situations,
the Concrete Institute of Australia (North
Sydney, New South Wales, Australia) is
developing a range of recommended prac-
tice guidelines. “VicRoads was the first
PRICE INSTRUCTOR
state road authority in Australia to publish
$400 Charlie Speed, Consultant standard specifications for concrete main-
$500 Peter Bock, CUI Consultant tenance work and has made a significant
contribution to the preparation of stan-
$250 Jim Bradford, Corrpro
dards such as 5100, Part 8,” adds
$300 Charlie Speed & 15 Other Experts Andrews-Phaedonos.
The ACA is a membership association
PRICE NACE CERTIFIED INSTRUCTORS
that works with industry and academia to
Raul Castillo P.E. research and disseminate information on
For pricing
and to register Jerry Byrd corrosion and its prevention through the pro-
for these vision of training courses, seminars, confer-
NACE General Ray Quinter
Education ences, publications, and other activities.
courses, go to Kat Coronado For more information, visit membership.
nace.org/ corrosion.com.au.
nolacourses
Kat Coronado
References
1 G. Koch, et al., “International Measures of
Prevention, Application, and Economics of
Corrosion Technologies Study,” NACE Inter-
For questions, call Charlie Speed at +1 504-400-7878
national, March 1, 2016.
2 AS(/NZS) 5100:2017 Series, “Bridge design”
(Sydney, NSW, Australia: Standards Australia,
INTERNATIONAL
2017).
NACE INTERNATIONAL: VOL. 56, NO. 9
Resources from NACE, the Worldwide Corrosion Authority®

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CATHODIC PROTECTION
Coupons for Cathodic
Protection Evaluation of
Mixed-Metal Piping Systems
Douglas E. gilroy, Bechtel Oil, Gas and
Chemicals, Inc., Houston, Texas, USA
A
34 SEPTEMBER 2017 MATERIALS PERFORMANCE
The measurement and interpretation
of cathodic protection (CP) data in
plants or other complex facilities
present inherent challenges where
mixed metals are electrically continu-
ous within the protected structures’
CP system. Often there is no attempt
to electrically isolate the buried steel
piping networks from other metals in
the facility for safety and practical
considerations. Coupons can be used
to assist in the evaluation of CP levels
on buried steel piping in mixed-metal
circuits; however, the present industry
practice of disconnecting the coupon
from the mixed-metal circuit to mea-
sure the potential and polarization,
without other considerations, raises
concerns because the instant discon-
nect condition may not be a true rep-
resentation of the protection status.
Although coupon usage has long been
recognized as a valuable tool for evaluating
cathodic protection (CP) conditions on
buried piping systems, their use in plants
and other complex facilities can increase
confusion and raise additional questions
on the CP status. Plant facilities frequently
include extensive buried networks of bare
conductors, including copper, steel-in-
concrete, mixed-metal circuits, different
fill materials, and protected buried struc-
tures that are within the influence of closely
coupled impressed current anodes. These
and other factors present inherent
challenges with regard to CP measure-
ments and the interpretation of data.
Depending on the complexity and
nature of the facility and equipment, estab-
lishing and maintaining electrical isolation
can be impractical on networks of steel pip-
ing systems within plants. Safety and prac-
tical considerations are the key reasons for
avoiding electrical isolation devices in clas-
sified areas, including the possibility for
arcing, reducing touch voltage hazards,
and minimizing the propensity for CP
downtime, since the failure of a single iso-
lation device in a system can result in com-
plete loss of protection. In critical double
containment piping systems, where fabri-
cation requires 100% welded construction,
mechanical fittings often are not permit-
ted. In these situations, the CP system is
designed to account for the mixed-metal
circuit, often using closely coupled
impressed current anodes that are distrib-
uted throughout the piping network.
When coupons are used in this type of
system, the coupon is also within the zone
of influence of the anode gradients. Cou-
pon size and placement are critical for col-
lecting meaningful data. The coupon size is
selected to match the surface area of a typi-
cal coating holiday that is anticipated at a
specific location, and proper coupon place-
ment can reduce voltage drop errors. It is
also important that the coupon be exposed
NACE INTERNATIONAL: VOL. 56, NO. 9
to the same local environment (including
any select fill or controlled density fill) that
is in contact with the pipe steel at coating
holiday(s). Accordingly, it is essential to
collect data at sufficient locations so they
are representative of conditions through-
out the facility.
Coupons are commonly used when the
CP current sources cannot be interrupted;
thus, the “current applied—coupon discon-
nected” (Vc-a-d) is frequently the accepted
measurement. However, the voltage drop
(sometimes called IR drop) in the measure-
ment can be significant when the coupon is
located within the gradient of closely cou-
pled anode systems. Further, the discon-
nected coupon potential may not be repre-
sentative of the normal piping condition in
a mixed-metal circuit. When it is possible
to interrupt the impressed current CP
sources for buried piping, coupon “on” and
“off ” potentials can be measured while con-
nected and disconnected.
The literature on coupons is extensive;
however, many questions arise on their
proper use when evaluating the CP status
of buried piping in a mixed-metal circuit:
• Is the coupon instant-disconnect
potential measurement an accurate
representation?
• How can the 100 mV polarization CP
criterion be used to satisfy NACE
International SP0169-2013?1
• Is it appropriate to leave the CP sys-
tem energized during the coupon
instant-disconnect potential mea-
surement?
• How can coupon current measure-
ments be used to evaluate CP status?
• Are other CP criteria appropriate for
the location?
Instant-Disconnect
Potential Measurements
NACE SP0104-2014,2 Section 3.11, dis-
cusses the use of coupons in complex pip-
ing environments where mixed metals are
electrically continuous with the protected
piping. NACE Publication 35201 3 also
addresses the use of coupons in detail, stat-
ing that the application of polarized poten-
tial or polarization criteria is not always
NACE INTERNATIONAL: VOL. 56, NO. 9
FIGURE 1 Coupon-to-soil potentials (vs. CSE) in a mixed-metal circuit.
technically correct, and during current
interruption, secondary voltage drops from
circulating galvanic currents can cause
errors in the measurements on structures
with characteristic potentials that can vary
widely. A suggested approach is to acquire
these measurements while locally discon-
necting the coupon from the structure. The
question remains whether the discon-
nected coupon’s potential measurement is
a true representation of the actual mixed-
metal circuit condition.
Simultaneous interruption of all con-
nections between the carbon steel (CS)
piping and the bare copper grounding con-
ductors (not a realistic concept) would not
be a valid representation of the CS piping
condition when in the mixed-metal circuit.
The pipe-to-soil potential would be
expected to become more negative when
the more noble metal (i.e., copper) is dis-
connected. Depending on the level of
polarization of the mixed-metal circuit,
similar behavior can be seen on a coupon
when it is disconnected.
Figure 1 is a plot of coupon-to-soil
potentials in a mixed-metal circuit that
includes bare copper grounding conduc-
tors and a closely coupled anode system.
These potentials were measured with the
rectifiers cycling on and off, and with the
coupon connected and disconnected dur-
MATERIALS PERFORMANCE SEPTEMBER 2017
ing the cycle. It includes four coupon-to-
electrolyte potentials, as described in
NACE SP0104-2014:
• Current applied—coupon connected
(Vc-a-c)
• Current applied—coupon discon-
nected (Vc-a-d)
• Current interrupted—coupon con-
nected (Vc-i-c)
• Current interrupted—coupon dis-
connected (Vc-i-d)
As shown in Figure 1, the potential of a
CS coupon can become more negative
when it is disconnected from CS piping
that remains connected to bare copper.
When this behavior is observed, it suggests
a greater accuracy concern as compared to
the impact of secondary voltage drops from
circulating currents during CP current
interruption. The Vc-i-c potential repre-
sents the coupon’s mixed-metal circuit
polarized potential and is considered to be
a necessary measurement for CP evalua-
tion. The current applied and interrupted
instant-disconnect potentials are also con-
sidered to be required measurements. The
native and disconnected depolarized
potentials are also important.
100 mV Criterion
In complex facilities, the use of alter-
nate protection criteria may be advanta-
35
CATHODIC PROTECTION
geous, including the 100 mV polarization
criterion. Correct interpretation in mixed-
metal circuits, however, is critical. Simply
measuring depolarization from the mixed-
metal polarized potential could result in an
improper conclusion that CP is effective if
this is 100 mV or more. Would this indicate
protection if the mixed-metal polarized
potential is more positive than the open-
circuit potential (OCP) of the CS pipe? For
example, if the mixed-metal polarized
potential is –450 mV vs. a copper/copper
sulfate reference electrode (CSE) and the
mixed-metal depolarized potential is –350
mV vs. CSE, can it be concluded that the CS
is protected if its OCP is more negative
than –450 mV vs. CSE?4
NACE SP0169-2013, Section 6.3.4, states,
“In mixed-metal piping systems, CP can be
typically achieved at a polarized potential
that is 100 mV more negative than the OCP
of the most active metal.” Coupons can be
used to meet the intent of this standard by
showing that the coupon’s mixed-metal
polarized potential is 100 mV more negative
than the OCP of the coupon.
NACE/ASTM G193-12D5 defines OCP as
the corrosion potential—the potential of a
corroding surface in an electrolyte mea-
sured under open-circuit conditions rela-
tive to a reference electrode (also known as
electrochemical corrosion potential, free
corrosion potential, and OCP). Typically,
native potentials are not measured on bur-
ied steel piping in plants prior to mechani-
cal completion. Where electrical isolation
is not established, native potentials mea-
sured after mechanical completion and
prior to applying CP are representative of
the mixed-metal native state and are not
considered to be the OCP of the most active
metal. However, a native potential on a
coupon can be measured before it is con-
nected to the mixed-metal circuit (after
sufficient aging and before initial CP is
applied). Upon the application of CP, this
measurement provides a baseline to refer-
ence the degree of cathodic polarization of
the mixed-metal circuit.
After CP has been applied, the depolar-
ized potential often differs from the initial
native coupon potential. Subsequent evalu-
ations can identify whether the discon-
nected coupon depolarizes 100 mV or more
positive than the coupon’s mixed-metal
36 SEPTEMBER 2017 MATERIALS PERFORMANCE
polarized potential; or, by allowing the cou-
pon to fully depolarize, reestablish its OCP
for comparison to the coupon’s mixed-
metal polarized potential. If the fully depo-
larized disconnected coupon potential is
desired, the CP system may have to be de-
energized for a prolonged time period
where coupons are in the zone of influence
of closely coupled anodes. The CP system
for CS piping in mixed-metallic circuits as
described here should continue to be ener-
gized to the greatest extent possible to
avoid accelerated corrosion at coating
defects on the piping because of the gal-
vanic couple to a massive cathode (i.e., bare
copper grounding network).
Voltage Drop
The reference electrode should be
located as close to the coupon as is practi-
cal, as described in NACE SP0104-2014, to
minimize voltage drop error in the poten-
tial measurements. A coupon within the
zone of influence of an energized anode, as
is the case with closely coupled anodes, can
show influence from the CP system regard-
less of whether the coupon is connected or
disconnected. SP0104-2014 recognizes that
current-applied coupon potential measure-
ments can include voltage drop error. In
this standard, “Appendix D, Coupon IR-
Drop Calculation Procedure” provides a
method to identify voltage drop error.
The most common measurements are
Vc-a-c and Vc-a-d. According to NACE
SP0104-2014, in mixed-metal circuits, and
where the voltage drop may be significant,
Vc-i-c and Vc-i-d also should be measured.
The difference between Vc-a-d and Vc-i-d is
the coupon voltage drop (Vc-IR).
Potential Measurement
Evaluation
In Figure 1, Vc-a-d and Vc-i-d are more
negative than the Vc-i-c (i.e., the mixed-
metal polarized potential). In this case,
Vc-i-d is 277 mV more negative than Vc-i-c
and, therefore, not considered an accurate
representation of the CS condition in the
mixed-metal circuit. The same concern
applies for the Vc-a-d measurement. Vc-IR
is ~–50 mV, which represents the voltage
drop error in the Vc-a-d measurement.
In Figure 1, Vc-i-c satisfies the polarized
–850 mV CP criterion. However, if Vc-i-c
was more positive than –850 mV vs. CSE,
the 100 mV criterion can be evaluated by
comparing Vc-i-c to the OCP of the coupon.
The coupon’s native potential that was
established before it was connected to the
mixed-metal circuit can be referenced as
the OCP for evaluating the degree of polar-
ization during the initial application of CP.
While this value also could be used for sub-
sequent evaluations in the mixed-metal
circuit case, it is recognized that the depo-
larized potential can differ from the native
potential after CP has been applied. Using
the native potential is usually preferable to
de-energizing the CP system for a long
duration that is sometimes necessary to
measure the fully depolarized potential.
Coupon Current
A shunt with a known resistance can be
installed in series with a coupon to deter-
mine the current magnitude and direction.
With the CP system energized, direct cur-
rent (DC) pickup can provide an important
indication of CP effectiveness at that loca-
tion. Protective current density can be esti-
mated from the surface area of the coupon,
however, in mixed-metal circuits with the
attempt to satisfy the –850 mV CSE polar-
ized criterion, the observed current densi-
ties can be orders of magnitude greater
than typical design CP current densities for
bare CS. Current discharge from a coupon
is an indication that protection is lacking
and corrosion may be occurring at that
location.
An indication of current pickup during
the “off ” portion of the rectifier cycle does
not necessarily imply that CP is effective, as
circulating currents can imply corrosion on
the piping at other locations. Currents mea-
sured during the off cycle also confirm the
caution in NACE SP0104-2014. The differ-
ence between the “on” and “off ” mV drops
across the shunt determines the net current
on the coupon. The polarities are important
to note in these measurements, as they indi-
cate the direction of current flow.
Conclusions
Coupon size, placement, and environ-
ment must be carefully considered to pro-
vide data that are representative of struc-
tural conditions at a variety of locations
throughout a facility.
NACE INTERNATIONAL: VOL. 56, NO. 9
 Coupons for Cathodic Protection Evaluation of Mixed-Metal Piping Systems

Editor’s note: Learn more about cathodic

In mixed-metal circuits, the coupon’s
instant-disconnect potential alone might
not be representative of the actual mixed-
metal condition.
The Vc-i-c potential is considered a
required measurement to evaluate protec-
tion status in mixed-metal circuits.
Measurements should be obtained with
the coupon connected and disconnected,
and with th e current applied and
interrupted.
Voltage drops can be present in the
Vc-a-d measurements, especially in the
case of closely coupled anode systems that
are common in plants.
The 100 mV CP criterion in mixed-
metal circuits, referenced from the Vc-i-c
potential and the OCP of the CP coupon,
meets the intent of NACE SP0169-2013,
Section 6.3.4.
CP response can differ in soils vs. areas
backfilled with controlled density fill where
longer polarization and depolarization
durations may be observed.
CP current pickup during the Vc-a-c
condition can suggest effective protection
at that location, assuming no sources of
foreign interference currents are present.
Coupons should be allowed to age until
stable native potentials have been estab-
lished. Coupons should not be connected
to the mixed-metal circuit until their
native potential is established, and then
only when the CP system is ready to be
energized.
4 W.B. Holtsbaum, “Application and Misappli-
cation of the 100 mV Criterion for Cathodic
Protection,” MP 42, 1 (2003): p. 30.
5 NACE/ASTM G193-12D, “Standard Termi-
nology and Acronyms Relating to Corrosion”
(Houston, TX: NACE, 2013).
This article is based on CORROSION 2017
paper no. 8824, presented in New Orleans,
Louisiana, USA.
DOUGLAS E. GILROY is a principal
engineer in the Materials Engineering
Technology group at Bechtel Oil, Gas and
Chemicals, Inc., Houston, Texas, USA. He
has 36 years of experience in onshore and
offshore CP design, installation, commis-
sioning, and testing, and in pipeline AC
interference. He has a M.S. in materials
engineering and is a NACE Corrosion
Specialist and CP Specialist, Fellow of the
Institute of Corrosion, and a registered
Professional Engineer in Texas. He has
been a member of NACE for 35 years.
protection (CP) for steel structures buried in
soil in this new Materials Performance
quarterly special feature, “The Science Behind
It.” Now that you’ve read the MP article about
CP on mixed-metal circuits, explore the
science behind the corrosion problem, which
is presented in these related CORROSION
articles:
D.A. Jones, “Analysis of Cathodic Protection
Criteria,” Corrosion 28, 11 (1972): pp. 421-
423. http://corrosionjournal.org/doi/
abs/10.5006/0010-9312-28.11.421.
Y. Hosokawa, F. Kajiyama, Y. Nakamura,
“New Cathodic Protection Criteria
Based on Direct and Alternating Cur-
rent Densities Measured Using Coupons
and Their Application to Modern Steel
Pipelines,” Corrosion 60, 3 (2004): pp. 304-
312. http://corrosionjournal.org/doi/
abs/10.5006/1.3287735.
G.K. Glass, “Technical Note: The 100-mV
Potential Decay Cathodic Protection
Criterion,” Corrosion 55, 3 (1999): pp. 286-
290. http://corrosionjournal.org/doi/
abs/10.5006/1.3283989.
M.H. Peterson, “Principles and Criteria
for Cathodic Protection of Steel in Sea
Water—A Review,” Corrosion 15, 9 (1959):
pp. 51-55. http://corrosionjournal.org/doi/
abs/10.5006/0010-9312-15.9.51.

Acknowledgments
Acknowledgement is given to my col-
leagues within the Bechtel organization
who provided contributions to this article,
especially M. Fang, H. Acuna, and D. Chew.

References
1 NACE SP0169-2013, “Control of External
Corrosion on Underground or Submerged
Metallic Piping Systems” (Houston, TX:
NACE International, 2013).
2 NACE SP0104-2014, “The Use of Coupons for
Cathodic Protection Monitoring Applica-
tions” (Houston, TX: NACE, 2014).
3 NACE Publication 35201, “Technical Report
on the Application and Interpretation of
Data from External Coupons Used in the
Evaluation of Cathodically Protected Metal-
lic Structures” (Houston, TX: NACE, 2001).

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 37

COATINGS & LININGS
Plasma Electrolytic Oxidation
Coatings for Aluminum Alloys
y. Zhang, W. Fan, anD h.Q. Du, School
of Mechanical Engineering, Zhejiang
Industry Polytechnic College, Shaoxing,
China
y.W. Zhao, Key Lab of E&M, Ministry of
Education & Zhejiang Province, Zhejiang
University of Technology, Hangzhou,
China
A
38 SEPTEMBER 2017 MATERIALS PERFORMANCE
Plasma electrolytic oxidation coatings
were formed on aluminum alloys in an
inexpensive and convenient electro-
lyte. The effects of current density
(CD) on corrosion resistance behavior
of the coatings were studied by po-
tentiodynamic polarization and elec-
trochemical impedance spectroscopy
(EIS) tests. The results proved that the
coating produced with a CD of 10
A/dm2 showed the best anticorrosion
properties. The longtime EIS test
showed that the 10 A/dm2 coating was
capable of protecting the aluminum
alloy substrate after immersion in a
0.59-M sodium chloride (NaCl) solu-
tion, which was confirmed by the re-
sults of a 10-day salt solution immer-
sion test in a 2-M NaCl solution.
Aluminum and its alloys have been
widely used in the aerospace and automo-
tive industries due to their high specific
strength, low density, good formability, and
nonmagnetic properties.1-2 Poor corrosion
resistance, however, greatly limits the
application of aluminum alloys, particu-
larly the susceptibility to localized damage
such as intergranular and pitting corrosion
caused by intermetallic constituent parti-
cles.3 Therefore, it is necessary to improve
the corrosion resistance of these alloys by
surface treatments.
Plasma electrolytic oxidation (PEO)—
also referred as microarc oxidation (MAO),
microplasma oxidation (MPO), and micro-
arc discharge oxidation (MADO) or anode
oxidation—has attracted considerable
attention as a surface treatment technol-
ogy for forming ceramic coatings on the
surfaces of valve metals (Al, Mg, Ti, and
their alloys).4-6 According to the report by
Li, et al.,7 the PEO process is a multifactor-
controlled process; and the properties of
PEO coatings can be influenced by factors
such as electrolyte concentration,8 electri-
cal parameters, 9 and additives. 10 Many
investigations on these influencing factors,
especially additives, have been conducted
in recent years so ideal coatings can be
obtained. It has been demonstrated that
the presence of glycerin in the electrolyte
composition resulted in both a stable solu-
tion and a dense, uniform coating without
any cracking. The glycerin additive was
also effective in enhancing the corrosion
resistance of the coating; however, this
study lacked of a full investigation on the
effect of current density (CD) on the corro-
sion properties of coatings formed in a
glycerin-containing alkaline electrolyte.
In the present work, PEO of 6063 alumi-
num alloy (UNS A96063) was conducted in
a phosphate-based electrolyte containing
glycerin. Corrosion resistance was studied
by potentiodynamic polarization and elec-
trochemical impedance spectroscopy (EIS)
tests.
Experimental Procedures
Material and Plasma Electrolytic
Oxidation Treatment
The substrate material used for the PEO
treatment, 6063 aluminum alloy, was com-
prised of 0.45 to ~0.90 wt% Mg, 0.35 wt% Fe,
0.2 to ~0.6 wt% Si, 0.10 wt% Cu, 0.10 wt%
NACE INTERNATIONAL: VOL. 56, NO. 9
Mn, 0.10 wt% Cr, 0.10 wt% Zn, 0.10 wt% Ti,
and the balance Al. The 30- by 29- by 3-mm
commercially available Al alloy specimens
were ground with 1,800-grit abrasive paper,
ultrasonically degreased in pure ethanol,
cleaned in distilled water, and dried in hot
air. The electrolyte used in this study was
an aqueous solution consisting of 30 g/L of
sodium hexametaphosphate [(NaPO 3) 6],
3 g/L of potassium hydroxide (KOH), 8 g/L
of borax (Na2B4O7), and 15 g/L of glycerin in
distilled water.
The PEO device consisted of a 30-kW
bipolar pulsed power source, stainless steel
vessel, cooling system, and stirring system
to maintain the temperature below 303 °K
in all cases. To ensure proper electrical con-
tact, a 2-mm diameter threaded hole was
made in the center of the samples; and a
thin, externally threaded aluminum rod
was screwed into them. Coatings were pro-
duced after 25 min in the electrolyte at CDs
of 5, 10, 15, and 20 A/dm2. After the PEO FIGURE 1 Potentiodynamic polarization curves of uncoated and PEO-coated 6063 Al alloys in a
0.59-M NaCl solution. PEO coatings were obtained with a CD of 5, 10, 15, and 20 A/dm2.
treatment, each coated specimen was
immediately rinsed in distilled water and
dried in ambient air.

Potentiodynamic Polarization and

Electrochemical Impedance
Spectroscopy Testing
The potentiodynamic polarization and
EIS tests were performed with a three-elec-
trode system. The uncoated and PEO-
coated specimens, cut into 100-mm2 sam-
ples and inlaid with resin, acted as the
working electrodes; a weight-saving plati-
num electrode was the counter electrode;
and a saturated calomel electrode (SCE)
was the reference electrode. All the elec-
trodes were submerged in a three-neck
flask filled with a 0.59-M sodium chloride
(NaCl) aqueous solution with an approxi-
mate pH of 7. The corrosion evaluation sys-
tem (a Corrtest CS350† Potentiostat/Galva-
nostat) was electrically connected. The
100-mm2 working electrode area was posi-
tioned close to the reference electrode to
minimize measurement errors associated
with electrolyte resistance. The coated
specimen was exposed to the corrosive FIGURE 2 Nyquist plots of PEO-coated 6063 Al alloy produced with a CD of 10 A/dm2 immersed in
a 0.59-M NaCl solution for different immersion times. The fitting equivalent circuits are shown in
†
Trade name. Figure 3, and the symbols correspond to the experimental values.

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 39

COATINGS & LININGS

TABLE 1. EIS SIMULATED DATA OF PEO-COATED 6063 Al ALLOY(A)

Immersion Time (h) Rs (Ωcm2) Qp (Ω–1sncm–2) np Rp (kΩcm2) Qb (Ω–1sncm–2) nb Rb (kΩcm2)
1 11 1.28 × 10–9 0.67 28.3 1.38 × 10–9 0.81 293
–9 –9
4 16 1.36 × 10 0.84 23.4 1.41 × 10 0.62 258.3
12 21 1.82 × 10–8 0.43 21.1 3.15 × 10–8 0.93 234.5
–8 –8
24 24 2.64 × 10 0.82 18.4 2.37 × 10 0.73 201.3
–8 –7
44 27 3.26 × 10 0.55 16.3 2.41 × 10 0.85 192.3
72 31 2.31 × 10–7 0.91 14.3 1.73 × 10–7 0.91 175.8
(A) 2
The PEO coating was produced with a CD of 10 A/dm and the coated sample was immersed in a 0.59-M NaCl solution for different
immersion times. The fitting equivalent circuits are shown in Figure 3 and the symbols correspond to the experimental values.

men at its corrosion potential. A 10-mV

FIGURE 3 Corresponding equivalent circuits for fitting the impedance data of PEO-coated 6063 Al
alloy.
FIGURE 4 The appearance of specimens after a salt solution immersion test in 2-M NaCl solution
for 10 days: (a) uncoated 6063 Al alloy, and (b) Al with a PEO coating produced with a CD of
10 A/dm2 for 25 min. The obvious corrosion area is marked by the red circle.
medium (0.59-M NaCl solution) for 30 min
to stabilize its corrosion potential (Ecorr).
Once the open-circuit potential was
nearly stable (i.e., fluctuating <5 mV), the
potentiodynamic polarization test was car-
ried out from –1.2 to –0.4 V vs. SCE at a
scanning rate of 1 mV/s. CorShow † soft-
ware was used to determine the potentio-
dynamic polarization data. As the corro-
sion status of the electrode system was not
significantly influenced by the EIS mea-
surement, it was carried out on the speci-
†
Trade name.
peak-to-peak amplitude potential signal
was selected. The frequency range was
from 105 Hz to 10–1 Hz. After EIS testing, the
data were analyzed using ZSimpWin 3.10†
software and fitted with the appropriate
equivalent circuit model. Under each test-
ing condition, potentiodynamic polariza-
tion curves and EIS measurements were
repeated three to five times to ensure reli-
ability and reproducibility.
Results and Discussion
Potentiodynamic Polarization Test
Potentiodynamic polarization curves of
uncoated and PEO-coated aluminum alloy
substrates after an initial immersion time
of 30 min in a 0.59-M NaCl solution are
shown in Figure 1. In a typical polarization
curve, as the corrosion potential (E corr)
moves in the electropositive positive direc-
tion, it is accompanied by reduced CD
(icorr), which corresponds to a lower corro-
sion rate. When compared to the uncoated
6063 Al alloy, these results show that the
corrosion potential of the coating obtained
with a CD of 5 A/dm2 shifted ~80 mV in the
positive direction and the corrosion CD
decreased by one order of magnitude.
When the application CD was increased
to 10 A/dm2, the PEO coating produced the
optimal corrosion potential and the lowest
corrosion CD (–0.653 V vs. SCE and 6.775 ×
10–8 A/cm2). In contrast, when the applica-
tion CD was increased to 15 and 20 A/dm2,
the corrosion potential decreased and the
corrosion CD increased, respectively. Thus,
there is no absolute relationship between
increasing the application CD and improv-

40 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9


ing the corrosion resistance of the PEO
coating. The coating formed with a CD of
10 A/dm2 exhibited the best anticorrosion
properties among these coatings.
Electrochemical Impedance
Spectroscopy Analysis
To understand the quantitative corro-
sion behavior of the PEO coating systems,
EIS tests were carried out to provide
detailed information on the corrosion pro-
cess at the electrolyte/electrode interface
and the property changes of the electrode.
This is quite important for understanding
the corrosion mechanism of the coating
system. 11 The Nyquist plots for the PEO-
coated 6063 aluminum alloy specimens are
shown in Figure 2. The corresponding sim-
ulated data are presented in Table 1, which
shows the PEO treatment significantly
improved the corrosion resistance of the
bare alloy. The equivalent circuit model is
shown in Figure 3 for analysis of the EIS
results based on a reasonable fitting of the
experimental values. The capacitance
behavior of the coatings and substrate can
be better simulated by constant phase ele-
ment (CPE) modeling, which is represented
by the symbol Q. The impedance formula
for Q is described by Equation (1):
1 solution.
( jv)
–n
ZQ =
Y0 (1)
In this equation, j is an imaginary unit
( j 2 = –1) and w is angular frequency
(w = 2pf ). The coefficient and the exponent
n (–1 ≤ n ≤ 1) are the parameters of CPE.
In the equivalent circuit presented in
Figure 3, R s stands for the solution resis-
tance between the specimen and reference
electrode; Rp is the resistance of the outer
porous layer (i.e., the resistance of defects
such as pores/cracks in the coating), which
is in parallel with a constant phase element
(Qp); and Rb denotes the inner barrier layer
resistance (including the resistance of the
coating/substrate interface), which is in
parallel with a constant phase element (Qb).
Corrosion Morphology
Figure 4 shows the corrosion morphol-
ogy of the uncoated specimen and a PEO
coating sample formed with a CD of 10
NACE INTERNATIONAL: VOL. 56, NO. 9
Plasma Electrolytic Oxidation Coatings for Aluminum Alloys
A/dm 2. The photographs show the two
samples after a salt immersion test in a 2-M
NaCl aqueous solution for 10 days.
Although the surface of the uncoated 6063
aluminum alloy is almost completely cov-
ered by corrosion products, the surface of
the PEO coating shows much less attack
after the 10-day immersion. No obvious
corrosion pits had developed on the sample
anodized in the electrolyte with a CD of
10 A/dm2, confirming the improved corro-
sion resistance of the PEO coating pro-
duced under the CD of 10 A/dm2.
Conclusions
PEO coatings were fabricated under dif-
ferent CDs in a phosphate-based electro-
lyte with the addition of glycerine. The
effect of the application CD on corrosion
properties of PEO coatings was studied.
• The potentiodynamic polarization
test showed that the coating formed
with a CD of 10 A/dm 2 showed the
best corrosion resistance among
these coatings.
• EIS tests showed that the PEO coat-
ing produced with a CD of 10 A/dm2
was still able to protect the substrate
after 72 h immersion in a 0.59-M NaCl
solution. This was confirmed by a
10-day immersion test in a 2-M NaCl
Acknowledgments
The financial aid of Research on Public
Welfare Technology Application Projects of
Zhejiang Province under grant no.
2017C31039, Shaoxing Research Project of
Public Welfare Technology Application
under grant no. 2015B70005, and the
National Natural Science Foundation of
China under grants no. 51275477 and
61572438 are gratefully acknowledged.
References
1 L. Wen, et al., Corros. Sci. 52 (2010): pp. 2,687-
2,696.
2 H.Y. Ding, et al., Tribol. Int. 43 (2010): pp. 868-
875.
3 G. Bierwagen, et al., Prog. Org. Coat. 68 (2010):
pp. 48-61.
4 H. Fadaee, M. Javidi, J. Alloys Comp. 604
(2014): pp. 36-42.
5 T.S. Lim, H.S. Ryu, S.H. Hong, Corros. Sci. 62
(2012): pp. 104-111.
MATERIALS PERFORMANCE SEPTEMBER 2017
6 Y.W. Zhao, et al., “Improved Corrosion Resis-
tance of Titanium Dioxide-Containing
Plasma Electrolytic Oxidation Ceramic Coat-
ings,” MP 55, 11 (2016): pp. 36-39.
7 Q.B. Li, J. Liang, Q. Wang, “Plasma Electro-
lytic Oxidation Coatings on Lightweight
Metals,” Modern Surface Engineering Treat-
ments, M. Aliofkhazraei, ed. (Rijeka, Croatia:
InTech, Rijeka, 2013), pp. 75-99.
8 Y.L. Cheng, et al., Corros. Eng. Sci. Technol. 46
(2011): pp. 17-23.
9 R.O. Hussein, D.O. Northwood, X. Nie, Surf.
Coat. Technol. 237 (2013): pp. 357-368.
10 T.S. Lim, H.S. Ryu, S.H. Hong, Corros. Sci. 62
(2012): pp. 104-111.
11 C.N. Cao, J.Q. Zhang, An Introduction to Elec-
trochemical Impedance Spectroscopy (Beijing,
China: Science Press, 2002), p. 158.
Y. ZHANG is a doctor at the School of
Mechanical Engineering, Zhejiang Industry
Polytechnic College, Shaoxing 312000,
China. His research interests focus on
mechanical engineering and materials.
W. FAN is a professor at the School of
Mechanical Engineering, Zhejiang Industry
Polytechnic College, Shaoxing 312000,
China.
H.Q. DU is a professor at the School of
Mechanical Engineering, Zhejiang Industry
Polytechnic College, Shaoxing 312000,
China.
Y.W. ZHAO is a professor at Key Lab of
E&M, Ministry of Education & Zhejiang
Province, Zhejiang University of Technol-
ogy, Hangzhou, Zhejiang, China, email:
zyzjipc@126.com. Her research interests
focus on mechanical engineering and
materials. She is the author or coauthor of
numerous journal publications and is a
member of NACE.
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41
COATINGS & LININGS
Hydrogen Sulfide Tube Failure
in a Seawater Heat Exchanger
hanan Farhat, College of the North
Atlantic-Qatar, Doha, Qatar
roy JohnsEn, Norwegian University of
Science and Technology, Trondheim,
Norway
42 SEPTEMBER 2017 MATERIALS PERFORMANCE
Severe tube damage was discovered
in a heat exchanger in which tubes
made from 90/10 CuNi (UNS C70600)
had thinned and collapsed. The main
cause of the failure was severe tube
thinning due to hydrogen sulfide
(H2S) corrosion. Sulfur was introduced
into the shell side of the exchanger
through a diisopropanolamine solu-
tion carrying more than the allowable
percentage of H2S over a long time
period.
D
Diisopropanolamine (ADIP) is used to
reduce hydrogen sulfide (H 2S) in natural
gas to low concentrations. Lean ADIP is a
25 wt% solution of diisopropanolamine in
desalinated water. The heat exchanger
(HX) is used to cool the lean ADIP after the
regeneration process. The lean ADIP is in
the shell side and exchanges heat with
chlorinated seawater in the tube side of the
HX. The highest operating inlet tempera-
ture and pressure of the shell side (lean
ADIP) were 75 °C and 5.3 MPa, respectively.
The maximum operating outlet tempera-
ture and pressure of the tube side (chlori-
nated seawater) were 42 °C and 0.52 MPa,
respectively.
The HX was manufactured in 1977 with
the shell made from carbon steel and the
tubes made from aluminum brass. The
tubes were replaced with 90/10 CuNi (UNS
C70600) in 1994.
The total number of tubes was 1,248—
each had a diameter of 19.05 ± 0.1 mm, wall
thickness of 1.63 ±0.13 mm, and average
length of 4,877 mm.
Inspection History
In February 2014, the HX experienced
abnormal operation caused by a backflow
of propane due to leaks in some of the
tubes. The tube bundle was not removed
and the tube conditions were not inspected.
The hydrostatic pressure test was reduced
to 5.0 MPa during this inspection due to
loud noise and other tube leaks. A total of
34 tubes were plugged. Minor leaks were
noticed after commissioning, and the oper-
ator reduced the shell side pressure to 3.0
MPa to avoid more leaks.
In April 2014, the HX failed to operate.
The block valve was closed and the shell fluid
(lean ADIP) was drained. The tube bundle
was pulled out to visually inspect the condi-
tion of the tubes. The tubes were severely
damaged and discolored with dark black
corrosion scale. A number of tubes were
compressed, similar to a drinking straw with
the end closed and the air sucked out.
During the failure investigation, several
inspection reports from 2009 to 2014 were
found that described the leaking and plug-
ging of the tubes.
Failure Investigation
Visual Inspection
During inspection of the HX, it was
noted that blocked tubes were damaged in
the form of both compression and elonga-
tion. All the plugged tubes were found com-
pressed. The damage seemed to be located
near the ADIP inlet in the third and fourth
passes.
One tube was split into two parts. A
thick black corrosion scale covered the sur-
face. The corrosion scale had poor adhe-
NACE INTERNATIONAL: VOL. 56, NO. 9
FIGURE 1 A micrograph of the control sample shows the typical
microstructure of 90/10 CuNi alloy.
sion and was flaking off. External discolor-
ation of the tubes, which was yellow, blue,
light reddish brown, and white, was
observed.
Nine tube samples from different passes
were selected for examination. Each tube
sample was cross sectioned into three sam-
ples: 1) tube start, 2) tube middle, and 3)
tube outlet. In addition, three reference
samples from an unexposed tube were
examined.
Measurements
The outside diameter (OD) and inside
diameter (ID) of each sample were mea-
sured to identify any external or internal
corrosion. In the same sample, it was found
that the wall thickness could vary. Three
measurements were taken and the average
was calculated. The measurements did not
show any obvious reduction in the ID (i.e.,
no internal corrosion), while the OD mea-
surements showed large reductions (i.e.,
external corrosion). In some of the col-
lapsed samples, the wall thickness was as
low as 0.42 mm, which was ~25% of the
original wall thickness.
Metallographic Examination
The microstructure of the samples was
documented. The samples were etched in a
solution of 5-g ferric chloride (FeCl 3 ),
NACE INTERNATIONAL: VOL. 56, NO. 9
FIGURE 2 The microstructure of a compressed tube shows no evidence of
grain growth. A porous black film is shown on the outer surface.
50-mL hydrochloric acid (HCl), and 100-mL
water for 3 s. The micrograph of the control
sample (Figure 1) reveals the microstruc-
ture of a typical 90/10 CuNi alloy with
twinned grains of alpha copper and an
average grain size of 25 µm. Similar micro-
structure can be seen in the damaged sam-
ple in Figure 2. No variation in the grain
size was observed, indicating that the tubes
were not exposed to high temperatures
that would result in grain growth. Figure 3
shows the microstructure of the corrosion
scale on a damaged sample. The scale has
multiple brittle layers that are full of voids
and cracks. The scale’s thickness varies
within the same sample.
Surface Characterization
The samples were observed under scan-
ning electron microscopy (SEM), and
energy-dispersive x-ray analysis (EDXA)
was performed. Three main areas were
checked: 1) external corrosion scale, 2)
internal corrosion scale, and 3) the area in
between.
Consistency was seen in the results
from the three analyzed areas on each sam-
ple. The external corrosion scale showed
high concentrations of sulfur, as illustrated
in Figure 4; the center of the sample showed
typical 90/10 CuNi alloy content; while the
internal corrosion scale had evidence of
MATERIALS PERFORMANCE SEPTEMBER 2017
calcium. The test results for all of the sam-
ples were the same, with various amounts
of sulfur in the external corrosion scale in
the range of 22 wt%.
A qualitative x-ray diffraction (XRD),
shown in Figure 5, revealed two copper-
sulfur components: copper sulfide (Cu1.8S),
which is indigo-blue or darker, and typi-
cally highly irridescent with brass-yellow to
deep red color; and djurleite (Cu 31S 16), a
copper sulfide compound that is gray, blue-
black, or black in color. Similar colors of
these sulfides were noticed on the tubes
during visual inspection. The relative
amounts were 11% Cu1.8S and 89% Cu31S16.
Discussion
The corrosion behavior of the 90/10
CuNi alloys depends on the presence of
oxygen and other oxidizers in the system.
During the primary corrosion reaction, an
adherent, protective cuprous oxide film
(Cu2O) is formed on the alloy surface. The
corrosion resistance of the alloy in sea-
water is determined by this naturally
occurring protective film, which reacts
with compounds in seawater and builds a
multilayered oxide structure. For the corro-
sion reaction to proceed, copper ions and
electrons must migrate through the Cu2O
film.1-3
To achieve adequate corrosion resis-
43
COATINGS & LININGS
FIGURE 3 The external corrosion scale in a damaged sample has multiple layers that are full of
voids.
FIGURE 4 The EDXA spectrum of the external corrosion scale on a damaged sample shows a high
concentration of sulfur.
FIGURE 5 An XRD plot shows the results of the qualitative analysis of the external corrosion scale.
tance in CuNi tubes that carry seawater,
clean, oxygen-containing seawater can
flow in the tubes for several hours, days, or
weeks. This enables the formation of a pro-
tective layer that can be maintained for a
long time period.1 Forming and maintain-
44 SEPTEMBER 2017 MATERIALS PERFORMANCE
ing this protective layer is crucial for opti-
mum life of the tube material.4
In an environment containing H2S, the
H2S reacts with Cu+ and produces a non-
protective black cuprous sulfide (Cu 2S),
which is poorly adherent, brittle, and results
in enhanced probability of corrosion and
erosion attack.1 H2S content in the range of
200 to 300 ppm wt% in lean ADIP was mea-
sured during a six month period in 2014.
The outcome of the investigation can be
summarized as:
• Severe tube thinning.
• Dominant external corrosion.
• Formation of a poorly adherent,
thick, multilayered black corrosion
film with voids and cracks on the
external surface.
• No change in metallographic micro-
structure and grain size between an
unused and used tube.
• High concentration of sulfur in the
external corrosion film. XRD showed
two sulfate components (Cu1.8S and
Cu31S16).
• H2S content in the range of 200 to 300
ppm wt% measured in the lean ADIP.
• The internal scale consisted mainly
of calcium (typical for seawater).
These findings led to the conclusion
that corrosion caused by H 2S is the root
cause of the failure. H2S corrosion is a form
of sulfidation that results in loss of wall
thickness and serious corrosion on the
external surface of the tubes. It is usually
accompanied by the formation of a sulfide
scale. The scale is about five times the vol-
ume of lost metal and may occur in multi-
ple layers. 5 Sulfide attack of CuNi alloys
typically leaves a porous nonprotective
black film on the surface. The film is poorly
adherent, and usually appears as patchy
deposits.3 Such a film can be seen in Figures
2 and 3.
The corrosion rate increased with tem-
perature and H 2S content.5 The tempera-
ture in a HX varied with the highest tem-
perature occurring during the fourth pass
(the last pass that gets cooled), followed by
the third pass, second pass, and first pass.
The severity of the damage was in the same
order, showing very severe damage in the
fourth pass and the least severe corrosion
in the first pass.
The possible failure scenario is as fol-
lows: the Cu2O layer was previously formed
when the tubes were installed in the
exchanger. The exchanger tubes were
externally exposed to the lean ADIP aque-
ous solution. No oxygen was present in the
lean ADIP solution. During the life of the
NACE INTERNATIONAL: VOL. 56, NO. 9
 Hydrogen Sulfide Tube Failure in a Seawater Heat Exchanger

HX, H2S was present in the system. Under
the influence of the H 2S, the Cu 2O film
broke down and a brittle Cu1.8S and Cu31S16
film was formed. Over time, corrosion
reduced the remaining thickness and when
the wall strength was not sufficient to
maintain the pressure, the tube collapsed.
The highest corrosion rates coincided with
the area of the highest fluid temperature,
mainly in the fourth pass. This area was
also the ADIP inlet area, in which the sur-
face was exposed to constant fluid flow
that chipped away the corrosion scale and
resulted in greater reduction of the tube
thickness in this pass vs. the second and
first passes.
Conclusions and
Recommendations
Material Selection
• In seawater applications, 90/10 CuNi
alloy is an acceptable alloy to use due
to its good corrosion resistance in
clean seawater without pollution.
The alloy’s resistance to biofouling is
also advantageous for HX tube
material.
• In lean ADIP, the H2S content needs
to be limited to 0.5 ppm wt% if 90/10
CuNi is used as the tube material. 4
For higher H 2S content, corrosion-
resistant alloys (CRAs) need to be
evaluated. In this case, the limita-
tions in seawater temperature for
CRAs would be an important factor.
• Titanium Grade 2 (UNS R50400) is
the most robust solution regarding
corrosion resistance under the actual
operating conditions, which include
seawater, H2S, high temperature, and
flow.6
References
1 W. Schleich, “Typical Failures of CuNi 90/10
Seawater Tubing Systems and How to Avoid
Them,” Technical Advisory Service, KM
Europa Metal AG, 2004.
2 “Gas Treating (Refinery/Natural Gas)—ADIP
Process,” Comprimo Sulfur Solutions, http://
www.jacobs.com/uploadedFiles/wwwjacob-
s c o m / 2 0 _ L e a r n _ A b o u t _ Us / 2 5 _ P r o d -
ucts/253_Comprimo_Sulfur_Solutions/
Te ch n o l o g i e s / Ha n d o ut % 2 0 Ja c o b s % 2 0
C S S % 20- %20 Ga s% 2 0Treatin g %2 0- %2 0
ADIP%20Process.pdf ( July 26, 2017).
3 A.K. Sinha, “Aspects of Failure of Condenser
Tubes and Their Remedial Measures at
Power Plants,” AKS Journal (2010): pp. 1-15.
4 A. H. Tuthill, B. Todd, J. Oldfield, “Experience
with Copper Nickel Alloy Tubing, Water
Boxes and Piping in MSM Desalination
Plants,” IDA World Congress on Desalination
and Water Reuse, paper no. 73 (Topsfield,
MA: IDA, 1977), p. 251.
5 API RP571, “Damage Mechanisms Affecting
Fixed Equipment in the Refining Industry”
(Washington, DC: API, 2003), pp. 5-13.
6 ISO 21457:2010, “Petroleum, petrochemical
and natural gas industries—Materials selec-
tion and corrosion control for oil and gas
production system” (Geneva, Switzerland:
ISO, 2010), p. 22.
HANAN FARHAT is a mechanical engineer-
i n g i n s t r u c t o r a n d l e a d c o r ro s i o n
researcher at the College of the North
Atlantic-Qatar (CNAQ), Doha, Qatar,
email: hanan.farhat@cna-qatar.edu.qa. She
has more than 20 years of experience
working in the oil and gas industry as an
inspection and corrosion engineer. She
joined CNAQ in 2012 performing corro-
sion research and failure analysis. She has
an M.Sc. degree in mechanical engineering
and is a member of NACE International.
ROY JOHNSEN is a professor at the
Norwegian University of Science and
Technology (NTNU), Trondheim, Norway,
email: roy.johnsen@ntnu.no. He has more
than 20 years of experience in the oil and
gas industry before joining NTNU in 2004.
He works in the areas of material selec-
tion, corrosion and corrosion protection,
and integrity management. He has a Ph.D.
in corrosion protection from NTNU and is a
member of NACE.

Monitoring and Inspection

• Assuming 90/10 CuNi is used, a sys-
tem for monitoring the H 2S content
in the lean ADIP, including actions to
be followed when critical values are
exceeded, needs to be implemented.
• An inspection plan based on risk-
based inspection should be imple-
mented for proper inspection of the
high-risk areas.

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 45

#SupportGenerationNext

The NACE Foundation—

Dedicated to Supporting Generation Next
Upcoming Student Scholarship Deadlines
Academic Scholarships
Funded by the generous contributions of individual members, NACE Sections and Areas, corporations, and other
non-profit entities, the NACE Foundation offers several scholarships that provide deserving students with vital
funding to pursue an education in science and engineering.
Application deadline for 2018 scholarships is January 1, 2018.

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Each year the NACE Foundation offers travel assistance to CORROSION Conference & Expo student registrants
who are presenting in the Student Poster Session, presenting a technical paper, or receiving a NACE Foundation
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Application deadline for CORROSON 2018 is February 1, 2018.

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#SupportGenerationNext
 COATINGS & LININGS ESSENTIALS
Investigation Indicates Osmotic
Blistering Caused Damage on
Jet Fuel Pipeline Lining
inspected internally with a robotic crawler.
The robotic inspection revealed lining
damage on 35 of the flooded pipe segments.
The damage included topcoat removal,
bubbles and blisters, rust, and staining,
which varied at different locations within
the pipelines. Rust had formed on exposed
metal at the welded joints, and at some
locations the lining had peeled off adjacent
to the joints. Initially, the cause of the lining
damage was thought to be caused by the
ingress of water and mud, followed by the
cleaning operations. Testing and analysis
were implemented, however, to determine
the actual cause of the lining damage.
Continued on page 49

N
EW
In CORROSION 2017 paper no. 9061, “Inter-
nal Lining Damage Investigation of 24-inch
Jet Fuel Pipelines,” authors Mushaid
Nauman and David Eyre with Penspen (Sur-
Measures the concentration of soluble salts
rey, United Kingdom) discuss an investiga- on metal surfaces using the Bresle method
tion into the damage of the epoxy lining on
two 24-in (610-mm) diameter pipelines for
a new fuel hydrant system. The pipelines, n Displays test duration, sample
constructed as part of an airport expansion temperature, conductivity (µs/cm)
project, were externally coated with three- and surface density
layer polyethylene (3LPE) and internally n Easy 1-2-3 gage interface guides
lined with epoxy. The lining was applied to users through the Bresle method
ensure a clean pipeline so contamination of n Includes PosiSoft suite of software
the aviation fuel could be avoided. It was for viewing and reporting data
not intended to be an anticorrosion barrier
coating. Since heat shrink sleeves were to
be applied at the joints, the girth welds
were not lined during construction. The
lining was comprised of a two-coat amine-
cured, modified epoxy coating with high
solids content in both the primer and top-
coat (65% and 63% by volume, respectively).
The dry film thickness (DFT) for both coats
was in the range of 100 to150 µm. The mate-
Innovative PosiPatch
TM

rial data sheet for the coating material indi-

n No adhesive residue
cated the epoxy could withstand 232 °C
n No sharps, no needles!
(450 °F) wet dry under insulation for short
For use with
periods, and cautioned that excessive hu- all Bresle patch
midity or condensation on the surface dur- types including
ing curing could interfere with the cure. the innovative
PosiPatch
During construction, a leak in a nearby
36-in (914-mm) irrigation line caused water
to flood an open trench that contained two
of the fuel hydrant system pipelines—83 of
the project’s 469 pipe segments were
flooded. The flooding caused mud, water,
and debris to accumulate in 472 m (1,549 ft)
1-800-448-3835
of pipe. The trench was drained and the www.defelsko.com
flooded pipelines were cleaned by flushing DeFelsko Corporation l Ogdensburg, New York USA
Tel: +1-315-393-4450 l Email: techsale@defelsko.com
with water, air blowing, and drying. After
the cleaning operations, the pipelines were

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 47

Start Your
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 ESSENTIALS
Continued from page 47

The mechanisms investigated as the

possible cause of the internal lining damage
were overheating of internal weld joints,
osmotic blistering, and amine blush. Tests
done during the investigation included an
amine blush test, weld joint test, aviation
fuel soak test, water soak test, DFT test,
cross cut adhesion test, pull-off test, as well
as a general visual inspection. The results
indicated the cause of blistering and delam-
ination damage in the flooded and flushed
pipelines was osmotic blistering due to the
presence of water-soluble material at the
interface between the primer and topcoat.
According to the authors, blisters are
local regions where the coating has lost
adherence from the substrate and allows
water to accumulate and corrosion to begin.
Three main constituents must be present for
osmotic blistering to occur: water (liquid
and/or vapor), salts or water-soluble (hygro-
scopic) organics, and a semi-permeable
membrane. Paint films are semi-permeable
membranes that are permeable to water but
impermeable to dissolved solids. The main
driver of osmotic blistering is the water-
soluble material at the interface between
the coating and the substrate or between
coats. The water-soluble materials that
cause the osmotic gradient are generally
either inorganic salts, corrosion products, or
retained solvents in the coating. When in
contact with an aqueous environment, the
water-soluble contaminant dissolves and
creates a solution with a different concen- MP READERSHIP
SURVEY
tration than the bulk environment. Water
accumulates and the blister is formed.
The authors note that osmotic blistering
has been related to chlorides, sulfates, and Coming to your inbox
other inorganic solubles often found on next month
substrates or beneath the topcoat. These
materials can result from environmental As the world’s largest circulation journal exclusively
contamination or depassivating salts such
dedicated to corrosion, MP is committed to providing our
as chlorides and sulfates. Water-extractable
materials accidentally or deliberately
readers with timely information on the latest technologies
entrained in the coating can also cause and practical solutions for corrosion prevention and control.
problems.
In the case of the fuel hydrant system So, how are we doing? This is your chance to let us know.
pipelines, the paint film on the internal pipe
surface was in contact with an aqueous We want to hear from you!
environment (i.e., the flood water). This
water was absorbed by the topcoat and A link to the online survey will be emailed during the week of
then transferred to the topcoat/primer October 2. Survey closes on October 20.

Continued on page 51

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 49

COATINGS & LININGS ESSENTIALS
Continued from page 47

interface. Here, the water encountered the
water-soluble material on the primer sur-
face, which was likely present due to expo-
sure of the primer to moisture before the
epoxy phenolic resin and amine hardener
had fully reacted. This indicates that the
problem was caused by poor procedures
during application of the topcoat. If the
water-soluble materials were present on the
substrate beneath the primer, blistering and
delamination would have occurred at sub-
strate/primer interface. Records at the
open. This eventually results in the death of
the microorganisms. As the electric
impulses impart a purely physical effect,
bacteria are not expected to develop resis-
tances, as they do in the case of biocides.
In the automotive industry, painting the
vehicle body consumes the highest amount
of water. For this reason, the electric
impulse technology is being integrated into
a new, automated, resource-efficient water
management and plant concept for pre-
treatment and immersion painting. To learn
more, visit www.kit.edu.
Source: Karlsruhe Institute of Technology.

T
plant that applied the lining indicated that ATABLE ·
PE
RE

F
conditions were not favorable over the

·
entire lining application period. Very low
ST
te

D
· FA
temperatures and high humidity conditions
re
nc
were observed.
co

BLE
Osmotic blistering is not expected if the
ure

on

RA
line is exposed only to aviation fuel, even
s

U
ea

with the presence of soluble material on the ·

A C C U R AT E
M

primer surface. Jet fuel transfer through the

coating to any significant degree is unlikely
because jet fuel molecules are larger than
water molecules and are unlikely to be
capable of penetrating through the epoxy
phenolic amine matrix in the coating.

Electric Impulses Clean

Industrial Water and Paints
Water-based coatings are environmentally
compatible but they have one drawback—
microorganisms such as bacteria can repro-
duce in the water and paints used and then
adversely affect the quality of surface coat-
ing. Typically, biocides have been used to
control these bacteria. Now, a sterilization
process for industrial water and paints that
uses electric impulses is being developed to
address this issue. The program is funded
by the German Federal Ministry of Educa-
tion and Research and coordinated by re-
searchers at Karlsruhe Institute of Technol-
ogy (Karlsruhe, Germany).
The new electric impulse technology,
which focuses on both surface treatment
for the automotive industry (cathodic The new Elcometer 500
immersion painting) and applications for can quickly, accurately and
general industry (coating of industrial repeatably measure dry film
goods by anodic immersion painting), thickness on concrete and
works without chemical additives, reduces other cementitious substrates.
water consumption, and contributes to
water protection. When cells or microor-
sales@elcometer.com
ganisms are exposed to an electric field, the USA & Canada: (800) 521-0635 elcometer.com/e500
cell membrane is polarized, which means
that electric poles form and aqueous pores

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 51

CHEMICAL TREATMENT
Electrochemical Approach
for Screening Concrete
Corrosion Inhibitors
I-Wen Huang, Fred goodWIn, and
Frank apIcella, BASF Construction
Chemicals, LLC, Beachwood, Ohio, USA
C
52 SEPTEMBER 2017 MATERIALS PERFORMANCE
To compare laboratory-synthesized
materials for corrosion inhibition ca-
pabilities, a new corrosion inhibitor as-
sessment methodology was intro-
duced that accounts for the onset of
corrosion inhibition during incubation
time, which often is ignored when a
single corrosion measurement proce-
dure is used. The robust analysis
described in this article uses a combi-
nation of open-circuit potential, elec-
trochemical impedance spectros-
copy, linear polarization, and
potentiodynamic polarization in simu-
lated pore solution. Combining these
electrochemical tests provides a tech-
nique to monitor the corrosion inhibi-
tion capability as a function of time.
The advantages and limitations are
also discussed in this article.
Concrete is the second most common
man-made material after potable water. 1
Nearly one cubic yard of concrete per
person is placed per year. Assuming a
typical service life, up to 30 times this
amount of existing concrete is in various
states of deterioration.2 Reinforcing steel
bars are installed in concrete to support
tensile and flexural stresses for structural
design requirements. However, reinforcing
steel in concrete is susceptible to corrosion
due to the presence of chloride ions or
reduced pH in concrete from carbonation.
The expansive stress induced by corrosion
product formation on the reinforcing steel
can cause the concrete cover to crack and
spall, which can cause hazardous conse-
quences such as structural failure.
One approach to protect steel from cor-
rosion is to incorporate corrosion inhibi-
tors: as admixtures within the freshly
placed concrete or a surface treatment
applied to existing concrete. The electro-
chemical evaluation of corrosion inhibitors
used in this manner is documented in for-
mer studies and standards. 3-11 However,
there is a lack of protocols to rapidly evalu-
ate the effectiveness of a corrosion-inhibit-
ing admixture with unknown corrosion
inhibition performance.
Typically, corrosion inhibitors form a
passive film on reinforcing steel that is
inert to corrosion reactions. Since this pas-
sive film formation occurs over time, any
testing method that ignores this time
dependence may not appropriately assess
and compare the effectiveness of inhibi-
tors. In addition, traditional evaluation
techniques (e.g., mass loss, surface mor-
phology imaging, etc.) require weeks or
even months (e.g., outdoor exposure) to
determine the effectiveness of a corrosion
inhibitor. This is not practical for screening
a number of inhibitors.
The testing protocol described in this
article combines the use of open-circuit
potential (OCP), electrochemical imped-
ance spectroscopy (EIS), linear polarization
resistance (LPR), and potentiodynamic
polarization tests to provide a rapid assess-
NACE INTERNATIONAL: VOL. 56, NO. 9
ment of the effectiveness of inhibitors for
protecting reinforcing steel from corrosion
in the presence of simulated concrete pore
water solution containing added chlorides.
Experimental Procedures
Corrosion behavior of reinforcing steel
was simulated using UNS G10800 carbon
steel (CS) sheets polished sequentially with
400, 800, and 1,200 grit emery paper, fol-
lowed by cleaning with methanol, and then
air dried in a ventilation hood before test-
ing. Simulated pore solution (pH 12.3) was
prepared by decanting water from a 2:1 (by
mass) water/Portland cement mixture.
This solution was combined with 3 wt%
sodium chloride (NaCl) and 1 wt% corro-
sion inhibitor. There were five water-solu-
ble corrosion inhibitors included in this
study, numbered 1 through 5, and one con-
trol specimen without inhibitor.
Electrochemical Tests
A saturated calomel electrode (SCE)
was used as a reference electrode and plati-
num mesh was used as a counter electrode
in a commercial flat cell. A 20-min OCP
measurement was conducted prior to EIS
measurements to ensure electrochemical
stability. Two EIS measurements were then
made: the first started immediately after
the OCP measurements at 100 kHz to 5
mHz in frequency, and the second EIS mea-
surement was made after 24 h to allow the
onset of passive film formation. A typical
10-mV (root mean square) voltage was
applied in sinusoidal fluctuation. EIS
results were modeled using a simplified
Randles circuit for quantitative polariza-
tion resistance (Rp) results. Afterward, LPR
was also used for measuring Rp from –20 to
20 mV vs. OCP with a relatively fast scan
rate (1 mV/s). The corrosion rate (icorr) was
then calculated using the Stern-Geary
equation,12 shown in Equation (1):
0.022
i corr =
Rp
(1)
Afterward, polarization tests were per-
formed from –50 to +450 mV vs. OCP with
the same scan rate as LPR. The sequence of
NACE INTERNATIONAL: VOL. 56, NO. 9
FIGURE 1 OCP measurements.
tests was determined by the destructive-
ness—from nondestructive to destruc-
tive—to retrieve the most information.
The time requirements were 20 min for
OCP, ~40 min for EIS, 1 min for LPR, and 9
min for polarization. This did not include
the dwelling time between each measure-
ment. The time required may vary depend-
ing on parameter settings and potentio-
stats used.
Results and Discussion
Tests of the solution pH after the elec-
trochemical test indicated no significant
pH change (pH 11.7), suggesting that car-
bonation and cathodic reactions such as an
oxygen reduction reaction did not signifi-
cantly affect the solution pH during the
24-h test.
Open Circuit Potential
Figure 1 shows the OCP results, where
the OCP for each specimen was measured
in the range between –0.48 to –0.38 V vs.
SCE in the specified solution. The control
test sample without inhibitor showed the
lowest OCP among all six measurements,
indicating the most active oxidation with-
out inhibitor at the onset. In general, the
OCP reading decreased with time, which
could be due to the ongoing corrosion reac-
tions at early stages.
Electrochemical Impedance
Spectroscopy
The EIS measurements in Nyquist plots
after 1-h and 24-h exposures are shown in
MATERIALS PERFORMANCE SEPTEMBER 2017
FIGURE 2 EIS-Nyquist plot after 1-h exposure.
FIGURE 3 EIS-Nyquist plot after 24-h
exposure with an enlarged scale in the inset.
Figures 2 and 3, respectively. A clear trend
of increasing corrosion inhibition was
found after the 24-h exposure. Corrosion
Inhibitors 1 and 2 did not show any corro-
sion inhibition after the 1-h exposure, while
Inhibitor 1 exhibited the best corrosion
inhibition after 24 h. Since the measure-
ments are conducted on bare CS with cor-
rosion inhibitors, the corrosion inhibition
is simulated by a simplified Randles circuit,
assuming the corrosion inhibition only
developed through a gradual passive film
formation. The simulation result of R p is
shown in Figure 4, which indicates that
Inhibitor 1 outperformed other inhibitors,
and Inhibitor 5 was the least effective.
Linear Polarization
Linear polarization results, as shown in
Figure 5, indicate very similar results when
compared to EIS. According to Equation
(1), the corrosion rate (i corr ) of CS can
be calculated where R p is polarization
53
CHEMICAL TREATMENT

Discussion
In summary, the performance of five
proprietary inhibitors was quantitatively
evaluated by a series of electrochemical
tests. This efficient and robust approach
considered the onset of corrosion inhibition
between 1 and 24 h of exposure; therefore,
an OCP delay longer than at least 1 h is sug-
gested to account for the incubation time.
Corrosion inhibition results measured by
EIS indicated that Inhibitor 1 is the best
FIGURE 4 Polarization resistance (Rp) simulated FIGURE 5 Linear polarization results. among these five inhibitors and this was
by a simplified Randles circuit.
confirmed by quantitative measurements of
Rp. The long measurement time of EIS can
be further shortened by reducing the mea-
TABLE 1. EIS AND LPR Rp RESULTS AND Icorr CALCULATED BY surement frequency range—for example:
STERN-GEARY EQUATION (EQUATION [1]) from 100 kHz to 0.1 Hz would likely be suf-
Rp (kΩ∙cm2) ficient in this case. LPR results provided
measurements similar to EIS in a short
Blank Inhibitor 1 Inhibitor 2 Inhibitor 3 Inhibitor 4 Inhibitor 5
time; however, the results obtained by LPR
EIS 12 210 101 83 83 28 may need further examination to avoid
LPR 17 220 56(A) 71 130 32 localized corrosion introduced during the
icorr (µA∙cm ) –2 measurement process. In addition, LPR
data interpretation may not be valid for
EIS 1.8 0.1 0.2 0.3 0.3 0.8
unfamiliar inhibitors without knowing the
LPR 1.3 0.1 0.4 0.3 0.2 0.7 Tafel region. This work simply used empiri-
(A)
Corrosion had initiated during previous tests cal assumptions. Potentiodynamic polar-
ization was the most time-efficient method
for obtaining corrosion information regard-
inhibitors, the effective Tafel region may be
less of its destructiveness. Polarization
narrower than the range of measurements,
results showed passivity in alkaline solu-
or there is a potential risk of introducing
tions, but estimating icorr could still be chal-
localized corrosion during measurement
lenging for untrained individuals.
(Inhibitor 2).

Potentiodynamic Polarization Summary

FIGURE 6 Polarization results.
resistance measured from the slope of LPR,
and 0.022 is an empirical value assuming
cathodic and anodic Tafel slopes are both
0.1 V/decade. The Rp slope calculation was
obtained using the linear region between
the arrowheads as shown in Figure 5.
According to this equation, the calculated
corrosion rates (i corr) from EIS and LPR
were very similar, as shown in Table 1.
However, there are still challenges for the
LPR measurement, such as the Tafel slope
interpretation (Inhibitor 3 in Figure 5).
Depending on the performance of the
Polarization results are shown in Figure
6, where all measurements showed passiv-
ity in the alkaline concrete pore solution.
According to the polarization results,
Inhibitor 1 is clearly the best material
among these five corrosion inhibitors,
which agrees with the EIS and LPR testing
results. Among all six measurements, only
the blank test shows passivity breakdown,
and Inhibitors 2, 3, and 5 may have pre-
existing corrosion that initiated during the
LPR testing. After the serial tests, corro-
sion—mostly introduced during polariza-
tion—initiated from the rim of the exposed
area and was found on all corroded sam-
ples. The susceptible rim area in a flat cell
is due to the designed geometry and possi-
ble crevice corrosion at the seal, which is
outside the scope of this article.
In conclusion, using a combination of
electrochemical tests provides a robust and
comprehensive analysis of inhibitor perfor-
mance in a relatively short time (24 h). Com-
parative analyses show similar corrosion
inhibition trends between EIS, LPR, and
potentiodynamic polarization results. This
approach is suggested for fast screening of
possible corrosion inhibitors with unknown
performance before conducting long-term
testing. In addition, the combination of mul-
tiple techniques provides rapid systematical
evaluation while also considering the incu-
bation period of the corrosion inhibitors.
References
1 M.-S. Low, “Material Flow Analysis of Con-
crete in the United States,” Massachusetts
Institute of Technology, 2005.

54 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 Electrochemical Approach for Screening Concrete Corrosion Inhibitors

2 C. Meyer, “Concrete Materials and Sustain-
able Development in the USA,” Structural
Engineering International 14, 3 (2004): pp.
203-207.
3 H.-W. Song, V. Saraswathy, “Corrosion Moni-
toring of Reinforced Concrete Structures—
A Review,” Int. J. Electrochem. Sci. 2 (2007): pp.
1-28.
4 ASTM G61-86, “Standard Test Method for
C onductin g Cyclic Pot entio dynamic
Polarization Measurements for Localized
Corrosion Susceptibility of Iron-, Nickel-, or
Cobalt-Based Alloys” (West Conshohocken,
PA: ASTM International, 2014).
5 ASTM G109-07, “Standard Test Method for
Determining Effects of Chemical Admixtures
on Corrosion of Embedded Steel Reinforce-
ment in Concrete Exposed to Chloride Envi-
ronments” (West Conshohocken, PA: ASTM,
2013).
6 ASTM G180-13, “Standard Test Method for
Corrosion Inhibiting Admixtures for Steel in
Concrete by Polarization Resistance in
Cementitious Slurries” (West Conshohocken,
PA: ASTM, 2013).
7 ASTM G59, “Standard Test Method for Con-
ducting Potentiodynamic Polarization Resis-
tance Measurements” (West Conshohocken,
PA: ASTM, 2014).
8 ACI 222R-01, “Protection of Metals in Con-
crete Against Corrosion” (Farmington Hills,
MI: ACI, 2001).
9 ICRI 510.1-2013, “Guide for Electrochemical
Techniques to Mitigate the Corrosion of
Steel for Reinforced Concrete Structures”
(St. Paul, MN: ICRI, 2013).
10 BS EN 480-14: 2006, “Admixtures for Con-
crete, Mortar and Grout—Test Methods—
Part 14: Determination of the Effect on Cor-
rosion Susceptibility of Reinforcing Steel by
Potentiostatic Electrochemical Test” (Lon-
don, U.K.: BSI, 2006).
11 C. Monticelli, A. Frignani, G. Trabanelli,
“A Study on Corrosion Inhibitors for Con-
crete Application,” Cement and Concrete
Research 30, 4 (2000): pp. 635-642.
12 M. Stern, A.L. Geary, “Electrochemical Polar-
ization: I. A Theoretical Analysis of the Shape
of Polarization Curves,” J. Electrochemical
Society 104, 1 (1957): pp. 56-63.
This article is based on CORROSION 2017 paper
no. 9046, presented in New Orleans, Louisiana, USA.
I-WEN EVAN HUANG is a corrosion scien-
tist at BASF Construction Chemicals,
Global Corrosion Competency Center,
Beachwood, Ohio, USA. He has a Ph.D.
from The Ohio State University and is a
member of NACE, ACI, ICRI, SSPC, and
ASTM G01.
FRED GOODWIN is the Global Compe-
tency Center head at BASF Construction
Chemicals, LLC, Beachwood, Ohio, USA.
He has more than 30 years of experience
as a chemist for cementitious materials. He
received the ASTM Award of Merit in
2016, the J.C. Roumain Innovation in Con-
crete Award in 2015, the 2012 JPCL Top
Thinker, and is an honorary member of
ASTM International C01 and C09. Good-
win is a NACE International-certified Cor-
rosion Technologist and Fellow of ACI,
ICRI, and ASTM. He is a member of NACE,
ACI, ICRI, SSPC—The Protective Coatings
Society, and SDC.
FRANK APICELLA is head of Technical
Centre, Middle East, BASF Construction
Chemicals UAE, LCC, Dubai, United Arab
Emirates. He has 25 years of experience
developing products that improve,
protect, and repair concrete construction.
He served two terms on the ICRI Technical
Activities Committee and is past chair of
the ICRI Coatings and Waterproofing
Committee. He is a former member of the
Board of Directions and Technology
Management Committee of the Strategic
Development Council of ACI. He holds
multiple patents and is a frequent
magazine author. He is a member of NACE.

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NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 55

MATERIALS SELECTION & DESIGN
Rust Layer Characterization of
a Buried Drinking Water Pipe
ZHanjun guo, Institute of Environmental
& Municipal Engineering, North China
University of Water Resources and
Electric Power, Zhengzhou, China
ZHIlIang cHen, Yangzhou Research
Academy of Energy and Material,
Chinese Academy of Sciences,
Yangzhou, China
S
56 SEPTEMBER 2017 MATERIALS PERFORMANCE
The surface corrosion layer of a steel
water pipe buried ~30 years in a soil
environment was investigated by con-
ventional and synchrotron x-ray dif-
fraction (XRD). The results indicate the
surface rust layer had entered a stable
state with a higher amount of goethite
(α-FeOOH) and a much lower amount
of lepidocrocite (γ-FeOOH). Because
the synchrotron XRD technique pro-
duces stronger and better-defined
peaks, it has a great advantage over
conventional XRD in evaluating the
stability of the steel rust layer in a soil
environment.
Steel pipes have been employed in
drinking water distribution systems for
over five centuries.1 As the thermodynami-
cally stable form of iron in contact with
oxygen is ferric iron [Fe(III)], steel pipes
can suffer from corrosion. This process
releases iron into solution or results in iron
scales. Corrosion may uniformly attack a
steel pipe surface (general corrosion) or
may be focused at specific sites (localized
corrosion). While general corrosion results
in the development of uniform scales, local-
ized corrosion can produce pitting. The
pipe lifespan can be determined by pitting
corrosion, which is closely related to the
environment surrounding the steel pipe,
the composition of the drinking water, the
bacteria activity under corrosion product
tubercles, and the flow of high-pressure
drinking water inside the pipe. 2 Uniform
corrosion usually occurs on the external
surface of the pipe exposed to atmospheric
conditions.
The interior of most steel drinking
water pipes used in domestic indoor envi-
ronments has a buildup of steel corrosion
products.3 The internal surface of the steel
pipe exposed to aqueous conditions usually
suffers more severe corrosion than the
external surface of the pipe that is exposed
to indoor atmospheric conditions. In the
underground soil environment, however,
the steel drinking water pipe’s external sur-
face usually suffers much more serious cor-
rosion attack than the internal surface
because soil is a much more corrosive envi-
ronment than the indoor atmosphere.3
Studies on steel corrosion in under-
ground soil environments are typically car-
ried out by placing a standard steel speci-
men at a certain depth in the soil being
studied. 4 These studies are beneficial for
investigating the corrosion effect of certain
soil compositions and illustrating the cor-
rosion mechanism of steel. Reports dis-
cussing in situ corrosion investigations of
steel pipe surfaces are scarce due to the dif-
ficulty of conducting these tests in the field.
In the present study, the corrosion of
one steel potable water pipe after ~30 years
of soil exposure was investigated with
attention focused on characterizing the
surface rust layer. This investigation has
practical and theoretical importance. First,
it provides field corrosion data on buried
steel water pipelines. Moreover, it provides
reference data for other locations that face
similar issues.
NACE INTERNATIONAL: VOL. 56, NO. 9
 Experimental Procedures
The steel drinking water pipe that is
part of the water distribution system in
Zhengzhou, China, is made of 16Mn carbon
steel. The water pipe has been buried for
~30 years.
The rust layer on the exterior surface of
the pipe was scraped off and ground to fine
powder in a mortar using a pestle, and then
characterized by x-ray diffraction (XRD) to
determine the iron oxide phases. The com-
mon XRD measurement was carried out
using a Rigaku-D/max 2000† diffractometer
with a CuKα target under 50 kV and 250 mA
at a scanning speed of 2 degrees/min. The
synchrotron radiation XRD characteriza-
tion was performed at a wavelength of
1.2398 Å based on a bending magnet, and a
Si(111) double crystal monochromator was
used to monochromatize the beam. The
focus spot size was ~0.5 mm and the end
station was equipped with a Huber 5021†
diffractometer. A sodium iodide (Nal) scin-
tillation detector was employed for data
collection. To compare the intensity differ-
ences of the XRD samples, the amount of
rust used for each analysis was kept the FIGURE 1 Visual observation of the corroded steel water pipe with close-up photographs of
same. In this case, the intensity of certain different corrosion sites (positions).
iron oxide phases, such as goethite
(α-FeOOH), lepidocrocite (γ-FeOOH), and
magnetite (Fe 3 O 4 ), semi-quantitatively Fe3O4, and/or akaganéite (β-FeOOH), and steel water pipe. The other three samples
reflected the relative amount of the phases much greater amounts of x-ray amorphous were taken from the outside wall of the
in the iron oxide samples.5-6 substances that do not give a well-defined steel water pipe.
Bragg peak by the XRD technique. 5 The For al l th e m ea sured sampl e s,
Results and Discussion γ-FeOOH is yellow-orange in color, and α-FeOOH, γ-FeOOH, and Fe3O4 peaks were
α-FeOOH and Fe 3O 4 are dark-brown in detected. However, the β-FeOOH peak was
Surface Observation color.7 not found in any of the samples. The XRD
of the Rust Layer comparison of the surface rust layers
Figures 1(a) through (d) show the visual Common X-Ray Diffraction shown in Figures 1(a), (b), and (c) indicates
observation of the corroded steel pipe with Characterization of the Rust Layer that the rust at the site in Figure 1(a) has
close-up photographs of the pipe itself. The Common XRD was used to characterize lower amounts of α-FeOOH, γ-FeOOH, and
rust layer color is not the same at different the powdered rust scraped from the differ- Fe3O4 than the rust at the site in Figure 1(c).
positions. In general, the rust layer in Fig- ent sites on the pipe shown in Figure 1. In The rust layer at the site in Figure 1(b)
ures 1(a), (c), and (d) is a dark-brown color, Figure 2, Position (a) corresponds to the was expected to have a higher amount of
while the rust layer in Figure 1(b) is a yel- rust at the site shown in Figure 1(a); Posi- γ-FeOOH due to the rust layer’s yellow-
low-brown color. This color change relates tion (b) corresponds to the rust at the site brown color. However, it had a lower
to changes in the iron oxide phases. Usu- shown in Figure 1(b); Position (c) corre- amount of γ-FeOOH than the rust at the
ally, the rust formed during corrosion of sponds to the rust at the site shown in Fig- sites in Figure 1(a) and (c), indicating that
steel in natural environments is composed ure 1(c); and Position (d) corresponds to the yellow-brown color was brought by the
of lesser amounts of α-FeOOH, γ-FeOOH, the rust at the site shown in Figure 1(d). newly formed surface rust layer, which was
The XRD pattern of Position (d) represents a relatively small portion of the total rust
†
Trade name. the sample taken from the inside wall of the amount.

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 57

MATERIALS SELECTION & DESIGN

For the rust at the site in Figure 1(d), the

XRD corrosion product peak intensities
were weak compared with the other three
XRD samples, indicating a lower amount of
α-FeOOH and γ-FeOOH. Morever, Figure 2
also shows that the Fe3O4 peaks at all sites
are very similar.
The environments where the rust
formed may be responsible for the differ-
ences. The steel water pipe was buried for
30 years in the underground soil environ-
ment and its outside surface was in direct
contact with the surrounding soil, while
the inside surface was in direct contact
with flowing drinking water. Therefore, the
environments should be responsible for the
composition differences of the rust formed.

Synchrotron Radiation X-Ray

Diffraction Characterization
FIGURE 2 Commonly used XRD characterization of the powdered rust scraped from the different
As mentioned previously, the rust
sites in Figure 1. Position (a) corresponds to the rust at the site in Figure 1(a); Position (b) corre- formed on steel under natural environmen-
sponds to the rust at the site in Figure 1(b); Position (c) corresponds to the rust at the site in Figure tal conditions is composed of lesser
1(c); and Position (d) corresponds to the rust at the site in Figure 1(d). amounts of α-FeOOH, γ-FeOOH, Fe 3O 4,
and/or β-FeOOH, and much greater
amounts of an x-ray amorphous substance,
which does not give a well-defined Bragg
peak by the standard XRD technique.6 The
special niche provided by synchrotron radi-
ation is that it permits XRD measurements
with increased energy, spatial, and time
resolution. Compared to conventional
x-ray tubes, the synchrotron radiation is
many times brighter and allows faster tab-
ulation on similarly sized samples. The
high intensity of synchrotron x-ray beams
greatly improves the signal-to-noise ratio,
allowing the analysis of minor amounts of
material.8 Figure 3 shows the synchrotron
XRD characterization of the powdered rust
scraped from the same four sites shown in
Figure 1. The 2θ-degree shift of the diffrac-
tion peaks results from the different wave-
lengths of synchrotron x-ray vs. the com-
monly used CuKα x-ray.
Figure 3 shows the rust at the site in
Figure 1(a) contains a higher amount of
FIGURE 3 Synchrotron XRD characterization of the powdered rust scraped from the different sites
γ-FeOOH and lower amounts of α-FeOOH
shown in Figure 1.
and Fe3O4 than the rust at the sites in Fig-
ures 1(b) and (c).
The rust at the site in Figure 1(d) has
obvious α-FeOOH and Fe3O4 peaks, but no
γ-FeOOH. A higher amount of γ-FeOOH
indicates a more active rust layer (i.e., the

58 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9


rust layer does not enter a stable state).9
From the XRD measurements, it can be
concluded that the area at the site in Figure
1(a) suffered the most serious corrosion
attack among the four sites investigated.
The galvanic effect at the steel tap may be
responsible for this.
Rust Layer Composition Discussion
Usually, Fe3O4 is as conductive as iron,
whereas α-FeOOH is dielectric. From the
electrochemical point of view,10 γ-FeOOH is
active and α-FeOOH is thermodynamically
stable and electrochemically inactive.
Moreover, γ-FeOOH can be reduced to
Fe3O4, which can be oxidized to α-FeOOH
as the corrosion process proceeds.11 Among
these transformations, x-ray amorphous
substances may act as intermediates.
Although β-FeOOH preferentially forms
in the presence of chloride ions (Cl−), it was
not found in the samples. It is believed that
Cl− exists in the drinking water as well as
the soil environment surrounding the steel
water pipe. Since the formation of β-FeOOH
in the presence of Cl– can be greatly affected
by the presence of sulfate ions (SO42–) in the
corrosion process,12 the presence of SO42– in
the environment is responsible for the lack
of β-FeOOH.
As the buried steel drinking water pipe
was in service for ~30 years, it is believed
that the rust layer on the steel water pipe
had entered a steady state without an obvi-
ous composition evolution difference as the
corrosion process proceeded. The relative
content of α-FeOOH is an important index
for evaluating the corrosion resistance of
the rust layer, 13 and a higher amount of
α-FeOOH is usually observed in the rust as
the rust layer enters a stable state.14
For the present investigation, it was dif-
ficult to carry out the corrosion evolution
time tests. By comparing the intensity of
the diffraction peaks, it was found that the
rust layer had entered a stable state after
the long burial time,15 with a higher amount
of α-FeOOH and lower amount of γ-FeOOH,
as shown in Figures 2 and 3. The synchro-
tron XRD characterization confirms that
the stronger diffraction intensity of the
α-FeOOH peak with a very weak or almost
nonexistent γ-FeOOH peak is an important
index in illustrating the stable state of the
NACE INTERNATIONAL: VOL. 56, NO. 9
Rust Layer Characterization of a Buried Drinking Water Pipe
rust layer. Therefore, the synchrotron XRD
technique has a great advantage in evaluat-
ing the stable state of the steel rust layer in
a natural environment.
Conclusions
Characterization of the surface rust
layer on an in-service steel drinking water
pipe after ~30 years in an underground soil
environment was investigated. The follow-
ing conclusions can be drawn:
• The surface rust layer on the steel
drinking water pipe had entered a
stable state with a higher amount of
α-FeOOH and much lower amount of
γ-FeOOH.
• The stronger diffraction intensity of
the α-FeOOH peak with a very weak
or almost nonexistent γ-FeOOH peak
is an important index in illustrating
the stable state of the rust layer.
• The synchrotron XRD technique has
a great advantage in evaluating the
stability of a steel rust layer in a soil
environment.
References
1 Z. Niu, et al., “Iron Stability in Drinking
Water Distribution Systems in a City of
China,” J. Environmental Sciences 18 (2006):
pp. 40-46.
2 P. Sarin, et al., “Physico-Chemical Character-
istics of Corrosion Scales in Old Iron Pipes,”
Water Research 35 (2001): pp. 2,961-2,969.
3 H.J. Jang, Y.J. Choi, J.O. Ka, “Effects of Diverse
Water Pipe Materials on Bacterial Communi-
ties and Water Quality in the Annual Reac-
tor,” J. Microbiology and Biotechnology 21
(2011): pp. 115-123.
4 I.S. Cole, D. Marney, “The Science of Pipe
Corrosion: A Review of the Literature on the
Corrosion of Ferrous Metals in Soils,” Corros.
Sci. 56 (2012): pp. 5-16.
5 M. Yamashita, H. Miyuki, H. Nagano, “The
Long Term Growth of the Protective Rust
Layer Formed on Weathering Steel by Atmo-
spheric Corrosion During a Quarter of a Cen-
tury,” Corros. Sci. 36 (1994): pp. 283-299.
6 T. Kamimura, et al., “Composition and Pro-
tective Ability of Rust Layer Formed on
Weathering Steel Exposed to Various Envi-
ronments,” Corros. Sci. 48 (2006): pp. 2,799-
2,812.
MATERIALS PERFORMANCE SEPTEMBER 2017
7 L.L. Wang, et al., “Corrosion Analysis of a
Steel Drinking Water Pipe in an Indoor Envi-
ronment,” MP 51, 9 (2012): pp. 61-65.
8 M. Yamashita, et al., “Structure and Protec-
tive Performance of Atmospheric Corrosion
Product of Fe-Cr Alloy Film Analyzed by
Mössbauer Spectroscopy and with Synchro-
tron Radiation X-Rays,” Corros. Sci. 45 (2003):
pp. 381-394.
9 Y.Y. Chen, et al., “Mechanical Properties and
Corrosion Resistance of Low-Alloy Steels in
Atmospheric Conditions Containing Chlo-
ride,” Material Science and Engineering A 398
(2005): pp. 47-59.
10 J. Lin, M. Ellaway, R. Adrien, “Study of Corro-
sion Material Accumulated on the Inner Wall
of Steel Water Pipe,” Corros. Sci. 43 (2001): pp.
2,065-2,081.
11 T. Misawa, K. Hashimoto, S. Shimodaira,
“The Mechanism of Formation of Iron Oxide
and Oxyhydroxides in Aqueous Solutions at
Room Temperature,” Corros. Sci. 14 (1974):
pp. 131-149.
12 K. Asami, M. Kikuchi, “In-Depth Distribution
of Rusts on a Plain Carbon Steel and Weath-
ering Steels Exposed to Coastal-Industrial
Atmosphere for 17 Years,” Corros. Sci. 45
(2003): pp. 2,671-2,688.
13 F. Corvo, et al., “Changes in Atmospheric
Corrosion Rate Caused by Chloride Ions De-
pending on Rain Regime,” Corros. Sci. 47
(2005): pp. 883-892.
14 I.M. Allam, J.S. Arlow, H. Saricimen, “Initial
Stages of Atmospheric Corrosion of Steel in
the Arabian Gulf,” Corros. Sci. 32 (1991): pp.
417-432.
15 M. Stratmann, K. Bohnenkamp, H.-J. Engell,
“An Electrochemical Study of Phase-Transi-
tion in Rust Layers,” Corros. Sci. 23 (1983): pp.
969-985.
ZHANJUN GUO is a teacher and research
assistant at North China University of
Water Resources and Electric Power,
Zhengzhou City, Henan Province, 450045,
China. His research focuses on environ-
mental and municipal engineering.
ZHILIANG CHEN is a research manager at
Yangzhou Research Academy of Energy
and Material, Yangzhou City, Jiangsu
Province, 225009, China. He has a Ph.D. in
environmental science and focuses on
environmental protection.
59
 MATERIALS
PERFORMANCE
CORROSION PREVENTION AND CONTROL WORLDWIDE

9TH ANNUAL COMPANY SHOWCASE

This feature, published annually in the September issue of MP, highlights

participating companies involved in the corrosion control industry. The
Showcase includes an overview of each company’s products and services,
as well as location and contact information.

Carboline Company
Carboline is a leading global manufacturer of high-performance
coatings, linings, and fireproofing products. Solving customers’
problems is how we got our start, and after 70 years, it’s still our
focus at Carboline. Our goal is to meet your needs and expectations
by recommending products that provide the right solutions.
By doing this, Carboline has become the global standard of
quality when it comes to high-performance coatings, linings, and
fireproofing products. Our unwavering focus on performance,
broad industrial market experience, continuous investment in
long-term product development and testing, and our ability to meet
challenges anywhere in the world makes us a source of coatings
knowledge customers find invaluable. Our global manufacturing
and sales structure allows us to coordinate and service all phases
of construction projects, regardless of location. Put our expertise,
experience, and know-how to work for you.

Carboline Company
2150 Schuetz Rd. • St. Louis, MO 63146, USA
Tel: +1 314-644-1000
Web site: www.carboline.com

60 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 2017 COMPANY SHOWCASE

Corrpro Companies, Inc.

Corrpro Companies, Inc. is the complete corrosion protection source for
a wide variety of structures and pipelines. As one of the industry’s leading
providers of cathodic protection and engineering services, Corrpro offers
the largest group of dedicated corrosion control professionals. Through
our pipeline integrity management program, Corrpro can help maximize
the useful life of pipeline assets by continuously combining strategically
designed engineering analyses and assessments. Our program provides a
wide variety of benefits to pipeline assets including increasing safety, risk
management, hazard identification, optimizing expenditures, and data
management.

We offer the industry’s latest engineering and design procedures, advanced

research, and proper application of a broad range of products and
services to help preserve piping, equipment, and infrastructure in various
industries and environments throughout the world. Our services prevent
the degradation of metallic and concrete structures due to corrosion,
mitigating substantial delays and the high costs associated with replacing
deteriorated and unsafe structures. With the latest engineering and a broad
range of continually improving materials, products, and services, Corrpro
helps to preserve the world’s energy resources, assets, and the environment.

Corrpro Companies, Inc.

7000 B Hollister • Houston, TX 77040, USA
Tel: 1 866-CORRPRO • Fax: +1 713-460-6060
Email: corrprosales@aegion.com
Web site: www.corrpro.com

Cortec® Corporation
Cortec® Corporation is trusted globally in the corrosion protection
business. Headquartered in St. Paul, Minnesota, Cortec® manufactures
environmentally friendly Vapor-phase Corrosion Inhibitor (VpCI®) and
Migratory Corrosion Inhibitor (MCI®) technologies. Our relentless dedication
to sustainability, quality, service, and support is unmatched in the industry.
Cortec® has over 400 products for construction, packaging, metalworking,
electronics, water treatment, oil and gas, and other industries that are
distributed worldwide. ISO 9001/ISO 17025/ISO 14001:2004 certified.
Cortec’s patented VpCI® technology represents a breakthrough solution
in corrosion prevention. Our VpCI® products protect metals with a
chemically adsorbed molecular layer that provides multimetal corrosion
protection. The coverage is complete—all surfaces, crevices, cavities, and
other inaccessible void areas receive total protection. The VpCI® barrier is
self-replenishing, even for packaging that’s repeatedly opened, and typically
protects for up to 24 months.
Cortec’s patented MCI® technology protects reinforcing metal in concrete
from corrosion. MCI® extends the life span of new and existing concrete
structures. Often, corroding deteriorated rebar in concrete is the cause of
costly repairs, financial losses, injuries, and even deaths; but Cortec® has the
corrosion solution. Cortec® MCI® products maintain structural integrity,
rehabilitate vulnerable structures, and alleviate environmental concerns.
Cortec® Corporation
4119 White Bear Pkwy. • St. Paul, MN 55110, USA
Tel: +1 651-429-1100 • Fax: +1 651-429-1122
Email: productinfo@cortecvci.com
Web site: www.cortecvci.com

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 61

2017 COMPANY SHOWCASE

Cosasco
By controlling pipeline corrosion and erosion, you control risk. Fail
to do so and you risk wasting money on excess corrosion inhibitor,
increased corrosion and decreased asset life, or even hazardous
loss of containment. Too many solutions rely on after-the-fact
inspection, or low-sensitivity sensors that give an incomplete or
confusing picture of what’s happening.

Cosasco offers complete corrosion control, from consultancy, to

manufacturing, to in-field support, and long-term maintenance.
Taking in both intrusive and non-intrusive corrosion and erosion
monitoring sensors—unrivalled in the market for sensitivity. These
data allow bespoke chemical optimization solutions to fine-tune
the levels of anticorrosion chemicals injected. All coupled with
complete data and communications solutions.

Anything less is false economy. Cosasco takes pride in providing

a bespoke, expert-led service. Its locations around the globe mean
that you can always be sure of speaking to a genuine corrosion
monitoring expert, not to a third party, no matter your time zone.
By doing so, Cosasco invests in long-term relationships that extend
asset lifecycles, increase safety, and reduce cost.

Cosasco
11841 Smith Ave. • Santa Fe Springs, CA 90670, USA
Tel: 1 800-635-6898 • +1 562-949-0123 • Fax: +1 562-949-3065
Web site: www.cosasco.com

Denso North America

Denso is a leading manufacturer of anticorrosion coatings that
include Protal liquid epoxies, Denso petrolatum tapes, mastics,
primers, bitumen tapes, butyl tapes, hot-applied tapes, coal tar
epoxies, a full line of marine pile protection systems, and tank lining
and coatings systems. Winn & Coales was originally established as
a business in London, England, in 1883 and the first petrolatum tape
manufactured in the United Kingdom was Denso tape, manufactured
under license by Winn & Coales (Denso) Limited. Denso tape was
developed over 85 years ago for the “Long Life Protection” of buried
steel pipelines against corrosion. Denso’s SeaShield Marine Systems
include fiberglass forms, epoxy grouts, underwater epoxies, injectable
epoxies, petrolatum tape wrap systems, and much more. With over
40 years of proven experience in protecting tanks worldwide, Denso
manufactures a full line of tank linings and coatings. Denso North
America has offices throughout the United States and Canada and is
a wholly owned subsidiary of Winn & Coales International. Denso is
recognized as a global leader in corrosion prevention.

Denso North America

9747 Whithorn Dr. • Houston, TX 77095, USA
Tel: +1 281-821-3355 • Fax: +1 281-821-0304
Email: info@densona.com
Web site: www.densona.com

62 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 2017 COMPANY SHOWCASE

Farwest Corrosion Control Company

Established in 1956, Farwest Corrosion Control Company is a
premier supplier of cathodic protection (CP) and corrosion control
materials and equipment. With nine office/warehouse locations
nationwide, each staffed by knowledgable personnel, we service all
industries and are the single-source solution for all your CP and
corrosion control needs.

Visit our web site: it is the largest corrosion-related site in the world with
over 1,000 pages of products, instructions, videos, printable MSDS sheets,
and much, much more.

Products include: • Services Include:

• Anodes • CP Engineering & Design
• CP Power Supplies • CP Surveys
• Coatings • CP Installation
• Isolators • Deep Well Drilling
• Test Equipment • System Repair
• And More... • And More...
Farwest Corrosion Control Company
12029 Regentview Ave. • Downey, CA 90241-5517, USA
Tel: 1 888-532-7937 (U.S. & Canada) • +1 310-532-9524
Email: sales@farwestcorrosion.com
Web site: www.farwestcorrosion.com

Complete Cathodic Protection and Corrosion Control Solutions for:

Oil & Gas, Pipeline, Energy, Water, Wastewater, Marine, and Offshore Industries

Jennings Anodes USA

Jennings Anodes USA is a new joint venture in America formed by
combining the manufacturing resources of two long-term global
players within the CP marketplace.

Specialist Castings UK (Jennings) and Yuxi China have over 30 years

of experience in manufacture and global supply.

We have combined our technical expertise, innovation, and know-how

to create an anode operation directly within the U.S. market. U.S.-
based in-house stock improves service levels and customer support.

We are a leading domestic supplier of anodes, including both

impressed current anodes as well as sacrificial anodes, and in the
latest third-party testing of silicon iron tubular anodes, we are shown
to outperform all other tested brands.

For further information or any queries please call, email, or visit our
web site at www.jenningsanodesusa.com.

Jennings Anodes USA

Contact: Chris Jennings
Tel: +1 713-799-3884 • Email: chris@jenningsanodes.com

Contact: Stephanie Sanchez

Tel: +1 281-844-6560 • Email: stephanie@jenningsanodes.com

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 63

2017 COMPANY SHOWCASE

MESA

MESA is proud to introduce another industry-leading customer satisfaction initiative showcasing our commitment to value-added
services. We call it our CEO Assurance Program, and are so confident in our products and customer service, we want to guarantee
them! With this program, we warranty that our material orders are:
• 100% accurate and error-free of any missed/incorrect products
• Shipped when promised and delivered to your specified location on-time in good condition
If we fall short, we will make things right with a full refund of freight charges (some exclusions apply). As an ISO 9001 certified
organization and recipient of two Malcolm Baldrige Quality awards, expect nothing less than exceptional quality and value. For
more information, visit us online @ www.mesaproducts.com or call 1 888-800-MESA(6372).

Tulsa +1 918-627-3188 | Houston +1 281-445-8700 | DFW +1 817-230-4249 | Rocky Mountains +1 720-833-7032 |

Midwest +1 614-503-1705 | Mid Con +1 405-603-6737 | Michigan +1 989-441-1500 | East Coast +1 843-628-1342 |
South East +1 850-893-9366 | West Coast +1 714-963-6202 | North West +1 425-903-4850 | Canada +1 780-453-6677

MESA
4445 S. 74th E. Ave. • Tulsa, OK 74145, USA
Tel: 1 888-800-MESA (6372) • Fax: +1 918-627-2676
Web site: www.mesaproducts.com

ROXUL Technical Insulation

Industrial Insulation Shaped By Experts!

ROXUL® Technical Insulation, a subsidiary of the international

ROCKWOOL Group, is the worldwide market leader in technical
insulation. We cover the whole industrial insulation market and
marine and offshore industry by providing a full range of pipe, board,
and wrap insulation products along with systems for the thermal and
firesafe insulation of industrial applications.

We also offer reliable expert advice, from documentation to delivery

and after-sales service. Throughout the whole chain, from specifier
through distributor to contractor and installer, we aim to add value.
We don’t just sell products, we supply solutions. It’s this total approach
that makes us the ideal choice for professionalism, innovation, and
trust.

ROXUL Technical Insulation

8024 Esquesing Line • Milton, ON, L9T 6W3 • Canada
Tel: 1 800-265-6878 • +1 905-878-8474
Fax: 1 800-991-0110
Email: contactus@roxul.com
Web site: www.roxul-rti.com

64 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

Corrosion
Never Sleeps
NACE WESTERN AREA CONFERENCE
November 28 – 30, 2017 | Las Vegas, Nevada | Red Rock Casino Resort & Spa

Billions of dollars are spent each year on corrosion prevention and maintenance on oil, gas, pipeline, power generation and
other infrastructure assets. To address this issue, NACE International and the NACE Southern Nevada Section invites you
to attend the 2017 Western Area Conference. Featuring unique educational presentations, forums, and new technologies
on the exhibit hall floor, this conference will be your opportunity to learn about local corrosion issues from experienced
local experts.

Technical Program Advance Registration Ends

▪ Underground buried pipelines – Natural gas, hazardous gas, October 28, 2017
petroleum product pipelines/tanks
▪

Root cause and analysis of coating failures and advancements in coating installation, coating in high-heat and
hazardous environments, advancements of molecular structure of coatings

Registration
▪ AC Corrosion root cause and analysis caused from induced high-voltage from overhead transmission power lines
▪ AC Mitigation methods and monitoring Advanced Registration
▪ Advancements in tank bottom, both internal and external Cathodic Protection (CP) design, material selection, Ends October 28, 2017
and improved installation methods
▪ Inhibitors - Vapor Transported (VCI) and Surface Coating Rust Preventive (RP)
NACE Member: $450 USD
▪ Advancements in CP design and installation methods in urban/congested areas Nonmember: $550 USD
▪ Upcoming changes to regulations and subsequent effects on interstate and intrastate natural gas and
petroleum product pipelines
Regular Registration
▪ Underground buried pipelines – Municipal water supply, Begins: November 23, 2017
water transmission, water treatment NACE Member: $550 USD
▪ Full Cycle Corrosion Management from Conceptual Design to Decommissioning
▪ Advancements in CP design and installation methods in urban/congested areas
Nonmember: $650 USD
▪ Advancements in tank bottom, both internal and external Cathodic Protection (CP) design, material selection,
and improved installation methods
▪ Water Treatment Vs. The Economics Associated with Risk and Reliability
One Day Registration
▪ Cost Effective Corrosion Management Begins: November 23, 2017
NACE Member: $250 USD
▪ General – Corrosion issues in Hydro Electricity – Focus on corrosion
affecting the Hoover Dam Nonmember: $300 USD
▪ General - Corrosion Management, Planning, Development,
Implementation & Success
▪ General - Corrosion Issues in Military Equipment and Facilities

OFFICIAL MEDIA PARTNERS

wac.nace.org
NACE NEWS NACE OFFICERS
PRESIDENT
Samir Degan*
Osnar Paints and Contracts Pvt.
Seventh in the Series Mumbai, India

VICE PRESIDENT

Strategic Planning at Jeffrey L. Didas*

Matcor, Inc.
Tucson, AZ, USA

TREASURER

NACE International Michael Ames*

Chapman Engineering
Boerne, TX, USA

PAST PRESIDENT
By NACE President Samir Degan and
Sandy Williamson*
Past President Sandy Williamson Consultant
Calgary, AB, Canada

CHIEF EXECUTIVE OFFICER

W
e have defined strate-
gic planning as a pro-
cess that provides a
roadmap for taking
our association from a
well-defined present state to a compelling
and significantly different future state. De-
velopment and implementation of our plan
for success is what makes strategic plan-
ning an effective, ongoing process, as op-
posed to a once-every-three-years event
that results in lofty goals, with little thought
on how to achieve them.
three years. The plan for success provides Robert H. Chalker*
the roadmap for how we will accomplish NACE International
Houston, TX, USA
our goals.
DIRECTORS
Perhaps some have heard the expres-
sion, “If everything is important, nothing Debra Boisvert/2015-2018
Target Products, Ltd.
is.” With a clear picture of our destination Burnaby, BC, Canada
in mind (i.e., where we want to be in three Richard B. Eckert/2015-2018
years), the board focused on establishing DNV GL
Dublin, OH, USA
the top priorities for the next year. Each of
Darby Howard/2015-2018
four teams were asked: JDH Corrosion Consultants, Inc.
8 What are the five or six most important Concord, CA, USA
things we need to focus on in the next Thomas Ladwein/2015-2018
year to move us toward our vision and Aalen University of Applied Science
Aalen, Germany
overarching goals?
Mohammed Al-Subaie/2016-2019
Once debated, the answers to this Saudi Aramco
question become our key strategic initia- Dhahran, Saudi Arabia
tives for the year. For each key strategy, we Jorge Cantó/2016-2019
Corrosion y Proteccion
create a brief description so that we all Hidalgo, Mexico
share a common understanding of what
Cris Conner/2016-2019
the key strategy is to address. But putting a Utility Service & Maintenance, Inc.
label on a key strategy isn’t enough. We St. Louis, MO, USA

also have to create a definition of success Andrew Haiko/2016-2019

LTK Engineering Services
that answers the question: Ambler, PA, USA
8 What must be true one year from now Eric Langelund/2016-2019
The model adopted by the Board of Directors for us to be able to look back and say, Piping & Corrosion Specialties, Inc.
to facilitate strategic planning at NACE. with any credibility, that we had a good Millersville, MD, USA

year? C. Lindsay Enloe/2017-2020

As illustrated in the model here, the
plan for success has three elements: key
strategic initiatives, implementation
plans, and review and reload sessions.
We’ll introduce all three steps in the plan-
for-success process this month, and
explore the current key strategic initiatives
Utility Safety & Design
Key strategies and associated defini- Swansea, IL, USA
tions of success establish in specific, mea- Michael S. O’Brien/2017-2020
surable terms what must be accomplished MARK 10 Resource Group, Inc.
Richmond, VA, USA
in the next 12 months to move us toward
the overarching goals we intend to achieve Toyoji Takeuchi/2017-2020
Sumitomo Heavy Industries Marine
in three years. But annual goals must be Engineering Co., Ltd.
broken down even further to make certain Yokosuka, Japan

in detail in next month’s post. we are making continual progress, and ad- EX OFFICIO DIRECTORS
Through this point in the strategic justing our plans as circumstances evolve. Keith Perkins
planning process, we have established an The implementation plan is a spread- President, NACE International Foundation

aspirational, timeless vision statement,
and specific, measurable overarching
goals that we fully intend to achieve in
sheet-based tool we utilize to break down Chris Fowler, FNACE
President, NACE International Institute
our annual goals even further, into three to
*Executive Committee members
five tasks that need to be accomplished for

66 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 Your Association in Action

each key strategy between each of the
board’s three face-to-face meetings.
At each board meeting, we conduct a
review and reload session. The owner of
each key strategy presents the work of the
team and answers four critical questions:
8 What was supposed to happen?
8 What actually happened?
8 Why was there a difference?
8 What can we learn from this?
After debate and exploration, each key
strategy team then presents a new imple-
mentation plan outlining the tasks to be
competed in the next period.
As indicated, we will explore each of
the three elements of our plan for success
model, in detail, in the next three months.
Note: This article is maintained as part
of an ongoing series of posts on the NACE
web site: www.nace.org.

NACE Area & Section News

Western Area
NACE San Francisco Section Holds Annual
Picnic Barbecue

Barbecue expert Billy Campbell (left) with

assistant Patrick Byrne.

San Francisco Section 2017 picnic barbecue attendees.

T
he NACE San Francisco Section held
its 5th annual picnic and barbecue
at the Lafayette Reservoir in Lafay-
ette, California on Saturday, May 20, 2017.
Approximately 80 people attended this
event, renowned for barbecue artist Billy
Campbell’s outstanding beef tri-tip and
barbecue beans. His tri-tip rub and beans
recipes are carefully guarded family secrets,
and they keep folks coming back for more
each year. Billy goes beyond the call of duty
by renting a trailer for his barbecue grill
and transporting it to the picnic site. In ad-
dition to the tri-tip, the group enjoyed
grilled chicken, hot links, fresh fruit, dried
fruit, nuts, chips, and soft drinks.
The picnic included vendor exhibits by
American Construction & Supply, Califor-
nia Aquastore, Corrpro, Northtown Co.,
Sherwin-Williams Co., and Trenton Corp.
A raffle was held with prizes provided by
Accurate Corrosion, B&W Distributors,
BCTS, California Aquastore, Cal State Con-
Greg Hytopoulos discusses Northtown Co.
structors, Corrpro, JDH Corrosion Consul-
supplies at the vendor display.
tants, Kelly Moore, Sherwin-Williams, and
Trenton Corp. The NACE San Francisco
Section provided over 40 raffle gifts, and
one generous prize was donated by
Charles Del Monte, president of Redwood
Painting.
Special thanks go to San Francisco Sec-
tion officers Mongkol Mahavongtrakul for
organizing the picnic and barbecue and
providing many of the food items; Michelle
Anderson for handling the reservations
and fees; and Patrick Byrne and Larry NACE Western Area Director Darby Howard
Wong for organizing and executing the addresses picnic attendees at the gift raffle.
cleanup. (—Dan Day)

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 67

NACE NEWS

East Asia and Pacific Area

NACE Coating Inspector Program Courses in Shanghai

Instructors Phil Fouche, Lerry Li, and Amy Wong instructed a Coating Fouche, Wong, and Gary Cheung instructed the CIP Level 2 course in
Inspector Program (CIP) Level 1 course in Shanghai, China to wind power Shanghai.
industry employees.

N
ACE International recently conducted CIP Levels 1 and 2 courses in Shanghai, China. NACE holds courses all over the world
that cover corrosion control technologies for every industry and environment. For more information, see www.nace.org/
training-education.

In Memoriam
L
ongtime
NACE In-
ternational
member James R.
Johnson, 75,
passed away on
Tuesday, June 20,
2017 at his home
in Yaak, Montana
of natural causes.  There was a need to detect the presence of
James “Jim” Johnson was born in Chi-
cago, Illinois on June 14, 1942 to Roy and
Pearl Johnson. He moved to Big Fork, Mon-
tana in 1967, and worked for Westmont
Tractor and on the Libby Dam. In 1974, Jim
started Johnson Lumber in Bigfork,
Kalispell and Seeley Lake.
In the 1990s, he became a protective
coatings contractor in Chandler, Arizona,
his largest account being Allied Signal.
Within a few coating failures, Jim had ana-
lyzed samples showing the cause to be sol-
uble salt contamination. In attempting to
solve such coating failures, the chemistry
for CHLOR*RID was developed. During
this time, he recognized the importance of
eliminating the contamination of soluble
salts on substrates prior to coating. His
work in this field led to his founding of
CHLOR*RID International, Inc. in the early
1990s, specializing in soluble salt testing
and removal products.
Jim didn’t stop at just a salt remover.
salts so he and the other owners of
CHLOR*RID developed a field test kit, as
well as other products over the years. The
company, still headquartered in Chandler,
Arizona, is growing, with representatives
throughout the United States.
Jim was an active member on NACE
technical committees since 1991, attended
numerous NACE conferences and net-
working opportunities over the years, and
presented papers. He was one of the
founders that led the coatings industry to
address soluble salt contamination—still a
leading cause of coating failures today.
CHLOR*RID members and his son Doug-
las remain active in NACE committees,
carrying on the important work in the
protective coatings field, particularly sur-
face preparation addressing soluble salt
detection and removal.
Jim resided in Montana semi-retired.
Outside of work, his interests included
working on his Montana home, spending
time with family, hunting, and contribut-
ing to charities that included the victims
of Hurricane Katrina and particularly, can-
cer-fighting research and support. His
daughter Laurie who had contracted can-
cer as a child, is still in remission. Jim was
a generous contributor to St. Jude’s Chil-
dren’s Research Hospital and other
research organizations.
Survivors include his children Jason
Johnson (Tricia ), Chattaroy, Washington;
Douglas Johnson (Pauline), Post Falls,
Idaho;  Laurie Johnson, Reardon, Washing-
Continued on bottom of next page

68 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

VOLUNTEERS SPOTLIGHT

NACE Volunteers in the Crowd

Volunteer: Jon R. Cavallo

Employer: Jon R. Cavallo PE LLC, Portsmouth,

New Hampshire, USA

Professional Role in Corrosion: Consulting engineer,

instructor for NACE International’s Coating Inspector
Program (CIP) and the Electric Power Research
Institute, and author of technical publications on
coatings and linings technology, including the recent
NACE International book, The History of Protective
Coatings in Nuclear Power Plants.

J
on Cavallo is a NACE-certified CIP Level 1, 2, and 3 Coating
Inspector with nuclear and bridge endorsements and a Reg-
istered Professional Engineer in three states. During his
more than 40 years of work in the coatings and corrosion mitiga-
tion field, Cavallo has gained a reputation as a world-renowned
coating and lining expert. His recent work has included assign-
ments in the United States, Canada, Slovenia, India, Peoples
Republic of China, Japan, and South Korea.
Cavallo has been a NACE member for 35 years, and is a NACE
volunteer. He says volunteering for NACE draws on his educa-
tional background and professional experience and has provided
him with the opportunity to increase his technical knowledge
and his visibility in the industry. “My volunteer work has permit-
ted me to meet other like-minded people from around the world sharing his high-level knowledge of coatings technology as well
and to experience aspects of the industry that I might not have as his personal and professional experience in coatings.
otherwise been exposed to,” he says. Cavallo says he was at a point in his career where he
At CORROSION 2017 in New Orleans, Louisiana, Cavallo vol- acknowledged that he has been mentored very well during his
unteered to assist the NACE Foundation with its third annual career and would like to now “pay it forward” to help assist
day-long corrosion mini-camp—CORROSION: Opportunities others who are entering the corrosion mitigation field. His most
Realized—where 50 local high school students learned about recent volunteer opportunity is assisting the NACE International
career and academic opportunities in corrosion from many of Institute in improving the examinations related to the CIP
the industry’s top leaders and professionals. His responsibilities courses.
included greeting high school students on the show floor and Browse open volunteer opportunities at volunteer.nace.org.

Continued from previous page

ton; grandchildren Cynthia Delong, Kyle 2017 at the family home in Yaak.  A Cele- com.  In lieu of flowers, memorials may be
Sullivan, Tiffany Johnson, Alix Johnson, bration of Life immediately followed at the made to St. Jude’s Children’s Hospital,
Sydney Johnson, and Tierra Norris; and Yaak Mercantile. Arrangements were by www.stjude.org, or to the Upper Yaak Vol-
great grandchildren Kristin, Rylan, Schnackenberg & Nelson Funeral Home in unteer Fire Department-Search and
Kayleigh, Lacey Kay, and Deegan.  Libby. Online condolences and memories Rescue. It was always Jim’s wish to have a
Services were held on Saturday, July 8, may be shared at www.schnackenbergfh. search and rescue in the Upper Yaak.

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 69

 NACE NEWS
NACE International Corporate Members
MP publishes the names of all Diamond and Gold Corporate Members in each issue, in addition to that month’s new
corporate members of all levels. Following are the companies that are in these categories as of August 15, 2017:
DIAMOND
Borouge (Abu Dhabi Polymers Co.), Ruwais,
Abu Dhabi, United Arab Emirates
BP Exploration & Production Operating Co.,
Ltd., Middlesex, United Kingdom
Carboline Company, St. Louis, Missouri,
USA
Colonial Pipeline Co., Alpharetta, Georgia,
USA
Corrpro, Houston, Texas, USA
Denso North America, Houston, Texas, USA
DNV GL, Dublin, Ohio, USA
Dunn-Edwards Corp., Los Angeles,
California, USA
El Paso Water Utilities, El Paso, Texas, USA
Elcometer, Rochester Hills, Michigan, USA
Enable Midstream Partners, Bossier City,
Louisiana, USA
Excet, Inc., Springfield, Virginia, USA
Exova, West Midlands, United Kingdom
Henkels & McCoy, Inc., Blue Bell,
Pennsylvania, USA
HMI Technical Solutions, Blue Bell,
Pennsylvania, USA
International Union of Painters and Allied
Trades, Hanover, Maryland, USA
Kuwait Oil Co., Ahmadi, Kuwait
Lake Superior Consulting, Duluth,
Minnesota, USA
Magnum Energy Services, Ltd., Ft. Kent,
Alberta, Canada
MATCOR, Inc., Chalfont, Pennsylvania, USA
MESA, Tulsa, Oklahoma, USA
National Grid, Beijing, China
Oil & Natural Gas Corp., Ltd. (ONGC),
Mumbai, India
Oneok Partners, Tulsa, Oklahoma, USA
Polyguard Products, Inc., Ennis, Texas, USA
PPG Performance Coatings (Hong Kong),
Ltd., Shanghai, China
Saipem SpA, San Donato, Milanese, Italy
Sandvik AB, Gavlenorg, Sweden
Seal for Life Industries, Stadskanaal, The
Netherlands
SGS, Camberley, Surrey, United Kingdom
Sherwin-Williams Co., Cleveland, Ohio, USA
70 SEPTEMBER 2017 MATERIALS PERFORMANCE
Southern California Gas Co., Los Angeles,
California, USA
Turner Industries Group, LLC, Port Allen,
Louisiana, USA
GOLD
Airtech Spray Systems, Houston, Texas, USA
Alpha Pipeline Integrity Services, Kemah,
Texas, USA
Atmos Energy, Jackson, Mississippi, USA
Baker Hughes, Sugar Land, Texas, USA
Bechtel Group, Inc., Houston, Texas, USA
Brand Energy & Infrastructure Services,
Kennesaw, Georgia, USA
BSS Technologies. Dubai, United Arab
Emirates
Chapman Engineering, Boerne, Texas, USA
ConocoPhillips Co., Bartlesville, Oklahoma,
USA
Corrosion Technology Services, LLC,
Sharjah, United Arab Emirates
CPC Corporation, Taiwan
Dominion, Bridgeport, West Virginia, USA
Dong Yang Corrosion Engineering Co., Ltd.,
Seoul, South Korea
Duke Energy, Cincinnati, Ohio, USA
Enbridge Pipelines, Inc., Schereville,
Indiana, USA
Evraz, Inc., Regina, Saskatchewan, Canada
Formosa Plastics Group (FPG), Taipei,
Taiwan
Galvotec Alloys, Inc., McAllen, Texas, USA
Haynes International, Inc., Kokomo, Indiana,
USA
HoldTight Solutions, Inc., Houston, Texas,
USA
Integrated Global Services, Richmond,
Virginia, USA
Interprovincial Corrosion Control, Ltd.,
Burlington, Ontario, Canada
Kuwait Pipe Industries and Oil Services Co.,
Safat, Kuwait
Marathon Pipeline, LLC, Findlay, Ohio, USA
Oceaneering International, Inc., Houston,
Texas, USA
Osmose Utility Services, Inc., Peachtree City,
Georgia, USA
Park Derochie, Inc., Edmonton, Alberta,
Canada
Petroineos, Grangemouth, Stirlingshire,
United Kingdom
Pipetech Corp., Ltd., Calgary, Alberta,
Canada
Pluspetrol, Caba, Argentina
PTT Global Chemical Public Co., Ltd.,
Bangkok, Chatuchak, Thailand
Raven Lining Systems, Broken Arrow,
Oklahoma, USA
RK&K, LLP, Charlotte, North Carolina, USA
ROSEN, Lingen, Germany
Southern Star Central Gas Pipeline,
Owensboro, Kentucky, USA
Specialty Polymer Coatings, Inc., Langley,
British Columbia, Canada
Strategic Materials, Houston, Texas, USA
TransCanada Pipelines, Calgary, Alberta,
Canada
Tubacex Group, Llodio, Alava, Spain
United States Coast Guard, Baltimore,
Maryland, USA
University of Akron, Akron, Ohio, USA
V&A Consulting Engineers, Inc., Oakland,
CA, USA
Weldbend, Argo, Illinois, USA
NEW CORPORATE MEMBERS
Parsons, Pasadena, California, USA—Silver
Riddle’s Dehi & Chemicas Service Co., Inc.,
dba E & P Services Group, Kilgore, Texas,
USA—Silver
Carolina Coating Solutions & Industrial
Services, Inc., Morrisville, North Carolina,
USA—Iron
Total NACE membership was 36,036 as of
July 15, 2017. For more information about
NACE corporate membership levels and
individual member benefits, contact the
FirstService department at tel: +1 281-228-
6223 or email: firstservice@nace.org.
NACE INTERNATIONAL: VOL. 56, NO. 9
 NACE NEWS
Calendar of Events
SEPTEMBER 2017
CORROSION TECHNOLOGY
WEEK 2017
September 10-14, 2017
JW Marriott Indianapolis
Indianapolis, IN, USA
More info: Lesley Martinez, NACE
International, tel: +1 281-228-6413,
email: lesley.martinez@nace.org
MATERIALS PERFORMANCE &
WELDING TECHNOLOGIES 2017
CONFERENCE & EXHIBITION
September 11-14, 2017
Sheraton Dammam Hotel &
Convention Centre
Dammam, Saudi Arabia
More info: web site:
www.mpwtconference.org
CORCON 2017
September 17-20, 2017
Sahara Star
Mumbai, India
More info: CaLae Browne, NACE
International, tel: +1 281-228-6263,
email: calae.browne@nace.org
OCTOBER 2017
SPE/NACE WORKSHOP:
CORROSION MANAGEMENT
FOR ONSHORE AND
OFFSHORE UPSTREAM
OIL & GAS PRODUCTION
INSTALLATIONS
October 30-31, 2017
Kuala Lumpur, Malaysia
More info: CaLae Browne, NACE
International, tel: +1 281-228-6263,
email: calae.browne@nace.org
NACE INTERNATIONAL: VOL. 56, NO. 9
NOVEMBER 2017 OCTOBER 2018
PIMS LATIN AMERICA 2017 NACE NONMETALLICS
November 15-17, 2017 CONFERENCE 2018
JW Marriott Lima October 16-18, 2018
Lima, Peru Qatar University
More info: Lesley Martinez, NACE Doha, Qatar
International, tel: +1 281-228-6413, More info: Reygie de Borja, NACE
email: lesley.martinez@nace.org International, tel: +966-13-8642040,
email: regie.deborja@nace.org
4TH KUWAIT CORROSION
CONFERENCE: PLANT MARCH 2019
AND PIPELINE INTEGRITY
MANAGEMENT CORROSION 2019
November 21-23, 2017 March 24-28, 2019
Hilton Kuwait Resort
Nashville, TN, USA
Al Mangaf, Kuwait
More info: CaLae Browne, NACE
More info: Reygie de Borja, NACE International, tel: +1 281-228-6263,
International, email: Reygie.deborja@ email: calae.browne@nace.org
nace.org
MARCH 2020
FEBRUARY 2018
CORROSION 2020
LIBERTY BELL CORROSION
COURSE March 15-19, 2020
Houston, TX, USA
February 7-8, 2018
More info: CaLae Browne, NACE
Normandy Farm International, tel: +1 281-228-6263,
Blue Bell, Pennsylvania email: calae.browne@nace.org
More info: David Krause, tel: +1 610-868-
9352, email: corban598@outlook.com
APRIL 2021
APRIL 2018
CORROSION 2021
April 18-22, 2021
CORROSION 2018
Salt Lake City, UT, USA
April 15-19, 2018
More info: CaLae Browne, NACE
Phoenix Convention Center International, tel: +1 281-228-6263,
Phoenix, AZ, USA email: calae.browne@nace.org
More info: CaLae Browne, NACE
International, tel: +1 281-228-6263,
email: calae.browne@nace.org
SEPTEMBER 2018 For the most up-to-date
CORROSION TECHNOLOGY
listing of events, click on
WEEK 2018 the Events tab at
September 16-20, 2018
Royal Sonesta Houston Galleria
www.nace.org.
Houston, TX, USA
More info: Lesley Martinez, NACE
International, tel: +1 281-228-6413,
email: lesley.martinez@nace.org Denotes NACE International event
MATERIALS PERFORMANCE SEPTEMBER 2017 71
NACE NEWS
NACE Course Schedule
ARGENTINA CIP Peer Review
CP1—Cathodic Protection Tester Shanghai....................................................Nov 11-14, 2017
Buenos Aires..............................................Nov 6-11, 2017 COLOMBIA
CP2—Cathodic Protection Technician Basic Corrosion
Buenos Aires..............................................Nov 13-18, 2017 Bogota.......................................................Oct 9-13, 2017
Internal Corrosion for Pipelines—Basic CP Interference
Buenos Aires..............................................Nov 27-Dec 1, 2017 Barranquilla................................................Oct 9-14, 2017
AUSTRALIA CP4—Cathodic Protection Specialist
CIP Level 1 Bogota.......................................................Oct 4-9, 2017
Sydney, NSW.............................................Nov 6-11, 2017 Internal Corrosion for Pipelines—Advanced
CIP Peer Review Bogota.......................................................Nov 14-18, 2017
Sydney, NSW.............................................Nov 9-12, 2017 DOMINICAN REPUBLIC
CP1—Cathodic Protection Tester CP1—Cathodic Protection Tester
Perth, WA ..................................................Oct 9-13, 2017 Cotui..........................................................Oct 9-13, 2017
CP2—Cathodic Protection Technician
ECUADOR
Perth, WA ..................................................Oct 16-20, 2017
CIP Level 2
AZERBAIJAN Quito .........................................................Oct 16-21, 2017
Basic Corrosion
EGYPT
Baku...........................................................Oct 30-Nov 3, 2017
CIP Level 1
Corrosion Control in the Refining Industry
Cairo ..........................................................Oct 7-12, 2017
Baku...........................................................Oct 2-6, 2017
CIP Level 2
CP3—Cathodic Protection Technologist
Cairo ..........................................................Oct 14-19, 2017
Baku...........................................................Oct 9-14, 2017
CP1—Cathodic Protection Tester
CP4—Cathodic Protection Specialist
Cairo ..........................................................Dec 10-15, 2017
Baku...........................................................Oct 16-21, 2017
CP2—Cathodic Protection Technician
Designing for Corrosion Control
Cairo ..........................................................Dec 17-22, 2017
Baku...........................................................Nov 6-10, 2017
CP4—Cathodic Protection Specialist
Internal Corrosion for Pipelines—Advanced
Cairo ..........................................................Nov 11-16, 2017
Baku...........................................................Oct 23-27, 2017
Internal Corrosion for Pipelines—Advanced
Marine Coating Technology
Cairo ..........................................................Dec 3-7, 2017
Baku...........................................................Nov 13-16, 2017
PCS 1 Basic Principles
BELGIUM Cairo ..........................................................Nov 25-27, 2017
CIP Level 1 PCS 2 Advanced
Antwerp .....................................................Oct 16-21, 2017 Cairo ..........................................................Nov 28-30, 2017
CANADA GERMANY
Basic Corrosion CIP Level 1
Calgary, AB................................................Oct 16-20, 2017 Frankfurt ....................................................Nov 6-11, 2017
CIP Level 1 CIP Level 2
Edmonton, AB ...........................................Nov 12-17, 2017 Frankfurt ....................................................Nov 13-18, 2017
Halifax, NS .................................................Nov 12-17, 2017
CP3—Cathodic Protection Technologist
Red Deer, AB.............................................Oct 1-6, 2017
Frankfurt ....................................................Oct 23-28, 2017
Red Deer, AB.............................................Oct 15-20, 2017
CIP Level 2 INDIA
Edmonton, AB ...........................................Nov 19-24, 2017 CIP Level 1
Montreal, QC.............................................Oct 22-27, 2017 Chennai .....................................................Oct 30-Nov 4, 2017
Red Deer, AB.............................................Oct 22-27, 2017 Chennai .....................................................Dec 4-9, 2017
CIP Peer Review Mumbai .....................................................Oct 2-7, 2017
Montreal, QC.............................................Oct 27-30, 2017 CIP Level 2
Corrosion Control in the Refining Industry Chennai .....................................................Nov 6-11, 2017
Edmonton, AB ...........................................Nov 13-17, 2017 Chennai .....................................................Dec 11-16, 2017
Mumbai .....................................................Oct 9-14, 2017
CP1—Cathodic Protection Tester
Calgary, AB................................................Nov 6-11, 2017 CP2—Cathodic Protection Technician
Mumbai .....................................................Oct 2-6, 2017
CP2—Cathodic Protection Technician
Calgary, AB................................................Nov 13-18, 2017 ITALY
Designing for Corrosion Control CIP Level 2
Edmonton, AB ...........................................Nov 6-10, 2017 Genova ......................................................Oct 22-27, 2017
Pipeline Coating Applicator Training JAPAN
Edmonton, AB ...........................................Nov 6-10, 2017 CIP Level 1
CHINA Imari...........................................................Oct 12-17, 2017
CIP Level 1 KUWAIT
Shanghai....................................................Dec 3-8, 2017 CIP Level 1
CIP Level 2 Fahaheel ....................................................Dec 2-7, 2017
Shanghai....................................................Dec 10-15, 2017

72 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

For the most up-to-date information, visit www.nace.org/eduschedule Your Association in Action

CIP Level 2 SPAIN

Fahaheel ....................................................Dec 9-14, 2017
Corrosion Control in the Refining Industry
Fahaheel ....................................................Oct 8-12, 2017
CP1—Cathodic Protection Tester
Fahaheel ....................................................Oct 15-19, 2017
CP2—Cathodic Protection Technician
Fahaheel ....................................................Nov 5-10, 2017
Internal Corrosion for Pipelines—Basic
Fahaheel ....................................................Jan 14-18, 2018
Internal Corrosion for Pipelines—Advanced
Fahaheel ....................................................Jan 21-25, 2018
Pipeline Corrosion Assessment Field Techniques (P-CAFT)
Fahaheel ....................................................Oct 15-19, 2017
MALAYSIA
CIP Level 1
Kuala Lumpur.............................................Oct 16-21, 2017
CIP Level 2
Kuala Lumpur.............................................Oct 23-28, 2017
PCS 1 Basic Principles
Subang Jaya, Selangor ..............................Nov 6-8, 2017
PCS 2 Advanced
Subang Jaya, Selangor ..............................Nov 9-11, 2017
MEXICO
CIP Level 1
Cuernavaca, MOR......................................Nov 6-11, 2017
Corrosion Control in the Refining Industry
Cuernavaca, MOR......................................Dec 4-8, 2017
THE NETHERLANDS
CIP Level 1
Ridderkerk .................................................Dec 11-16, 2017
CIP Level 2
Ridderkerk .................................................Nov 27-Dec 2, 2017
NEW ZEALAND
CIP Level 1
Auckland....................................................Oct 9-14, 2017
NIGERIA
Basic Corrosion
Victoria Island, Lagos.................................Nov 27-Dec 1, 2017
CP3—Cathodic Protection Technologist
Victoria Island, Lagos.................................Dec 5-10, 2017
PERU
CIP Level 1
Lima ...........................................................Oct 2-7, 2017
In Line Inspection
Lima ...........................................................Oct 16-20, 2017
PUERTO RICO
CP1—Cathodic Protection Tester
San Juan ....................................................Nov 13-18, 2017
SAUDI ARABIA
Basic Corrosion
Dammam ...................................................Nov 26-30, 2017
CP1—Cathodic Protection Tester
Dammam ...................................................Nov 5-10, 2017
CP2—Cathodic Protection Technician
Dammam ...................................................Oct 15-19, 2017
CP3—Cathodic Protection Technologist
Dammam ...................................................Oct 28-Nov 2, 2017
SOUTH AFRICA
CIP Level 1
Midrand .....................................................Nov 13-18, 2017
CP3—Cathodic Protection Technologist
Midrand .....................................................Nov 27-Dec 2, 2017
Offshore Corrosion Assessment Training (O-CAT)
Cape Town ................................................Oct 23-27, 2017
CIP Level 1
Madrid .......................................................Nov 20-25, 2017
CIP Level 2
Madrid .......................................................Nov 27-Dec 2, 2017
CP4—Cathodic Protection Specialist
Madrid .......................................................Oct 9-14, 2017
Internal Corrosion for Pipelines—Basic
Madrid .......................................................Oct 23-27, 2017
Internal Corrosion for Pipelines—Advanced
Madrid .......................................................Oct 30-Nov 3, 2017
Offshore Corrosion Assessment Training (O-CAT)
Madrid .......................................................Dec 11-15, 2017
PCS 2 Advanced
Madrid .......................................................Nov 8-10, 2017
THAILAND
CIP Level 1
Pattaya.......................................................Nov 27-Dec 2, 2017
CIP Level 2
Pattaya.......................................................Dec 4-9, 2017
CP1—Cathodic Protection Tester
Bangkok.....................................................Oct 30-Nov 3, 2017
CP2—Cathodic Protection Technician
Bangkok.....................................................Nov 6-11, 2017
TRINIDAD AND TOBAGO
Basic Corrosion
Point Lisas, Couva......................................Nov 6-10, 2017
TURKEY
CIP Level 1
Istanbul ......................................................Oct 30-Nov 4, 2017
CIP Level 2
Istanbul ......................................................Nov 6-11, 2017
Marine Coating Technology
Istanbul ......................................................Oct 3-6, 2017
UNITED ARAB EMIRATES
CIP Level 1
Dubai .........................................................Nov 4-9, 2017
CIP Level 2
Dubai .........................................................Nov 11-16, 2017
CIP Peer Review
Dubai .........................................................Nov 4-7, 2017
CP1—Cathodic Protection Tester
Dubai .........................................................Oct 15-19, 2017
CP2—Cathodic Protection Technician
Dubai .........................................................Oct 21-25, 2017
CP3—Cathodic Protection Technologist
Dubai .........................................................Nov 11-16, 2017
CP4—Cathodic Protection Specialist
Dubai .........................................................Nov 18-23, 2017
Internal Corrosion for Pipelines—Advanced
Dubai .........................................................Dec 10-14, 2017
UNITED KINGDOM
Basic Corrosion
Woking ......................................................Nov 20-24, 2017
CIP Level 1
Aberdeen...................................................Nov 5-10, 2017
Harrogate ..................................................Oct 23-28, 2017
Newcastle upon Tyne ................................Oct 1-6, 2017
Newcastle upon Tyne ................................Oct 9-14, 2017
CIP Level 2
Aberdeen...................................................Nov 13-18, 2017
Newcastle upon Tyne ................................Oct 9-14, 2017
CIP Peer Review
Newcastle upon Tyne ................................Oct 21-24, 2017
Continued on page 74

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 73

NACE NEWS
Continued from page 73
UNITED STATES
Basic Corrosion
Austin, TX ..................................................Oct 9-13, 2017
Houston, TX...............................................Oct 23-27, 2017
New Orleans, LA........................................Dec 4-8, 2017
Orlando, FL................................................Oct 9-13, 2017
San Bernardino, CA ...................................Jan 22-26, 2018
CIP Level 1
Aiken, SC ...................................................Nov 5-10, 2017
Albuquerque, NM......................................Oct 1-6, 2017
Anaheim, CA .............................................Oct 1-6, 2017
Baton Rouge, LA .......................................Dec 10-15, 2017
Buffalo, NY ................................................Oct 29-Nov 3, 2017
Cape Canaveral, FL ...................................Dec 3-8, 2017
Charlotte, NC ............................................Dec 3-8, 2017
Chicago, IL.................................................Dec 10-15, 2017
Cincinnati, OH ...........................................Oct 1-6, 2017
Commerce, CA ..........................................Oct 8-13, 2017
Commerce, CA ..........................................Dec 10-15, 2017
Denver, CO................................................Oct 15-20, 2017
Houston, TX...............................................Oct 1-6, 2017
Houston, TX...............................................Oct 8-13, 2017
Houston, TX...............................................Oct 15-20, 2017
Houston, TX...............................................Oct 16-21, 2017
Houston, TX...............................................Oct 29-Nov 3, 2017
Houston, TX...............................................Nov 5-10, 2017
Houston, TX...............................................Nov 12-17, 2017
Houston, TX...............................................Nov 26-Dec 1, 2017
Houston, TX...............................................Dec 3-8, 2017
Houston, TX...............................................Dec 4-9, 2017
Houston, TX...............................................Dec 10-15, 2017
Houston, TX...............................................Dec 11-16, 2017
Houston, TX...............................................Dec 17-22, 2017
Jacksonville, FL..........................................Oct 30-Nov 4, 2017
Kansas City, MO ........................................Nov 12-17, 2017
Lanham, MD ..............................................Oct 1-6, 2017
Lanham, MD ..............................................Dec 10-15, 2017
Montvale, NJ .............................................Oct 16-21, 2017
Montvale, NJ .............................................Jan 8-13, 2018
New Orleans, LA........................................Nov 5-10, 2017
Newington, NH .........................................Oct 8-13, 2017
Orlando, FL................................................Nov 5-10, 2017
Philadelphia, PA ........................................Oct 1-6, 2017
San Ramon, CA..........................................Oct 23-28, 2017
Seattle, WA................................................Nov 5-10, 2017
St. Louis, MO .............................................Oct 29-Nov 3, 2017
Virginia Beach, VA .....................................Nov 5-10, 2017
Waipahu, HI...............................................Oct 8-13, 2017
Weston, WV...............................................Nov 5-10, 2017
CIP Level 2
Anaheim, CA .............................................Oct 8-13, 2017
Cape Canaveral, FL ...................................Dec 10-15, 2017
Commerce, CA ..........................................Oct 15-20, 2017
Denver, CO................................................Oct 22-27, 2017
Houston, TX...............................................Oct 8-13, 2017
Houston, TX...............................................Oct 22-27, 2017
Houston, TX...............................................Nov 5-10, 2017
Houston, TX...............................................Nov 12-17, 2017
Houston, TX...............................................Dec 3-8, 2017
Houston, TX...............................................Dec 17-22, 2017
Jacksonville, FL..........................................Nov 6-11, 2017
Lanham, MD ..............................................Oct 8-13, 2017
Lansing, MI ................................................Oct 15-20, 2017
New Orleans, LA........................................Nov 12-17, 2017
Newington, NH .........................................Oct 15-20, 2017
Orlando, FL................................................Nov 12-17, 2017
Philadelphia, PA ........................................Oct 8-13, 2017
Pittsburgh, PA............................................Nov 12-17, 2017
San Ramon, CA..........................................Nov 13-18, 2017
Seattle, WA................................................Nov 12-17, 2017
St. Louis, MO .............................................Nov 5-10, 2017
Waipahu, HI...............................................Oct 15-20, 2017
74 SEPTEMBER 2017 MATERIALS PERFORMANCE
CIP Peer Review
Cape Canaveral, FL ...................................Dec 15-18, 2017
Houston, TX...............................................Nov 17-20, 2017
Houston, TX...............................................Dec 15-18, 2017
Coatings in Conjunction with Cathodic Protection
Houston, TX...............................................Nov 6-11, 2017
Corrosion Control in the Refining Industry
Houston, TX...............................................Oct 23-27, 2017
New Orleans, LA........................................Dec 4-8, 2017
CP1—Cathodic Protection Tester
Downey, CA...............................................Dec 11-16, 2017
Houston, TX...............................................Oct 2-6, 2017
Houston, TX...............................................Oct 9-13, 2017
Houston, TX...............................................Oct 23-27, 2017
Houston, TX...............................................Oct 30-Nov 3, 2017
Houston, TX...............................................Nov 13-18, 2017
Houston, TX...............................................Nov 27-Dec 2, 2017
Houston, TX...............................................Dec 11-16, 2017
Kilgore, TX.................................................Dec 18-23, 2017
Las Vegas, NV............................................Nov 27-Dec 2, 2017
Plano, TX ...................................................Dec 4-9, 2017
Rosebush, MI .............................................Oct 16-20, 2017
Salt Lake City, UT ......................................Oct 30-Nov 3, 2017
Tulsa, OK ...................................................Oct 23-27, 2017
CP2—Cathodic Protection Technician
Akron, OH .................................................Nov 27-Dec 2, 2017
Houston, TX...............................................Oct 2-6, 2017
Houston, TX...............................................Oct 16-20, 2017
Houston, TX...............................................Nov 6-11, 2017
Houston, TX...............................................Dec 11-16, 2017
Salt Lake City, UT ......................................Dec 4-9, 2017
CP3—Cathodic Protection Technologist
Downey, CA...............................................Jan 22-27, 2018
Houston, TX...............................................Oct 23-28, 2017
CP4—Cathodic Protection Specialist
Houston, TX...............................................Dec 17-22, 2017
Seattle, WA................................................Oct 1-6, 2017
CP Interference
Houston, TX...............................................Dec 4-9, 2017
Designing for Corrosion Control
Houston, TX...............................................Oct 2-6, 2017
New Orleans, LA........................................Dec 4-8, 2017
San Bernardino, CA ...................................Jan 22-26, 2018
In Line Inspection
Houston, TX...............................................Nov 27-Dec 1, 2017
Internal Corrosion for Pipelines—Basic
Houston, TX...............................................Oct 9-13, 2017
Houston, TX...............................................Nov 27-Dec 1, 2017
Internal Corrosion for Pipelines—Advanced
Houston, TX...............................................Oct 16-20, 2017
Marine Coating Technology
Houston, TX...............................................Oct 30-Nov 2, 2017
Offshore Corrosion Assessment Training (O-CAT)
Houston, TX...............................................Oct 30-Nov 3, 2017
PCS 1 Basic Principles
New Orleans, LA........................................Dec 4-6, 2017
PCS 2 Advanced
New Orleans, LA........................................Dec 7-9, 2017
Pipeline Corrosion Assessment Field Techniques (P-CAFT)
Houston, TX...............................................Nov 13-17, 2017
Pipeline Corrosion Integrity Management
Houston, TX...............................................Oct 30-Nov 3, 2017
Shipboard Corrosion Assessment Training (S-CAT)
Houston, TX...............................................Oct 9-13, 2017
Virginia Beach, VA .....................................Oct 9-13, 2017
For the complete course schedule, visit www.nace.org/eduschedule.
NACE INTERNATIONAL: VOL. 56, NO. 9
 MAKING
CONNECTIONS

“ I’ve worked for 35 years as an inspector

in the oil & gas industry, inspecting pressure
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pipelines. It would be impossible to imagine my

”
career without the imprint of NACE. When I was
designing my career, I always found some course
and certification that gave more validity and
recognition.

– José Caprarulo, NACE CIP Level 2, CP1, and

Corrosion Technologist Certified, Self-Employed

NACE Career Development, your experts in

training and certification

Developed by Industry,
Globally Recognized.

nace.org/career-development
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181 Grefer Lane 6712 S. 36th Street
Harvey, LA 70058
Tel.: (504) 362-7776
ANODES McAllen, TX 78503
Tel.: (956) 630-3500
Fax: (504) 269-1418 Fax: (956) 630-3595
anodes@galvotec.com
www.galvotec.com

Pin Brazing
Easybond equipment & consumables available in
Cathodic Protection & Corrosion Engineering the USA through sole importers Galvotec Corrosion
Design • Installation • Inspection • Materials • Services Services and GMC Electrical
Pin Brazing • Retrofit Systems • On-Shore • Off-Shore Contact
Dave Johnson on 504-362-7373
300 Bark Dr., Harvey, LA
or
Tel. 504-362-7373 Fax. 504-362-7331
www.galvoteccorrosion.com
TARGET YOUR AUDIENCE Gary Matlack on 909-947-6016
Email: service@galvotec.com
To reserve your ad space,
call +1 281-228-6269.

76 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

 CORROSION ENGINEERING DIRECTORY
Project Management GPS Surveys ILI Digs Phone/fax: 210/923-5999
Engineering Stray Current & Interference Analyses
Remediation SSCDA ECDA ICDA DCVG
E-mail: metaspec@earthlink.net
AC Mitigation
Casings
Bellhole
Excavations
& Inspections
Construction METASPEC Co.

Groundbeds Test Stations

VpCI Design/Build
Technical
METAL TEST SPECIMEN, COUPONS, PANELS
Maintenance Installation RODS, FIXTURES, RACKS AND HOLDERS

Tanks & Terminals

Anode Manufacturing Materials
CP Solutions J Boxes
P.O. BOX 240898 r SAN ANTONIO, TEXAS 78224
we do it all. 1.888.800.MESA mesaproducts.com

Quality Control Based on Verified Data

» Full Service Materials Laboratory

» Materials Performance Evaluation
» Accelerated Life Testing
» Simulated Environments
» Root Cause Failure Analysis
724.519.9068
rjleegroup.com

ST RAT EG I C CH E M I STRY
Experienced and trusted
worldwide in Gas and Oil
Production Chemistry.
www.strategic-chemistry.com

www.tinker-rasor.com TRI-STAR INDUSTRIES PTE LTD

Website: www.tristar.com.sg
Email: sales@tristar.com.sg
Tel: +65 6266 3636
Fax: +65 6265 3635 / 6265 2801

Specialist Manufacturer of Aluminum & Zinc

Anodes. We also provide full CP surveys, installations &
commissioning, including ICCP systems.

www.teststations.com
Plated and PTFE Coated Fasteners.
ZINGA Film Galvanizing System.

Attn. NACE Sections:

Looking for ways to build your local
corrosion workforce?
The NACE Foundation can help.
Learn more at nace-foundation.org/programs/

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 77

Corrosion is
EVERYONE’S Business
NACE NORTHERN AREA EASTERN CONFERENCE
October 29 - 31, 2017 | Montreal, Canada | Hyatt Regency Montreal
Billions of dollars are spent each year on corrosion issues related to infrastructure, utilities, transportation, production,
manufacturing and government facilities thereby impacting the economy. This conference seeks to present papers on
various methods of corrosion control. To address this issue, NACE International and the NACE Montreal Section invites
you to attend the 2017 Northern Area Eastern Conference. Featuring unique educational presentations, forums, and new
technologies on the exhibit hall floor, this conference will be your opportunity to learn about local corrosion issues from
experienced local experts.

Technical Program nac.nace.org

Coatings
Coatings and linings: Life cycle cost, case studies of different coatings systems used,
protection of steel and concrete infrastructures, new coating formulations, application
Registration
technologies, inspection methodologies, instrumentation and standards. Regular Registration
NACE Member: $300 USD
QCQA Nondestructive Testing
QCQA Non-Destructive Testing: Surface preparation inspection and standards, Quality Nonmember: $350 USD
control issues and optimization. New non-destructive technologies. Environmental
control and technologies. One Day Registration
NACE Member: $150 USD
Design & Selection Nonmember: $175 USD
Design & Material Selection: material selection and design for extended structure integrity
and service life

Cathodic Protection
Corrosion control method and investigation: cathodic protection, ILI, ECDA, HVAC, SCC,
HVDC, interferences, rebar in concrete, corrosion under insulation, high temperature
corrosion, case studies (municipal infrastructures, concrete structures, aboveground and
underground tanks, pipelines…etc.)

OFFICIAL MEDIA PARTNERS

AD INDEX
LISTING OF ADVERTISER CONTACT INFORMATION
Advertiser....................................Page No. Advertiser....................................Page No.

ACA – Australian Corrosion Association......................................................23 MP Annual Company Showcase

www.conference.corrosion.com.au
Carboline Company ..................................................................................... 60
ACI – American Concrete Institute .............................................................. 12 Corrpro Companies, Inc. .............................................................................. 61
www.concrete.org, +1 248-848-3700
Cortec® Corporation .................................................................................... 61
Anotec Industries, Ltd.................................................................................. 11 Cosasco ........................................................................................................ 62
www.anotec.com, +1 604-514-1544 Denso North America .................................................................................. 62
Farwest Corrosion Control Company ..........................................................63
Axalta Coating Systems................................................................................ 21 Jennings Anodes USA .................................................................................. 63
www.axalta.us/powder, 1 800-247-3886 MESA ............................................................................................................ 64
BORIN Manufacturing, Inc...........................................................................BC ROXUL Technical Insulation ......................................................................... 64
www.borin.com, +1 310-822-1000
NACE International
Carboline Company ....................................................................................... 1 www.nace.org, +1 281-228-6223
www.carboline.com, +1 314-644-1000
Back to School with CORROSION Journal .....................................................48
Corrpro Companies, Inc. (Aegion) ............................................................... 13 MP Advertising Opportunities...................................................................... 55
www.aegion.com/corrosion-protection, 1 844-619-2926 MP Readership Survey.................................................................................. 49
Cortec® Corporation .................................................................................... 37 NACE Career Development........................................................................... 75
www.cortecvci.com, 1 800-4CORTEC NACE International Foundation.................................................................... 46
NACE Northern Area Eastern Conference ....................................................78
Dampney Co., Inc......................................................................................... 22 NACE Publications ........................................................................................ 33
www.thurmalox.com, 1 800-537-7023 NACE Western Area Conference................................................................... 65
SPE/NACE Workshop .................................................................................... 50
DeFelsko Corporation ............................................................................ 47, 49
www.defelsko.com, 1 800-448-3835
De Nora Tech, Inc. ........................................................................................ 25
www.denora.com, +1 440-710-5300 CLASSIFIED
Denso North America .................................................................................... 9
www.densona.com, 1 888-821-2300
D. E. Stearns Co., The................................................................................... 45
www.destearns.com, +1 318-635-5351
Elcometer ................................................................................................. 7, 51
www.elcometer.com, 1 800-521-0635
Electrochemical Devices, Inc. ...................................................................... 18
www.edi-cp.com, +1 617-484-9085
EpoxyTec ...................................................................................................... 19
www.epoxytec.com, 1 877-463-7699
Fischer Technology, Inc. ............................................................................... 15
www.protective-coating-inspection.com, 1 800-243-8417
Galvotec Alloys, Inc...................................................................................... 27
www.galvotec.com, +1 956-630-3500
IRT Integrated Rectifier Technologies, Inc...................................................24
www.irtrectifier.com, +1 780-447-1114
Loresco® International................................................................................... 3
www.loresco.com, +1 601-544-7490
NACE New Orleans Section.......................................................................... 32
www.nace.org/nolaedu
Nippon Steel & Sumitomo Metal ...............................................................IBC
www.tubular.nssmc.com, +1 713-654-7111
Pittsburgh Corning ......................................................................................... 5
www.foamglas.com, 1 800-545-5001
Polyguard ................................................................................. Belly Band, IFC
www.polyguard.com, +1 281-580-5700
Sauereisen.................................................................................................... 16
www.sauereisen.com, +1 412-963-0303
Tnemec Company, Inc.................................................................................. 26
www.tnemec.com, +1 816-483-3400

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 79

 Understanding the basic principles
CORROSION BASICS and causes of corrosion

Corrosion Inhibitors

A
n inhibitor is a substance
that slows down a chemical
reaction (in the present con-
text, a corrosion reaction).
Corrosion inhibitors are
commonly added in small amounts to
acids, cooling waters, steam, and many
other environments—either continuously
or intermittently—to reduce the intensity
of corrosion that might otherwise threaten
the intended design life of a structure.
The use of chemical inhibitors to de-
crease the rates of corrosion processes is
quite varied. In the oil extraction and pro-
cessing industries, corrosion inhibitors
have always been considered to be the first
line of defense against corrosion. A great
number of scientific studies have been de-
voted to the subject of corrosion inhibi-
tors. Nevertheless, rules, equations, and
theories to guide inhibitor development
and use are very limited. Most of what is
known has grown from trial-and-error ex-
periments, both in the laboratories and in
the field. The degree of corrosion protec-
tion may not be proportional to the
amount of inhibitor in all concentrations.
Therefore, it is always important to evalu-
ate the concentration of inhibitor that
provides the optimal ratio of benefits to
cost.
Some inhibitors retard corrosion by
adsorption to form a thin, invisible surface
film only a few molecules thick; others
form visible bulky precipitates that coat
the metal and protect it from attack. An-
other common mechanism consists of
causing the metal to corrode in such a way
that a combination of adsorption and cor-
rosion product forms a passive layer.
Other types of inhibitors either cause
conditions in the environment to be more
favorable for the formation of protective
precipitates or remove an aggressive con-
stituent from the environment. Corrosion
inhibitors have grown to be one of the
most universal methods of combating cor-
rosion. Inhibitors that function by differ-
ent mechanisms are often combined in
commercial formulations.
Control of corrosion by inhibition may
be desirable for several reasons:
8 To extend the life of equipment
8 To prevent shutdowns
8 To prevent accidents resulting from
brittle (or catastrophic) failures
8 To avoid product contamination
8 To prevent loss of heat transfer
8 To preserve an attractive appearance
Potential savings for each of these
goals must be evaluated to determine if a
program of corrosion inhibition will be ec-
onomically justified. Because costs are
sometimes difficult to estimate, the best
method is to obtain data on maintenance,
replacements, and repairs/reconditioning
from the past history of either the system
that is to be protected or similar systems.
There are several costs associated with
the use of inhibitors. In fact, the cost of
one or more of the following must be fac-
tored into any economic evaluation of cor-
rosion inhibition:
8 Installation of injection equipment
8 Maintenance of injection equipment
8 Purchase of inhibitor chemical(s)
8 Monitoring inhibitor concentration(s)
8 System changes to accommodate the
inhibitor
8 System cleaning
8 Waste disposal
8 Personnel safety equipment
In cases where major shutdowns can
be avoided through the use of inhibitors,
the economic advantages of inhibition un-
doubtedly will be clear. Other cases will re-
quire detailed economic evaluations.
This article is adapted by MP Technical
Editor Norm Moriber from Corrosion
Basics—An Introduction, Second Edition,
Pierre R. Roberge, ed. (Houston, TX: NACE
International, 2006), pp. 521-522.

www. ma t e rials pe r f o r m a n c e . c o m
Get the latest corrosion news online and on-the-go!
Brought to you by Materials Performance (MP),
the world’s largest circulation magazine dedicated exclusively to
corrosion prevention and control.

80 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

400,000 units installed.

www.borin.com ∙ (310) 822-1000