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PRODUCTS

Instruments - Probes - Coupons

Access Systems - Injection Systems

Instruments Probes Coupons Access Injection

Systems Systems

Phone: 256-358-4202 Email: msc@alspi.com

www.metalsamples.com
 LORESCO
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Quality•Service•Price
875 Old Richburg Rd. | Purvis, MS 39475
Website: www.Loresco.com | Email: info@loresco.com
Phone: (601) 544-7490 | Fax: (601) 544-7531
A L LV E N T ® V E N T P I P E M A D E I N U S A LO R E S C O . C O M
Certified to
NSF NSF/ANSI/CAN/60
IN THIS ISSUE APRIL 2022
VOL. 61, NO. 4

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

SPECIAL FEATURE

24 An Urban Search & Rescue Expert Reflects on His

Experience at the Site of the Champlain Towers South
Collapse in Surfside, Florida, USA—Part 2
Alysa Reich

CATHODIC PROTECTION

28 Anode Performance of Subsea Vibration Data Logger System

Suresh Divi, Melissa Gould, and Dan Efird
About the Cover
COATINGS & LININGS With the theme of Corrosion of Offshore
Structures: Oil and Gas, this issue of MP focuses
32 Isocyanate-Free Water-Repellent Topcoat for Offshore Protection
Rifnur Latipov and David Morton on several applications to help prevent damage
in the highly corrosive seawater environment. In
addition to technical articles on corrosion
37 Coatings & Linings Essentials
37 Field Joint Coatings prevention of subsea assets and an isocyanate-
free water-repellent topcoat for offshore
protection, the Material Matters article on p. 20
CHEMICAL TREATMENT discusses how graphene-enhanced anti-
corrosion coatings are being used on U.K.
40 Enhancing Corrosion Mitigation via Novel Surface Treatment
Application maritime assets.
Sarah E. Specht, Julia Heigl, Melinda J. Dent, Mary Lyn C. Lim,
Brianne Georgic, Arif Mubarok, and Rebekah Wilson

MATERIALS SELECTION & DESIGN

44 An Engineered, Integrated Approach to External Corrosion

Management
Keith Parker and Trey Johnston

48 Materials Selection & Design Essentials

48 Polymeric Technology Helps Accelerate Decarbonization Across
Multiple Industries

CORROSION MANAGEMENT

52 Model for Predicting Corrosion Under Insulation Using

Nondestructive Testing
Khaled Hamdan

2 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

IN THIS ISSUE APRIL 2022
VOL. 61, NO. 4

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

14 18 20
DEPARTMENTS

6 What’s Online @ materialsperformance.com

8 From the Editor’s Desk

10 Up Front

12 Company News
www.ampp.org
14 Material Matters
14 New Multifunctional Viscoelastic Coating System
18 DNV Fully Certifies Thermoplastic Composite Tape for Pipes
20 U.K. Maritime Assets Receive Graphene-Enhanced Anti-Corrosion Coatings

MP (Materials Performance) is published monthly by AMPP (ISSN 0094-

22 Product Showcase
1492; USPS No. 333-860). Mailing address and editorial
offices: 15835 Park Ten Place, Houston, TX 77084; tel: +1 281-228-6200. 70 Building Business Connections
70 Corrosion Engineering Directory
Internet address: www.ampp.org. Preferred periodicals nonprofit postage
71 Advertisers Index
paid at Houston, TX and additional mailing offices. Canada Post: Publications
Mail Agreement #40612608. Copyright 2022 by AMPP. Reproduction of
the contents, either as a whole or in part, is forbidden unless permission 72 Corrosion Basics
72 Atmospheric Corrosion of Iron and Steel
has been obtained from the publisher. Articles and editorials herein repre-
MP (Materials Performance) is published monthly by NACE International
sent the opinions of the authors and not necessarily those of AMPP.
(ISSN 0094-1492; USPS No. 333-860). Mailing address and Editorial
AMPP NEWS
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and additional
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58 AMPP Editorial: In South Florida and Coastal Areas Worldwide,
Corrosion is a Cry for Help
Publications Mail Agreement #40612608. Canada Returns to be sent to
the advertising companies and there is no involvement or endorsement by
Pitney Bowes, PO Box 25542, London, ON N6C 6B2. Copyright 2014 by
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of AMPP.
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that isornot
either as a whole
has been obtained from the publisher.
in 59 AMPP Releases New, Revised, and Reaffirmed Standards

Articles and editorials herein represent the opinions of the authors and not
necessarily
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charges guaranteed. an educational service,
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61 AMPP Publishes Four Waterjet Standards
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61 AMPP Issues Correction to In-Line Pipe Inspection Standard

62
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65
SCRIPTION annual nonmem-
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issue(s) copy $20,
in question for availability permitting.and
domestic subscribers, Rates to nonmembers
6 months of the date
subject to change. Subscriptions must be prepaid. Claims made within
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available for up to 2 years. Requests for address changes should include
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65 AMPP Affiliate Corporate Members
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subscriber.
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continued delivery (phone: 1 800-797-6223 U.S. and Canada or
org). Cancellation must be made in writing. Refunds will be prorated less a
+1 281-228-6223 worldwide or e-mail: firstservice@nace.org). Cancel-
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writing. Refunds an AMPP
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and e-mail address. PRINTED IN THE U.S.A.

4 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

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WHAT’S ONLINE @ www.materialsperformance.com

Get the Latest See What’s Online

Corrosion News... This Month
Following are just a few of the
articles featured this month on

Online and
www.materialsperformance.com.

Features

On-the-Go! Establishing the Chloride

Threshold of Stainless Steel in
Concrete
Stainless steels differ in terms of corrosion
resistance, and the need to determine their
corrosion resistance is essential. A standard
test method that is reliable, reproducible,
and quick is crucial.

AMPP Member Reflects on

Champlain Towers Efforts: Part 1
In this three-part series, longtime AMPP
member Byron Evetts provides his
perspective on the Champlain Towers South
recovery efforts and wreckage in the days
after the devastating collapse.

Editor’s Choice
Michigan Works to Reinforce
Bridges with Carbon Fiber
Technology
Carbon fiber strands have a tensile strength
comparable to steel, but they resist
corrosion and require less maintenance over
time. Longer service life is the major benefit,
according to Michigan Department of
Transportation officials.

AMPP Introduces Communities of

Interest as New Member Benefit
More formalized than existing groups with
moderators and formed under AMPP
program committees, professionals can
engage with those who share a common
interest, demographic, or are from the same
geographic area.

For even more corrosion news, visit

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

6 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

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FROM THE EDITOR’S DESK

Corrosion of www.materialsperformance.com

EDITORIAL
Offshore Oil MANAGING EDITOR-IN-CHIEF
EDITOR
Gretchen A. Jacobson
Rebecca A. Bickham

and Gas Structures TECHNICAL EDITOR

STAFF WRITER
Jack Tinnea
Ben DuBose
EDITORIAL ASSISTANT Anthony Punt
PRODUCT MANAGER, Husna Miskinyar
ELECTRONIC MEDIA

A
GRAPHICS
QUAD

A
MPP’s inaugural Conference + Expo last month in San Antonio, Texas, USA ADMINISTRATION
CHIEF EXECUTIVE OFFICER Robert (Bob) H. Chalker
was a great success—bringing together corrosion and coatings professionals
DIRECTOR, MEDIA AND Eliina Lizarraga
alike. All in attendance benefitted from the technical symposia, forums, PUBLICATIONS
workshops, meetings, networking events, etc. that were offered. It was wonderful to see
familiar faces and to meet many new ones as we all came together to forward AMPP’s ADVERTISING
mission of advancing materials performance to protect society, assets, and the environ- SALES MANAGER Diane Gross
diane.gross@ampp.org,
ment. +1 281-228-6446
The April issue of MP focuses on the corrosion of offshore oil and gas structures. EXHIBIT AND SPONSORSHIP Tiffany Krevics
These structures are subjected to extremely harsh conditions that can lead to the degra- SALES REPRESENTATIVE tiffany.krevics@ampp.org,
dation of these important assets. When failures occur, companies are at risk of property +1 281-228-6411

damage, lost revenue, and even loss of life. For these reasons, it is important to design and MEDIA SALES REPRESENTATIVE Janis Mason
janis.mason@ampp.org,
maintain safe, protected structures. +1 847-234-6402
In one of our technical articles, you’ll read about the subsea vibration data logger that MEDIA SALES REPRESENTATIVE Leslie Whiteman
can be installed directly on subsea equipment to monitor wave-induced motion, vessel- leslie.whiteman@ampp.org,
+1 281-228-6248
induced motion, vortex-induced vibration, and/or flow-induced vibration, which occur in
ADVERTISING AND Brenda Nitz
deep-water applications. This article can be located on page 28. MANUSCRIPT COORDINATOR brenda.nitz@ampp.org,
In another technical article on page 32, Rifnur Latipov and David Morton describe a +1 281-228-6219
durable isocyanate-free topcoat that can actively repel water to provide outstanding pro-
NACE International Contact Information
tection for offshore steel structures from corrosion. Additional information, including Tel: +1 281-228-6200 Fax: +1 281-228-6300
the effect of this topcoat compared to conventional coatings, is found in the article. Email: customersupport@ampp.org Web site: www.ampp.org
In one of this issue’s three Material Matters articles, you’ll learn about the invention
of a unidirectional carbon fiber tape known as VESTAPE PA12-CF. It is a strong, non-cor- EDITORIAL ADVISORY BOARD
rosive, spoolable, lightweight technology that can potentially have reduced costs and less Zahid Amjad, FNACE Walsh University
of an environmental footprint. To read more about this exciting innovation, see page 18. Wayne Frenier Frenier Chemical Consultants
Our feature article this month, which can be found on page 24, is part two of a three- Fred Goodwin Consultant

part series in which Urban Search & Rescue Specialist Byron Evetts describes his experi- Jerry Holton Specialty Polymer Coatings USA, Inc.
W. Brian Holtsbaum Corsult Associates (1980), Ltd.
ence at the collapsed Champlain Towers South (Surfside, Florida, USA). Evetts provides
Russ Kane iCorrosion, LLC
insight into the part corrosion may have played in the collapse, along with his thoughts
Ernest Klechka CITGO Petroleum Corp.
on inspection and maintenance of coastal buildings.
Guo Liu Beijing Cathtop Technology Co., Ltd.
We hope you enjoy reading this collection of articles pertaining to corrosion of off-
Lee Machemer Jonas, Inc.
shore oil and gas structures. As always, I enjoy hearing from our readers, so please feel
Calvin R. Pynn Prydwen International, Inc.
free to reach out to me anytime! Vilupanur A. Ravi California State Polytechnic
University, Pomona
John S. Smart III John Smart Consulting Engineer
Laura Machuca Suarez Curtin Corrosion Centre

Rebecca Bickham,
Editor, rebecca.bickham@ampp.org

8 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

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UP FRONT
Why Iron Catalyzes Corrosion in ‘Inert’ Carbon
Dioxide New Research Targets
Corrosion of Manufactured
Iron that rusts in water theoretically shouldn’t corrode in contact with an Metals
“inert” supercritical fluid of carbon dioxide (CO2), but it does. The reason
has eluded materials scientists to now, but a team at Rice University (Hous-
ton, Texas, USA) has a theory that could contribute to new strategies to pro-
tect iron from the environment.
Materials Theorist Boris Yakobson and his colleagues found through
atom-level simulations that iron itself plays a role in its own corrosion when
exposed to supercritical CO2 (sCO2) and trace amounts of water by promot-
ing the formation of reactive species in the fluid, which come back to attack
it.
In their research, which
was supported by the U.S. Yao “Yolanda” Fu, an assistant professor at
Department of Energy, Virginia Tech, received two U.S. research
they conclude that thin grants to study the environmental-related
behaviors of additively manufactured metals.
hydrophobic layers of two-
Photo by Peter Means for VT.
dimensional materials like
graphene or hexagonal
boron nitride could be Yao “Yolanda” Fu, an assistant professor in
employed as a barrier aerospace and ocean engineering at Vir-
between iron atoms and ginia Tech (VT) (Blacksburg, Virginia, USA),
sCO2’s reactive elements. received two U.S. research grants to study
Supercritical fluids Iron (blue) can react with trace amounts of water to the environmental-related behaviors of
are materials at a tem- produce corrosive chemicals. Image by Evgeni Penev, additively manufactured metals. Fu received
perature and pressure Rice University. one grant from the National Science Foun-
that keeps them roughly dation (NSF) and another from the Office of
between phases—say, not all liquid, but not yet all gas. The properties of Naval Research (ONR), each worth over
sCO2 make it an ideal working fluid because, according to the researchers, it $500,000.
is “essentially inert,” noncorrosive, and low-cost. With the NSF grant, Fu hopes to answer
While previous studies attributed corrosion to the presence of bulk two questions about additively manufac-
water and other contaminants in the superfluid, that isn’t necessarily the tured metals: how the fatigue behavior of
case, according to Rice’s research. these alloys differs from conventionally
“Water, as the primary impurity in sCO2, provides a hydrogen bond net- manufactured counterparts under normal
work to trigger interfacial reactions with CO2 and other impurities like and corrosive environments, and how their
nitrous oxide [N2O] and to form corrosive acid detrimental to iron,” says unique microstructures contribute to
Qin-Kun Li, a graduate student and co-lead author. behavioral differences.
The simulations showed that iron itself acts as a catalyst. It lowers the Using experimentation and computa-
reaction energy barriers at the interface between iron and sCO2, ultimately tional methods, Fu and her research team
leading to the formation of a host of corrosive species: oxygen, hydroxide will investigate how these metals react
(OH-), carboxylic acid (R−CO2H), and nitrous acid (HNO2). under tensile/compressive testing and high-
To the researchers, the study illustrates the power of theoretical model- cycle fatigue testing. From there, they will
ing to solve complex chemistry. In this case, it is predicting thermodynamic perform similar tests in corrosive environ-
reactions and estimates of corrosion rates at the interface between iron and ments and examine environmental factors
sCO2. Furthermore, it shows that if there is more than a trace of water in the such as varying temperatures, humidity, and
superfluid, corrosion could accelerate. salinity levels.
For more information, visit news.rice.edu. By understanding microstructural fea-
tures and any effects on fracture and crack-
ing in a corrosive environment, the
researchers hope to develop parts with pro-
longed service life and limited fatigue
failure.

10 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 With the ONR grant, Fu will examine
stainless steels often used in marine envi-
ronments, particularly the performance of
hybrid structures consisting of parts that
are partially printed and partially conven-
tionally processed. These hybrid steel struc-
tures will allow researchers to evaluate how
their environmentally assisted cracking
behavior differs from that of conventional
or bulk counterparts.
Fu’s team will also investigate how the
material’s solidification texture and grain
directionality can affect corrosion-related
properties over a range of temperatures. In
doing so, they plan to study corrosive
behaviors in sodium chloride (NaCl) solu-
tions with concentrations close to that of
seawater, including an electrochemical
analysis of the corrosion characteristics,
stress corrosion cracking, high cycle fatigue,
and crack propagation testing.
By understanding the underlying mech-
anisms leading to corrosion, cracking, and
failure, researchers can better control fea-
tures and defects during manufacturing.
One application of interest to ONR is
improvements to additively manufactured
Type 316L stainless steel, which inevitably
corrodes due to saltwater exposure.
For more information, visit vtx.vt.edu.
Researchers Develop Silica
with ‘Engineered Living’
Properties
This block M is composed of engineered
bacteria and silica—a material commonly
used in plaster—cross-linking together.
Photo by Sunyoung Kang, postdoctoral
associate, UMN’s Schmidt-Dannert Lab.
In a recent study, University of Minnesota
(UMN) (Minneapolis, Minnesota, USA)
researchers showed how silica can be trans-
MATERIALS PERFORMANCE: VOL. 61, NO. 4
formed into a self-assembling, dynamic, and
resilient material by combining the strength
of conventional building materials with the
responsiveness of living materials. While
not yet available for widespread commer-
cial use, these materials have potential
applications in both construction and bio-
medical fields.
While the current additive approach of
engineered living materials—in which a liv-
ing component is added—has benefits, it
falls short of the aspirational model in
which a product grows, self-organizes, and
heals itself. To that end, the researchers
used well-studied and benign bacteria
known as Bacillus subtilis, which are a
strong candidate for commercial use due to
its ability to go dormant in unfavorable con-
ditions and activate in favorable ones. The
team engineered the bacteria and studied
the optimal approach to integrate it into the
structure.
“The first time we saw that the bacteria
and the silica were cross-linking and form-
ing a rigid material was pivotal,” says Clau-
dia Schmidt-Dannert, a biochemistry
professor who led the UMN research. “At
that moment, we knew it was working.”
The findings provide a framework for
designing novel engineered living materials
for coatings and plasters, key building
materials. Today, researchers are exploring
new starting materials.
“We’re now interested in going beyond
silica, using different cells—maybe even
multiple cell types—to develop novel engi-
neered living materials for a range of appli-
cations,” Schmidt-Dannert says.
For more information, visit twin-cities.
umn.edu.
APRIL 2022 11
COMPANY NEWS

and seamless access to the most innovative

Coatings Manufacturer Carboline Hires Managing
Director for Europe
Global coatings manufacturer Carboline
(St. Louis, Missouri, USA) announced that
Anthony Verberght joined the company as
managing director of Carboline Europe,
effective February 28, 2022. In that role, he
reports to Chris Tiernay, president and chief
operating officer.
In his role, Verberght will be responsible for
overseeing Europe’s strategy development,
growth, and profitability in conjunction with
Carboline’s executive team. He will also drive
the successful implementation of the European
portion of the company’s global expansion
Anthony Verberght
project, which is designed to significantly
Image courtesy of Carboline.
increase Carboline’s European business.
Verberght joins Carboline with more than 20 years of experience in
protective coatings, which he gained as an entrepreneur and in senior roles
within a large protective coatings company. He has held numerous positions
throughout Europe and Asia.
“Anthony brings exceptional experience, knowledge, and leadership in
sales, key account management, business development, engineering, selling,
distribution, and strategy development,” Tiernay says. “We look forward to
Anthony joining the Carboline team and our continued growth in Europe.”
IGS Acquires Cleaning, world-class asset performance for our cli-
Inspection Solutions ents. Our acquisition of Tube Tech repre-
Firm Tube Tech sents another step in IGS’ mission to be the
Integrated Global Services, Inc. (IGS) (Rich- most valued provider of engineered surface
mond, Virginia, USA), a leading provider of solutions in the world for mission-critical
thermal spray and other surface protection equipment.”
solutions and a portfolio company of invest- Tube Tech leads the market in the
ment affiliates of J.F. Lehman & Company research and development of innovative
(JFLCO), has acquired international clean- fouling removal technologies. According to
ing and inspections solutions provider Tube IGS, the company’s pioneering research and
Tech (Houston, Texas, USA). development program has included the
With over 30 years of experience in help- launch to market of the world’s first robotic
ing customers evaluate and solve critical fouling removal solutions, which are guaran-
surface engineering challenges, IGS says it teed to restore assets to design efficiency
has the largest global footprint in the sector, regardless of fouling.
delivering proprietary solutions on six “We are delighted to be part of IGS,” says
continents. Jon Camp, managing director of Tube Tech.
“We could not be more excited to intro- “There is a vast amount of experience and
duce Tube Tech to our global customer capability between the two organizations,
base,” says Rich Crawford, president and with aligned values and a shared mission to
CEO. “This transaction significantly expands innovate and transform. The benefits and
our portfolio of specialty services and returns on investment for our customers are
enables us to directly address both fouling significant, from increased asset uptime and
protection and maintenance to enable shorter turnarounds to enhanced reliability
and effective solutions on the market.”
GARDCO, Byk-Gardner
Name Physical Test
Equipment Manager
The Paul N. Gardner Company (GARDCO)
(Pompano Beach, Florida, USA), in con-
junction with Byk-Gardner USA—world-
wide partners of the industrial,
automotive, paint, and plastics industries
for quality control of color, appearance,
and physical test equipment—announced
the addition of Matthew Fajt as business
line manager for physical test equipment.
In that role, Fajt will be providing
direction for the physical test line of equip-
ment of the Paul N. Gardner Company and
Byk-Gardner Company with worldwide
responsibilities. According to the groups,
his expertise, strategy, and process
improvements will help grow and
strengthen the organization, as well as cre-
ate a long-lasting relationship with clients
and vendors.
Fajt arrives with over 20 years of sales,
management, and application experience
in the coatings and inspection equipment
industries. His background is with Sher-
win-Williams, KTA-Tator Inc., and Satter-
field Painting Inc. He holds his NACE
Coating Inspector Program Level 2 (CIP II)
certification.
Fajt currently resides in Pittsburgh,
Pennsylvania, USA, and he can be reached
at Matthew.Fajt@altana.com or by phone
at +1 412-736-9011.
ChemQuest Group Hires
Manufacturing Operations
Specialist as Director
The ChemQuest
Group (Cincinnati,
Ohio, USA), a
global business
strategy and exter-
nal technology de-
velopment firm
with focus and ex-
Robert G. Kramer pertise specific to
Image courtesy of the specialty chem-
ChemQuest Group. icals markets, an-

12 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

nounced the addition of Robert G. Kramer
as director.
Kramer joins ChemQuest and brings de-
cades of specialty chemical manufactur-
ing operations, financial, and sales
experience. He started his path toward
management and operations at Robert
Morris University (Moon Township,
Pennsylvania, USA), where he received a
degree in business administration.
In his professional career, Kramer
has held multiple positions in the spe-
cialty chemicals industry ranging from
sales to executive-level management.
Furthering his expertise in lean opera-
tions management, Kramer holds a Six
Sigma green belt. Using his expertise in
manufacturing operations, process opti-
mization, and business development,
Kramer will aid in the expansion of
ChemQuest’s manufacturing excellence
pillar, according to the company.
“Bob is exactly the kind of person we
aim to recruit at ChemQuest,” says CEO
Dan Murad. “His broad experience in
specialty chemical operational manage-
ment paired with his general manage-
ment and communication skills make
him a welcomed addition to the team.”
Most recently, Kramer was president
at rose plastic, where he was responsible
for the overall financials and operations
for North America. According to Chem-
Quest, his leadership led to improve-
ments in operational performance while
helping to stabilize employee turnover
and morale despite the COVID-19 pan-
demic. In addition to his leadership
prowess, Kramer was instrumental in
establishing a team to successfully
establish a new medical production
facility, which required ISO 13485 certifi-
cation to include the transition of
customers.
Arkema to Open New
Powder Coating Resins Lab
Arkema announced a significant invest-
ment in the construction of a brand new
powder coating resins lab in Cary, North
Carolina, USA, the company’s headquar-
ters for coating resins. The facility is ex-
MATERIALS PERFORMANCE: VOL. 61, NO. 4
pected to begin operations by the end of
the 2022 third quarter.
“The new lab in Cary will expand our
ability to work closely with customers in
the high-growth powder coatings seg-
ment,” says Amber Goodyear, global mar-
ket manager for powder resins. “Arkema
continues to strategically invest in low-
VOC [volatile organic compounds] pow-
der technology as part of our ongoing
commitment to sustainability, recyclabil-
ity, and innovation. Our new state-of-the-
art lab, in collaboration with our other
powder labs worldwide, will help to
accelerate Arkema’s ability to develop
innovative solutions for the market that
are on the leading edge of sustainability
and performance.”
Operations at the new lab will focus
on formulation and application/testing
support for Arkema’s REAFREE resins,
including those made with polyester res-
ins, hybrid systems, polyurethane resins,
UV curable products, various additives,
and much more. Additionally, it will give
researchers more immediate hands-on
access to the Arkema test fence facility at
the Cary headquarters location, offering
years of realistic exposure data across a
range of resins and substrates.
“In the past 10 years, we have seen a
significant increase in demand for pow-
der coating resins that offer a higher level
of performance while using less energy to
cure and fewer volatile organic com-
pounds,” says Chris Miller, senior global
research director. “Our global network of
labs dedicated to these technologies
allow us to continually look to the future
and develop new, innovative solutions for
low-temperature cure formulations,
super-durables, and more emergent tech-
nologies that can help companies
throughout the value chain improve their
global performance and sustainability
efforts.”
Arkema supplies powder coating for-
mulators with REAFREE polyester resins
and other products worldwide and oper-
ates additional labs at facilities in North
Kansas City, Missouri, USA; Sant Celoni,
Spain; and Navi Mumbai, India.
APRIL 2022 13
MATERIAL MATTERS

New Multifunctional Viscoelastic

Coating System Requires Minimal
Surface Preparation

T
here exists a need in the oil and
gas, power, marine, and water
industries, among others, for a
multi-functional polymeric
coating to preserve aging infrastructure
and extend the service life of existing
assets. Historically, anti-corrosion coat-
ings include high standard surface treat- Figure 1: Left—being installed in the field, middle—the base layer, right—the outer coat.

ment and application requirements,

which aren’t conducive to resources
already in service. To apply these coat-
ings, the existing coating system must be
completely removed, leading to downtime
and health, safety, and environmental
(HSE) concerns.
Because of these drawbacks, an uncon-
ventional, anti-corrosion protection sys-
tem was created. It is viscoelastic, easy to
apply, has few HSE concerns, protects
against extreme environments, requires
little surface preparation, and has a long
service life. Researcher Kaveh Sarikhani
with Canusa-CPS, a ShawCor Ltd. Com-
pany (Etobicoke, Ontario, Canada), evalu-
ated this novel, cold-applied coating sys-
tem through conventional and
non-conventional test methods based on
current industrial standards and perfor-
mance specifications.
Through proper selection of rehabilita-
tion coatings, industries can prolong the
life of aging, exposed infrastructure that is
at risk of, or experiencing, corrosion.
Unfortunately, most rehabilitation coat-
ings require surface treatment that is not
only complex, but costly. This is impracti-
cal for assets already in service, but this Figure 2: Neutral salt spray (NSS) testing before (top) and after (bottom) 720 h of testing.
new coating system enables continued
operation during rehabilitation, extending
the life of the assets. The new multi-func-
tional system is viscoelastic, can reflow
into a damaged area, and is self-healing.

14 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Information on corrosion
control and prevention

Viscoelastic coatings are able to

instantly bond to surfaces without the
need for much surface preparation, nor do
they require preheating or curing time.
Solutions can be tailored to specific prob-
lems by adding additional layers that pro-
vide extra protection, depending upon the
need.
Viscoelastic coatings are amorphous
and inert, so they maintain their wetting
properties after installation. This is
advantageous because the adhesive com-
pound can flow into cervices and pores,
which increases the contact surface area.
Figure 1 shows how the viscoelastic coat-
ing is applied onto steel. Furthermore, in
comparison with paint, these coatings do
not require any heavy equipment, pre-
treatment, cure times, and are “low com-
plexity.” They are water resistant and
reduce rust creep; and they do not contain
any volatile organic compounds (VOCs).
To study this novel coating system,
Sarikhani tested it on various substrates
ranging from smooth to grit blasted, on
both curved and flat segments. Testing
methods conducted included adhesion
testing at ambient and coating rated tem-
peratures, determining non-crystallinity,
hot water immersion and thermal aging,
and impact resistance. Non-standard tests
were also performed such as salt water
immersion, peel adhesions tests, and salt
spray exposure (Figures 2 and 3). These
helped determine the level of corrosion
protection the system provides, as well as
its durability in adverse environments.
Testing proved that the novel visco-
elastic coating system was able to with-
stand direct exposure to salt water, even
when submerged for a significant time,
while preserving its strength and anti-
corrosion functionality. Additional find-
ings show that it is rated for 720 h under
NSS with the coating remaining intact
with no corrosion creep observed at the
edges of coated panels. It is amorphous
and self-healing without losing significant
adhesive strength over time under acceler-
ated hot water immersion tests and ther- Figure 3: Samples after being removed from the NSS chamber (left), with adhesive carrier and
mal aging studies, demonstrating a calcu- outercoat removed (middle), and the corresponding adhesive carrier and outercoat (right).
lated lifetime of over 25 years.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 15

 MARK YOUR
CALENDAR

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 Information on corrosion
control and prevention

Research also found it to be compatible AMPP offers more than 300 books
with various levels of surface preparation
covering every aspect of corrosion control
and substrates while providing instant
in all industries. For more information,
tackiness upon contact. Another notewor-
visit the AMPP Store at store.ampp.org.
thy benefit is the HSE and ease-of-applica-
tion features facilitated by this coating
system, allowing in-service rehabilitation
and reducing the amount of space and
equipment needed for installation.
The viscoelastic compound lends itself
to several installation conditions, and
combining it with an outercoat facilitates
an abundance of operating and environ-
Pu
mental exposure conditions in its ultimate
use. Unlike paint, testing has proven vis-
coelastic coatings to be easy to apply,
usable in hot and cold climates, do not
D wn
w
require much installation equipment, and
can be applied to active infrastructure/
pipes. It adheres quickly to bare substrate
Y ur
u
or to existing coatings and is self-healing
(even if damaged), protecting an area of
exposure until repairs can be made.
Final benefits include the HSE proper-
W rk
ties in which limited personal protective
equipment is needed, no VOCs are present,
no chemicals are leached into the sur-
Gl ve
rounding environment, and it is safe to
store and to handle, requiring no regula-
(We’ve
tions for disposal.
Sarikhani notes that further studies Maintaining a pipeline is no easy task. With so many things to worry
(such as dielectric constant measurement about, you need products you can depend on. Always. Our solid-state
and performance at lower temperatures) decouplers help improve your cathodic protection system’s performance
should be performed on these novel visco- and stand up to AC faults and lightning strikes, in all sorts of conditions.
elastic coatings to determine their capa- We make them rugged so that you can trust them to perform. Always.
bilities and application extremes. Applications Include:
This article is based on CORROSION • AC Voltage Mitigation
2021 paper no. 16731, presented virtually. • Insulated Joint Protection
• Decoupling Equipment
— Rebecca A. Bickham Grounding Systems
• Gradient Control Mat Isolation

Learn more about our

Always Rugged Promise:
AUTHORS WANTED Dairyland.com/AlwaysRugged
AMPP is looking for industry experts
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write jean.broge@ampp.org
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MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 17

MATERIAL MATTERS
DNV Fully Certifies Thermoplastic Composite
Tape for Pipes
T hermoplastic composite pipe
manufacturer Strohm (IJmuiden, The
Netherlands) and specialty chemicals
company Evonik (Essen, Germany) were
recently awarded full certification from
classification society DNV GL (Oslo,
Norway) for their unidirectional carbon
fiber tape known as VESTAPE PA12-CF.
The certification attests that the PA12
The technology is appropriate for any
dynamic application ranging from jumpers
to flowlines and risers, according to project
officials.
Strohm executives believe the TCP technology could offer a safe and cost-effective solution to
many challenges faced in the offshore hydrogen industry.
18 APRIL 2022
tape, which is used in Strohm’s thermoplas-
tic composite pipe (TCP) solutions, is fit to
use for dynamic sweet and sour hydrocar-
bons, as well as in water and gas injection
applications, according to the DNV-ST-F119
standard.
“The invention of high-performance
thermoplastic composite tapes such as
PA12 offers innovative alternative solutions
for pipeline infrastructure, which can
potentially have lower costs and environ-
mental footprint,” explains Ramin Mosle-
mian, principal consultant at DNV and lead
for non-metallic technologies.
“This is the case, not only for traditional
oil and gas industries, but also for pipeline
infrastructure of the energy transition for
the transportation and storage of carbon
dioxide [CO2] in carbon capture and stor-
age, as well as hydrogen,” he adds.
TCP is a strong, non-corrosive,
spoolable, lightweight technology that is
delivered in long lengths. According to the
developers, this can result in a significant
reduction of transportation and installa-
tion costs. TCP is installed using small ves-
sels or subsea pallets, which also reduces
CO2 emissions. It is 100% recyclable.
Following a major investment and test-
ing program, the two companies—in part-
nership with the Netherlands Aerospace
Centre (NLR) (Amsterdam, The Nether-
lands)—have led intense efforts over the
past five years on the development, quali-
fication, and supply of PA12 for numerous
TCP applications.
“Our fully non-metallic solution for
load-bearing structures shows great poten-
tial to meet any challenges that corrosive
environments can bring,” says Alexandre
Paternoster, material technology team lead
at Strohm. “Being applicable to both static
and dynamic mode in hydrocarbon offers a
great variety of addressable applications,
including flowlines and risers.”
According to the companies, their
approach seeks a fundamental understand-
ing of the material to demonstrate the
expected lifetime performance for products
operating in challenging chemical, ther-
mal, and mechanical environments. They
have established a relationship between a
pipe’s functional requirements and the per-
formance characteristics of its materials.
NLR provided the main composite test-
ing facilities to allow parallel dynamic and
long-term testing, which it says sped up the
process significantly when compared to
traditional sequential testing.
“Testing carbon-reinforced, saturated,
PA12 specimens in situ in NORSOK fluid at
elevated temperatures was quite a chal-
lenge,” says Rens Ubels, principal project
engineer at NLR. “We successfully
designed and built dedicated fatigue and
stress rupture set-ups to be able to meet
the test specifications and the safety and
health regulations.”
According to the developers, PA12 is a
fully non-metallic, corrosion-resistant solu-
tion. Due to the use of carbon fibers, it is
particularly resistant to fatigue-based fail-
ures. According to the companies, this
makes it an appropriate choice for any
dynamic application from jumpers to flow-
lines and risers. This can include environ-
ments with sweet and sour hydrocarbons,
as well as water and gas service.
WWW.MATERIALSPERFORMANCE.COM

The high stiffness of carbon fibers
paired with the load transfer capability of
PA12 also enables it for deepwater service
and operating pressures up to 700 bar, as
well as temperatures up to 80 °C, according
to the companies. The material has been
qualified for a lifetime of up to 30 years.
Going forward, further expansion of the
research scope will include hydrogen and
carbon capture, utilization, and storage.
“Developing a material class for disrup-
tive technologies is always challenging. PA12
for Strohm’s TCP applications was no excep-
tion,” says Carsten Schuett, industrial and
energy technology leader at Evonik. “The full
application of the DNV’s standard’s
approach to qualify the material has only
added to the complexity. But, with the help
of our partners, we finally succeeded in
characterizing the material in unprece-
dented detail and unlocked its full potential.
The resulting dataset can be used generi-
cally, removing the need for material qualifi-
We have moved!
13764 Airline Highway • Baton Rouge, LA 70817
225.275.6131 • 225.275.6134 fax • coastalcorrosion.com
MATERIALS PERFORMANCE: VOL. 61, NO. 4
Information on corrosion control and prevention
cation in further projects—which further
enables us to use it for energy transition
applications such as hydrogen transport and
carbon capture utilization and storage.”
Looking ahead, Strohm says its track
record and extensive offshore experience
with TCP is a prerequisite to aiding the off-
shore energy industry’s transition from
hydrocarbons to green alternatives. The
company stresses its commitment to sup-
porting the global industry’s goal of net
zero carbon emissions.
“Hydrogen embrittlement and carbon
dioxide dense phase transportation are of PA12 is a fully non-metallic, corrosion-resis-
no concern for this material class,” says tant solution. Due to the use of carbon fibers,
Caroline Justet, business growth executive it is particularly resistant to fatigue-based
at Strohm. “TCP is the preferred technology failures. Image courtesy of Strohm.
to unlock the potential of offshore wind-to-
hydrogen, providing a safe and cost-effec- tion of PA12 Carbon Fibre for TCP applica-
tive solution to the challenges faced in tion” at Strohm’s web site, strohm.eu/tcp-
today’s offshore hydrogen industry.” application-whitepaper.
Further information is available in a Source: Strohm, www.strohm.eu.
white paper titled, “The Material Qualifica-
— Ben DuBose
Material Sales A/C Modeling and
Pipeline Integrity Mitigation Installation
Onshore / Offshore IMP Digs
Construction Inspections
Survey Atmospheric Inspections
Engineering Solar Evaluations
Hydro Vac CIS & DCVG Surveys /
ECDA Services
Anode Ground Beds
Right of Way Maintenance
APRIL 2022 19
MATERIAL MATTERS
U.K. Maritime Assets Receive Graphene-Enhanced
Anti-Corrosion Coatings
A pplied Graphene Materials (AGM)
(Redcar and Cleveland, United
Kingdom), a leading graphene dispersion
and application technology company,
recently announced that its Genable
CX-based anti-corrosion primer was
successfully applied to flood defense
assets belonging to the Environment
Agency (EA), a non-departmental public
body charged with environmental protec-
tion and regulation in England. Ideally
suited to CX, or extreme marine environ-
ments, AGM’s new graphene enhanced
primer coated the coastal flood defense
Promoting anti-corrosion performance with a graphene-based primer. Photo courtesy of AGM.
EA flood gate in Skinningrove on the U.K.’s North East coast. Photo courtesy of AGM.
20 APRIL 2022
gates in Skinningrove and Redcar and
Cleveland, all located on the North East
coast of England.
The completion of the EA coating proj-
ect marks the culmination of an 18-month
period marked by in-depth testing and
evaluation of anti-corrosion performance
for both salt-spray and immersion in harsh
test regimes. With the successful applica-
tion of its harsh environment, anti-corro-
sion coating system, AGM further demon-
strated its bona fides in the barrier
performance and anti-corrosion product
marketplace.
According to AGM, the Genable CX
primer is a high-performance hybrid sys-
tem that relies on graphene and aluminum
chemistries to provide anti-corrosion pro-
tection for offshore, marine, and other
harsh environments. The EA project is a
milestone for both the company and its
product in that it was the first customer
application of the graphene-enhanced
coating system on a coastal facility. But it
will not be the last, as AGM has several
planned applications of the system on
other EA assets.
“Being based in the North East and see-
ing our products used locally is testament
to the excellent platform of graphene R&D
[research and development] which AGM
has developed in the region,” says Adrian
Potts, chief executive officer of AGM. “After
many years of product development and
rigorous testing of example graphene for-
mulations for a range of increasingly harsh
corrosion environments, it is extremely
gratifying to see the successful application
of these coatings in harsh coastal and sea
spray conditions through the EA.”
WWW.MATERIALSPERFORMANCE.COM

For its part, the EA observed the tangi-
ble benefits of AGM coatings on its assets
and foresees a beneficial partnership going
forward.
“We have welcomed the opportunity to
engage with AGM, who have supplied us
with their new advanced graphene primer
that was used in December 2021 on one of
our FRM [flood risk management] assets,”
says John Abraham of EA. “The asset, com-
prising two flood barrier gates, two sluice
gates, and various auxiliary components,
[are] all within the harsh coastal environ-
ment where we have to carry out frequent
maintenance due to its location. We have
uniquely used this FRM asset, with the other
half in the standard offering we use, giving
us a direct comparison [and] real-world
results in a relatively short period of time.”
Extending the Life of Coated
Assets in Real-World Conditions
Half of the coastal flood defense gates in
Skinningrove and Redcar and Cleveland
were coated with AGM’s graphene-
enhanced Genable CX anti-corrosion
primer, while the other half were coated
with a commercially available primer from
another global producer. The same topcoat
was then applied across the full site. Over
the coming months and years, the two paint
systems will be compared alongside one
another to assess the performance of the
AGM coating under real-world conditions.
“We are excited by the opportunity to
engage with England’s Environment Agency
and look forward to seeing how the partner-
ship develops,” says Andy Gent, commercial
director for AGM. “The application of our
anti-corrosion graphene-based primer on
EA asset before, during, and after the anti-corrosion coating application. Photo courtesy of AGM.
MATERIALS PERFORMANCE: VOL. 61, NO. 4
Information on corrosion control and prevention
further EA assets represents another posi-
tive step towards the wider adoption of
AGM’s innovative graphene dispersion tech-
nology across the coatings sector.”
The EA has set forth ambitious sustain-
ability targets, including a reduction of its
carbon footprint to reach net zero by 2030.
By using a coating system like the Genable
primer that incorporates a graphene-
based alternative to traditional additives,
EA assets will have increased surface pro-
tection. As a result, required maintenance
intervals of FRM assets will be lengthened
and costs minimized, while also offering
EA a more environmentally friendly solu-
tion that reduces its carbon footprint in
maintenance activities.
“We are looking forward to working
with AGM [on] further trials in 2022 of this
interesting and innovative product within
a range of real-world environments,” says Graphene can reduce corrosion damage
Abraham. over time. Photo courtesy of AGM.
— Anthony Punt
Next Month in MP
Editorial Theme: Water and
Wastewater Corrosion
Sustainable and Robust
Closed Loop Corrosion
Inhibitors
A more environmentally friendly surface
A 97-Year-Old Cement
protection system. Photo courtesy of AGM. Mortar-Lined Cast Iron Pipe
Copper Pipe Corrosion
After Sulfide-Containing
Well Water/Ozone Exposure
Nondestructive Corrosion
Rate Monitoring for
Steel in Soil
FBE Coatings in MEG and
Brine Sour Environments
APRIL 2022 21
PRODUCT SHOWCASE

ROI Calculator for Visualizing

Surface Treatment Gel for Rust Removal and Strategic CP Automation
Corrosion Prevention
CRW Consulting & Distribution, LLC
(Houston, Texas, USA), in partnership
with Corrosion Innovations
(Pasadena, Texas, USA), have
released their Corr-Zee 200 Gel
surface treatment product. This gel
meets SSPC-SP 8 Pickling Standard
and is applied directly to prepared,
rusted metal surface areas. Once the
gel has been applied and allowed to
MOBILTEX (Calgary, Alberta, Canada)
dwell on the corroded site, it should
completed the development of an online,
be rinsed with Corr-Ze 100, a liquid material supplied in 5-gal (18.9-L) pails,
publicly available cathodic protection
for optimal results. This two-step process pristinely cleans the metal at a
(CP) automation return on investment
microscopic level to remove surface impurities, including water-soluble (ROI) calculator. This calculator allows
contaminants such as chlorides, sulfates, and nitrates, as well as non-water customers to accurately determine the
soluble contaminants such as sulfides, flash rust, and blast media. The break-even point from CP automation
result is a passive surface that provides superior coating adhesion. While specific to their current operations, as
improving coating performance, the non-toxic and biodegradable Corr-Ze well as see tremendous operating
200 Gel also significantly reduces carbon footprints by eliminating the expenses by adopting its technology
need for repeat surface preparation and same-day coating in most portfolio. “We’ve always known that the
environments. In addition, Corr-Ze corrosion treatment products are impact of our CorView platform and
water-based, dry quickly without leaving any film or residue at any CorTalk hardware portfolio on corrosion
prevention programs is immense,” says
concentration, and will not damage blasting equipment (valves, ceramic
CEO Marc Bracken. “We’ve been thrilled
rods, and dynamic seals). Tel: +1 713-623-1894, web site: www.crwusa.com.
with the results from our current
customers, and through our product
Low-Bake Powder Coating development and VoC [Voice of the
for the ACE Market Customer] programs that have helped us
cures at a low deliver the broadest remote monitoring
temperature, as it portfolio in the industry. We can now
takes these steel confidently share the return-on-
pieces a long time to investment numbers that future
absorb heat and customers can expect by applying our
must reach a certain technology to solve unique CP monitoring
temperature before challenges that others in our space just
curing can take simply cannot provide. That’s why we
place. This low-bake decided to make our internal ROI
feature, along with calculator publicly available for the first
Specialty chemical supplier allnex good flow and excellent flexibility, allows time.” Users can now access this ROI
(Frankfurt, Germany) recently introduced the proper cure to take place while tool—and continue to work with
CRYLOCOAT 2435-6, a low-bake resin providing both blooming and boiling MOBILTEX directly to modify report
with excellent blooming resistance for the water resistance. This ensures the final parameters—to quantify that the
agriculture and construction equipment coating can withstand tough outdoor automation of CP data collection
(ACE) market. CRYLOCOAT 2435-6 fulfills conditions while providing an excellent significantly reduces operating costs. It
a need in the ACE market for low-bake finish that will hold up for years to come. also, in most cases, enables users to
applications to thick steel substrates such Tel: +49 (69) 6435710, web site: allnex.com. completely recover the capital cost of
as tractors and truck beds. This resin

22 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 The Latest Tools for
Fighting Corrosion

RMU devices in less than two budget structural material behavior. With version
cycles. Tel: +1 844-689-3282, web site: 6.0, COMSOL promises to boost the
www.mobiltex.com. productivity of engineers, their teams,
and their enterprises in the areas of
product design, process development, and
Updated Version of
manufacturing. Tel: +1 781-273-3322, web
Multiphysics Simulation
site: www.comsol.com.
Software
Two New Colors for Metal
Roofing
LLC, a Titan Steel partner company that
sells a range of fabricated metals across
the U.S. Tedlar-laminated metal products
from Metal Alliance carry up to a 50-year
warranty, without coastal restrictions,
providing project owners with a like-new
appearance for decades. Tel: 1 800-441-
7515, web site: www.dupont.com.
New Abrasive Metering Valve

COMSOL (Burlington, Massachusetts,

USA), a leading provider of software
solutions for multiphysics modeling, has
released version 6.0 of the COMSOL
Multiphysics software. This new release
introduces the Model Manager, a new
workspace that enables efficient
simulation data management and
collaboration. The Model Manager is fully
Clemco Industries Corp. (Washington,
integrated into the user interface and is
Missouri, USA) has debuted the
designed for simulation data
GritWizard, a new pneumatically
management, version control, tracking
DuPont (Wilmington, Delaware, USA), in operated, pressure-hold metering valve
changes, and advanced search
collaboration with Titan Steel (Baltimore, that meters all commedia from aluminum
functionality within models, computer-
Maryland, USA), launched two new colors oxide to glass bead for about every
aided design data, and other related
of Tedlar polyvinyl fluoride (PVF) film: application. The GritWizard works with
external files. It provides a structured
Charcoal Gray and Dark Bronze. Along automated and manual cabinets, blast
workspace where colleagues and teams
with their high demand for metal roofing rooms, and more, making it a go-to valve
can collaborate within their organizations
and siding, these two new colors are an for a variety of jobs without the need for
and even with external parties, putting
excellent match for existing outside-the-box modifications. It delivers
the focus on effective product design and
polyvinylidene fluoride coating colors precise, consistent media flow with all
innovation. Also introduced with version
with the same superior Tedlar PVF film common media, and can even be adjusted
6.0 is the Uncertainty Qualification
performance. “We continue to collaborate while the valve is actuated. With its 60%
Module, a new add-on that uses
with partners like Titan Steel to bring fewer wear components, this metering
probabilistic design methods to quantify
solutions to the building and construction valve is easy to install with simple
uncertainty in analyses and
market,” says Matt Urfali, Tedlar global maintenance and repair needs to fulfill.
predetermined safety margins. The
sales and marketing director, DuPont Because the GritWizard lasts 12 times
Uncertainty Quantification Model makes
Advanced Materials. “Tedlar films have longer—regardless of the media you use or
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accurate, and useful multiphysics models.
of lasting color, film integrity, and continue their blasting operations
The new software further brings major
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improvements to the solvers with
excited to expand the available color frustration. Tel: +1 636-239-4300, web site:
performance speed-up by a factor of 10 in
palette of this amazing product.” The new www.clemcoindustries.com.
engineering areas such as heat radiation
colors are available for roofing material
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MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 23

FEATURE ARTICLE

An Urban Search & Rescue

Specialist Reflects on His
Experience at the Site of the
Champlain Towers South
Collapse in Surfside, Florida,
USA—Part 2
By Alysa Reich

C
Corrosion experts notice things most people miss. Whether one is situated on a bridge, a ship, or a lamppost, a little rust may be overlooked,
but a corrosion professional sees the cause or imminent damage of that rust. In this three-part series, Byron Evetts provides his perspective on the
Champlain Towers South recovery effort and wreckage in the days after the devastating collapse.

40 Years Between Inspections Is Too Long

Engineers are puzzled by the 40-year inspection rule that was developed by Dade and Broward County (south Florida) after a significant collapse
in the Miami-Dade, Broward County area. Many think the lengthy timeline was driven by developers and builders who have historically held the most
influence on building codes in Florida.
Throughout his career, Byron Evetts’ work has covered territory extending from Hawaii to Aruba to Africa, and up and down the east coast of
Florida. “We have not seen a single building in my service area that could go 40 years without undergoing its first major maintenance,” he says. “Ten
years could be adequate because at the 20-year mark you’re going to start seeing significant corrosion damage. I think right now there are a lot of
building officials in Florida who are busy rewriting that rule.”
Fortunately, insurance companies appear to be stepping in to play a larger role as they recognize just how much is at stake when building codes
and inspection requirements are lacking. Evetts believes that greater involvement by insurance companies could be beneficial to the industry and
especially advantageous to public safety in the long run.
“People realize the 40-year inspection regimen is insufficient,” says Evetts. “Here in Florida, I’m hearing talk about a 10-year inspection require-
ment and that’s a lot better. Since June, my phone has been blowing up with people who want me to look at their buildings. If the building is 20 years
old and I checked it three years ago, I’m not going to ask them to spend thousands of dollars to inspect it again. Because we engage in best practices
in our structural assessments and restoration design, I know that such a building will be okay for a time. But if their building design is like Champlain
Towers—built using plate slab and column construction—for a much smaller fee I’ll look at the design to see if we can identify any similarities. If I
find any, I’ll strongly recommend that they do a complete reverse-engineering analysis using modern structural engineering tools.”

24 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Urban Search & Rescue Specialist Byron Evetts.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 25

FEATURE ARTICLE
Evetts at a site in Florida
“At this point, I’d be shocked if there’s a
high-rise condo board in coastal Florida that
hasn’t considered an engineering condition
survey, or at least scheduled one,” Evetts
explains. “I’ve done about a half dozen ‘desk’
design reviews since the collapse and have not
found any of similar design to the collapsed
building. The market doesn’t have the time and
money to reverse engineer every 20- or 30- or
40-year-old building, but if we identify a design
and construction type that’s problematic, I’m
going to urge my customers to reverse engineer
the building to see how close to marginal it is.”
Since the Surfside tragedy, Evetts and other
corrosion experts are most concerned about
the lack of focus on corrosion control. “I’ve
done a couple of those 40-year inspections in
South Florida,” Evetts says. “And they’re focused
halfway on electrical concerns and halfway on
structural concerns; the county-provided doc-
ument itself is wholly inadequate; the process
behind a 40-year inspection should be thor-
ough and robust.”
Neglected Corrosion-
Control Measures
“It’s almost criminal that we don’t require
more corrosion-control measures such as the
use of inhibitors in concrete, and in some
cases, the use of cathodic protection systems
built into the concrete,” says Evetts. “I happen
to be a big fan of concrete corrosion inhibitors.
There may be instances where coatings have
their place, or they may provide an important
additional layer of protection, but putting cor-
26 APRIL 2022
rosion inhibitors in con-
crete could safely take a
re i n f o rc e d c o n c re t e
structure to a 40- to
50-year life before its first
major maintenance. But
right now, you see side-
walk-variety concrete
being used in coastal
condominiums, instead
of inhibitor-reinforced
concrete, and the science
indicates the first major
maintenance cycle
should be 15 to 20 years.”
“The science is based
on chloride permeability
of concrete, things like
that,” notes Evetts. “So, if
the science is saying that
it takes 15 to 20 years to reach the first major
maintenance, and we’re seeing spalling in
buildings that age, then why are they waiting 40
years to do the first real assessment? Waiting
40 years to inspect someone’s most important
capital investment is irresponsible. I think
because of what happened in Surfside to
Champlain Towers, we will soon see a change
to the inspection frequency.”
The Cost of Corrosion
Concrete with corrosion inhibitors costs
slightly more than the concrete that has com-
monly been used for decades, but Evetts says
the long-term savings of using concrete with
corrosion inhibitors far outweighs the savings
of less expensive concrete, which usually
requires expensive restoration.
“If you look at the total cost of concrete in a
reinforced concrete building, and the cost of
windows, guardrails, finishes, etc., the concrete
itself probably amounts to only a single-digit
percentage of construction costs,” says Evetts.
“It’s a little trickier to do, but I’ve seen a lot of
skilled builders pour corrosion-inhibited con-
crete into just the outdoor elements alone like
balconies and exposed surfaces. That’s proba-
bly one or two percent of the cost of the build-
ing, and then the building can stand for 40 to 50
years before its first major maintenance.”
Before their building collapsed, the Cham-
plain Towers community faced more than $15
million of restoration. This was a prohibitive
amount that led to delays and, ultimately, to
mass casualty.
Finding Insight into Building
Condition—What Building
Owners Should Be Doing
According to Evetts, a building’s handyman
may be the first person to notice something as
seemingly harmless as rust stains running from
the bottom of a balcony, or a cracked beam in
the garage, or something that may indicate
deeper structural issues. “Once anyone points
out ‘rust bleed,’ meaning for example, that once
you see rust bleed at the edge of your condo
balconies, or once you’re seeing rust leak in a
pattern, these signs represent corrosion of the
embedded reinforcing bar [rebar],” says Evetts.
“That means it’s time to do something.”
In cautioning condo owners and their asso-
ciations, Evetts would offer the following rec-
ommendations: “Don’t tell the handyman to
just caulk up a crack or paint over a rust stain;
don’t listen to a friend of a friend who considers
himself an expert because he drove a concrete
truck for six years. If you see signs of corrosion,
or if you are aware that corrosion is down to
the rebar depth, you will want to bring in an
expert to check it out. At this point, repairs
become an engineering process, and you’ll
need qualified engineers with restoration on
existing structures credentials. You want to use
people who have worked on these buildings
before, people who understand NACE, SSPC,
ACI [American Concrete Institute], and ICRI
[International Concrete Repair Institute] coat-
ings and specifications. This is what engineers
do. This is what I want people to know so they
can make safe decisions.”
“The rate of growth to corroded concrete
after corrosion damage has begun is exponen-
tial,” says Evetts. “Once you see rust bleed, it’s
time to start reacting. The first thing you
should do is hire a professional engineer with
experience in corrosion control. Finding a pro-
fessional engineer with a protective coatings or
cathodic protection background, or even a cor-
rosion specialist, is hard, but you really want
your assessment done by someone who’s regis-
tered in your state and has a corrosion and res-
toration background. You don’t want to do this
more than once, so get the right person. That
person should be able to advise on the need for,
and the cost of, an upcoming restoration.”
“When we go in to survey a building, we
break it down into three priorities:
1 Aesthetics—For example, chalky and
peeling paint or handrails that may be
pitting but are sound overall.
WWW.MATERIALSPERFORMANCE.COM
2 Asset Preservation—This is when we
look at something and recognize that
we need to get started working on it
right away because we see corrosion,
which may lead to something like water
leaks, which in turn can then cause the
corrosion to get exponentially worse.
3 Life Safety—This is our most important
priority. If we find something that needs
to be remediated immediately, we stop
our process, notify the client, and get
someone on it right away. It may be
something seemingly simple like re-
attaching a balcony handrail picket,
which is very common. We’ll close off
that balcony until it has been repaired.
In some cases, we stay on the scene
until the problem is fixed.”

Typical Restorations and the

Homeowner Experience
“ We try to avoid displacing people,
although sometimes you have to if you’re going
to repair or replace things like walkways,” says
Evetts. “Typically, on the balcony side it’ll be
done by the ‘stack,’ or as a vertical assault
method, so you have swing stages or mast
AMERICA’S PREMIER ANODE MANUFACTURER
climbers, which will move the crew up and
down. The first crew may do all the demolition
under the guidance of an engineer; then we’re Setting
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going to decide whether it needs shoring up or
other repairs. After that, the crew may move to
the next set of balconies, and then afterward, a
form-and-pour crew preps the concrete, forms Excellence
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homeowners like it,” emphasizes Evetts. “But INNOVATION Anodes
when they walk onto their new balcony—possi-
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bly with new guardrails and new deck coat- Cathodic
ings—they see the value of it. I live in a small Protection Magnesium
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community, and realtors call us to ask about the l wi Leader NACE Ce
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state of a particular condo and when it was last Accredited Services Specialty
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restored. The return on investment on a restora-
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ment cost and it should be done frequently.” Anode Superior
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work on a building, we recommend a condition Sales Office: 181 Grefer Lane | Harvey, LA 70058 | Tel.: (504) 362-7776 | Fax: (504) 362-7440
assessment every five years, mainly because of Headquarters: 6712 S. 36th Street | McAllen, TX 78503 | Tel.: (956) 630-3500 | Fax: (956) 630-3595
the warranty, but also because over the long
term it makes the whole process more afford-
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anodes@galvotec.com
able.”
Certificate: 3612.01

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 27

CATHODIC PROTECTION

Anodes Performance of
Subsea Vibration Data
Logger System
SureSh Divi, MeliSSa GoulD, anD
Dan efirD, Stress Engineering Services,
Inc., Houston, Texas, USA
In deep-water applications in the Gulf
of Mexico, vibration-induced fatigue
issues often arise due to wave-induced
motion, vessel-induced motion, vor-
tex-induced vibration, and/or flow-
induced vibration. A subsea vibration
data logger (SVDL) can be installed
directly on subsea equipment to mon-
itor these and other forms of vibration
and to assess fatigue. To protect the
SVDL from corrosion in seawater, the
system is electrically isolated from the
main structure and aluminum anodes
are connected to the SVDL body.
Based on exposure time and seawater
temperature, the size of the anode
and its exposed area are important for
area ratios. The 1000 series aluminum
anodes and three cathode materials, super
duplex SS, Type 316L SS, and NAB, were
studied. The laboratory tests were per-
formed at two seawater temperatures, 4 °C
and 24 °C, and three anode/cathode area
ratios.
Galvanic CDs and corrosion rates from
the testing indicated that aluminum anodes
provide effective corrosion protection to
super duplex SS and Type 316L SS. An
equal-area aluminum anode was found to
be sufficient to protect the NAB material at
both temperatures. Test results also indi-
cated that there is no significant galvanic
effect between the NAB and super duplex SS
in the SVDL system.
In this study, laboratory electrochemi-

T
protecting the SVDL components.
The subsea vibration data logger (SVDL)
system1 is a purpose-built vibration moni-
toring system that is installed directly on
subsea equipment to measure and record
vibration data at a particular location and
to then assess fatigue (Figure 1). The SVDL
body is constructed from UNS S31603 (Type
316L stainless steel [SS]), UNS S32550
(super duplex SS), and nickel-aluminum
bronze (NAB) UNS C63000. During service
in seawater, the SVDL is protected from
corrosion by attached aluminum anodes.
This study presents results from labora-
tory electrochemical corrosion testing
involving galvanic current density (CD)
measurements for various anode/cathode
cal corrosion testing was performed to
measure the galvanic CD using a commer-
cially available 1000 series aluminum anode
in combination with various cathodes,
including SD255 super duplex SS, Type 316L
SS, and NAB at two seawater temperatures
and three anode/cathode area ratios.
Test Setup
Electrochemical galvanic corrosion
testing was performed in accordance with
ASTM G71-812 in synthetic seawater (ASTM
D1141) using the anode and cathode mate-
rials previously described. All sample elec-
trodes consisted of solid rods with the same
surface finish (machined surface). Tests
were performed at two temperatures, 4 °C
and 24 °C, under no- or low-flow conditions.

28 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM


FIGURE 1 SVDL system installed on a drilling riser.3-4
Each test was performed for a total of 360
min. The potentials were measured using a
saturated calomel electrode (SCE).
Test Results
Galvanic current and potential mea-
surements at 4 °C and 24 °C are listed in
Tables 1 and 2, respectively. Relative CDs
observed at an anode/cathode area ratio of
10:1 were not significantly higher than CDs
observed at a ratio of 1:1. Aluminum (1000
series) coupled with SD255, at 4 °C and 24
°C, and aluminum coupled with NAB, at 4
°C, exhibited higher galvanic corrosion CD
compared to aluminum coupled with Type
316L SS.
No significant galvanic corrosion was
observed between SD255 and NAB. Simi-
larly, no significant galvanic corrosion was
observed between Type 316L SS and NAB.
MATERIALS PERFORMANCE: VOL. 61, NO. 4
FIGURE 2 Galvanic CD of Al/SD255 galvanic couple at 24 °C.
FIGURE 3 Galvanic corrosion rates with anode/cathode ratio of 1:1.
As expected, the galvanic CD was higher
at 24 °C, indicating that sacrificial anodes,
such as aluminum, are consumed more rap-
idly at ambient and warmer temperatures.5-6
Figure 2 shows a graph of galvanic CD of the
Al/SD255 galvanic couple at three area
ratios. These data show that a larger cathode
consumes more sacrificial anode.
Galvanic anode corrosion rates were
then calculated from the corrosion CD data
using Equation (1):
GCR=0.0033∙i∙EW/ρ (1)
where GCR = galvanic anode corrosion rate in
mm/year, 0.0033 = constant, i = CD in μA/cm2,
EW = equivalent weight in g, and ρ = density
in g/cm3.
Calculated galvanic anode corrosion rates
are provided in Table 3. Like the CDs, the
galvanic corrosion rates of aluminum
anodes were relatively higher at 24 °C with
all three cathodes (Figure 3). With a higher
anode/cathode ratio (10:1), the galvanic
corrosion rates did not increase signifi-
cantly compared to anode/cathode ratio
of 1:1 (Figure 4). This indicates that larger
anodes are preferable to protect the compo-
nents.
Discussion
The effect of the relative areas of the
anode and cathode on the rate of galvanic
corrosion depends on the type of control in
the system.7 If the galvanic system is under
cathodic control, varying the anode area
has little effect on the total rate of corro-
sion. The opposite is true if the system is
under anodic control. On the other hand,
APRIL 2022 29
CATHODIC PROTECTION

Galvanic currents in many situations

TABLE 1. GALVANIC CURRENT AND POTENTIAL MEASUREMENTS AT 4 °C
are proportional to the surface area of the
Galvanic Couple Area Couple Potential Galvanic Current cathode. In this study, the galvanic corro-
(Anode/Cathode) Ratio (mV) Density (μA/cm2)
sion of aluminum increased with a higher
Al/Type 316L SS 1:1 -757.2 105.7 cathode (SD255).
Al/Type 316L SS 10:1 -784.0 165.9 Galvanic corrosion testing showed that
there is no significant galvanic effect
between SD255 and NAB. Similarly, no sig-
Al/NAB 1:1 -557.4 142.1
nificant galvanic corrosion occurred
Al/NAB 10:1 -703.2 171.0 between Type 316L SS and NAB. This out-
come indicates that the galvanic effect does
Al/SD255 1:1 -593.6 193.2 not inf luence the corrosion of NAB
Al/SD255 10:1 -518.9 276.1 observed in seawater.

Conclusions
NAB/Type 316L SS 1:1 116 -1.705 1. Relative CDs measured at an
NAB/Type 316L SS 10:1 134.7 -14.47 anode/cathode area ratio of 10:1
were not significantly higher than
the currents measured at an
NAB/SD255 1:1 163.1 -64.29
anode/cathode area ratio of 1:1.
NAB/SD255 10:1 185.3 -38.88 2. Aluminum anodes (1000 series)
coupled with SD255, at 4 °C and 24
°C, and aluminum anodes coupled
TABLE 2. GALVANIC CURRENT AND POTENTIAL MEASUREMENTS AT 24 °C
with NAB, at 4 °C, exhibited higher
Galvanic Couple Couple Potential Galvanic Current galvanic corrosion CDs compared
(Anode/Cathode) Area Ratio (mV) Density (μA/cm2)
to aluminum coupled with Type
Al/Type 316L SS 1:1 -774.8 148.9 316L SS.
Al/Type 316L SS 10:1 -698.8 123.9 3. No significant galvanic corrosion
Al/Type 316L SS 1:10 (A)
-356.0 391.9 was observed between SD255 and
NAB. Similarly, no significant gal-
vanic corrosion occurred between
Al/NAB 1:1 -557.4 142.1 Type 316L SS and NAB.
Al/NAB 10:1 -708.2 129.9 4. Test results indicate that the gal-
Al/NAB 1:10 (A)
-482.6 486.0 vanic corrosion of the aluminum
anode in this system is primarily
cathodically controlled. Thus,
Al/SD255 1:1 -431.3 224.0 larger sacrificial aluminum anodes
Al/SD255 10:1 -532.5 223.4 are recommended in this scenario.
Al/SD255 1:10 (A)
-328.8 699.7
References
1 S. Divi, M. Gould, D. Efird, “Galvanic Current
NAB/Type 316L SS 1:1 42.62 -1.189
Density Measurements of Anode for Subsea
NAB/Type 316L SS 10:1 -94.40 0.913 Vibration Data Logger (SVDL) System,” COR-
ROSION 2021, paper no. 16717 (Houston, TX:
NACE International, 2021).
NAB/SD255 1:1 277.3 -89.50
2 ASTM G71-81 (Reapproved 2019): “Standard
NAB/SD255 10:1 31.90 -93.84 Guide for Conducting and Evaluating Galvanic
NAB/ D255 1:10 177.3 -36.81 Corrosion Tests in Electrolytes” (West Con-
(A)
1:10 ratio tests were performed only at 24 °C. shohocken, PA: ASTM International, 2019).
3 https://www.stress.com/capabilities/up-
the galvanic corrosion of aluminum aluminum anode in this system is primarily stream/instrumentation-and-data/ss-data-
logger.
changed only very slightly with an increas- cathodically controlled. Thus, larger sacrifi-
ing aluminum anode area. These results cial aluminum anodes are recommended in 4 https://www.hartenergy.com/exclusives/
monitoring-riser-and-wellhead-fa-
indicate that the galvanic corrosion of the this scenario.
tigue-177133.

30 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Anodes Performance of Subsea Vibration Data Logger System

5 S. McNeill, et al., “Drilling Riser Fatigue Moni-

tored in Real Time Aboard Drillship,” World
TABLE 3. GALVANIC CORROSION RATE AT 4 °C AND 24 °C
Oil, March (2013): pp. 53-59. Galvanic Corrosion Rate (mm/year)
Galvanic Couple
6 F.E. Varela, Y. Kurata, N. Sanada, “The Influ- (Anode/Cathode) Area Ratio at 4 °C at 24 °C
ence of Temperature on the Galvanic Corro-
Al/Type 316L SS 1:1 1.9 2.7
sion of a Cast Iron/Stainless Steel Couple (Pre-
diction By Boundary Element Method),” Cor- Al/Type 316L SS 10:1 2.3 3.0
ros. Sci. 39, 4 (1997): pp. 775-788.
7 R. Francis, “Galvanic Corrosion of High Alloy Al/NAB 1:1 2.6 2.8
Stainless Steels in Sea Water,” British Corrosion
J. 29,1 (1994): pp. 53-57.
Al NAB 10:1 2.1 3.1
8 R. Francis, Galvanic Corrosion: A Practical
Guide for Engineers, 1st ed. (Houston, TX: Al/SD255 1:1 3.5 4.1
NACE, 2001).
Al/SD255 10:1 3.6 4.1
SURESH DIVI is a senior associate at Stress
Engineering Services, Inc. Corrosion Tech-
nology Center (CTC), Houston, Texas, USA. NAB/Type 316L SS 1:1 0.00 0.01
He primarily provides corrosion engineer-
NAB/Type 316L SS 10:1 0.20 0.00
ing support for oil and gas (upstream, mid-
stream, and downstream) and chemical pro-
cess industry sectors. His major work at
CTC involves designing and supervising in- NAB/SD255 1:1 0.00 0.00
house corrosion testing projects, standards NAB/SD255 10:1 0.00 0.00
(NACE/ASTM), and customized testing
according to the clients’ requirements. His
areas of testing include standard immer-
sion, flow effects on corrosion (jet impinge-
ment testing), packer fluid corrosion, drill-
ing fluid corrosion, acidizing corrosion
control, HPHT production corrosion, corro-
sion inhibitors, electrochemical (alternating
current and direct current) corrosion, OLI,
NORSOK corrosion modeling, and develop-

DID YOU KNOW….

ment of non-standard corrosion test tech-
niques. Divi has earned a Ph.D. and Texas
PE. He has been a member of NACE Inter-
national (now AMPP) for 18 years.

MELISSA GOULD is a principal at Stress

The New AMPP YouTube channel brings you the latest news and
Engineering Services, Inc., Houston, Texas,
USA, email: melissa.gould@stress.com. She
information about corrosion, coatings, asset protection, AMPP
has spent over 30 years performing
detailed engineering of subsea pipeline
education, certification, conferences, events and much more!
and equipment, including cathodic protec-
tion designs and assessments, and has
overseen component fabrications and
installations. FIGURE 4 Galvanic corrosion rates with anode/cathode ratio of 10:1.

DAN EFIRD is a subject matter expert at

Stress Engineering Services, Inc.
Don’t miss out on any
valuable content!

DID YOU KNOW….

Subscribe to our channel to
stay informed, connected
and to become part of the
AMPP community
The New AMPPtoday!YouTube channel brings you the latest news and

information about corrosion, coatings, asset protection, AMPP

education, certification, conferences, events and much more!
youtube.com/c/AMPPorg

Don’t miss out on any

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 31
valuable content!
COATINGS & LININGS
Isocyanate-Free Water-
Repellent Topcoat for
Offshore Protection
rifnur latipov anD DaviD Morton,
Hempel A/S, lyngby, DenmArk
32 APRIL 2022
To obtain long-term corrosion protec-
tion in demanding offshore environ-
ments, the coating system needs to
protect the structure from water to
prevent corrosion. We have devel-
oped a durable isocyanate-free top-
coat that can actively repel water to
provide outstanding protection for
offshore steel structures from corro-
sion. In this article, the development
of a water-repellent, isocyanate-free
topcoat is described, and the effect of
this topcoat is compared to conven-
tional coatings. The topcoat is tested
in a single coating system, applied
directly to metal and in a two-coat sys-
I
tem with a zinc-rich primer.
In the coating industry, it is common to
assume that the main goal of topcoats is to
provide color, ultraviolet (UV) light protec-
tion, and aesthetic characteristics to coat-
ing systems, especially if the coating sys-
tems are designed for harsh environments.
In those environments, polyurethane (PUR)
chemistry is the most used chemistry in the
topcoat finishes, and polysiloxane chemis-
try is the most common for isocyanate-free
environments.
Strict and costly health and safety mea-
sures must be implemented in the manu-
facture and application of conventional
PURs because many diisocyanates are clas-
sified as skin and respiratory sensitizers
and are thought to be the trigger for a high
number of cases of occupational asthma
reported across all European Union (EU)
member states.1 Regulatory bodies around
the world are now looking toward phasing
out the use of isocyanates. Thus, it is
expected that the market will navigate
toward substitution of the PUR topcoats,
and alternative chemistries will emerge
into the topcoat market.
As mentioned earlier, the protective
properties of the topcoats are often over-
looked. Indeed, due to certain characteris-
tics of polymers used in topcoats, the water
penetrates through the topcoat layer easily
or topcoats tend to be brittle when cured.
Therefore, generally there is always a layer
or two of protective coatings underneath
the topcoat to provide corrosion protec-
tion. The addition of each coating layer
adds up in time, costs, and environmental
impact of the coating system application
process. Normally, in aggressive environ-
ments like offshore, a coating system would
comprise a zinc-rich primer applied on top
of the steel, an epoxy intermediate adding
some barrier properties to the coating sys-
tem, and a topcoat to provide aesthetic
properties and UV light protection. Zinc-
rich epoxy primer provides galvanic corro-
sion protection and ensures proper adhe-
sion to the substrate. The intermediate
epoxy layer plays an auxiliary role in corro-
sion protection, and it can be eliminated if
the topcoat would be able to prevent water
from penetrating and collecting in the
interface with zinc-rich epoxy.
One of the ways to decrease water permit-
tivity of the topcoat is to make it hydrophobic
WWW.MATERIALSPERFORMANCE.COM
or water repellent. The interest in superhy-
drophobic or water-repellent coatings has
increased during the last years, driven by the
potential industrial applications of these sur-
faces in different areas. Several techniques
have been employed to create superhydro-
phobic coatings, and the majority rely on the
generation of a coating surface profile or
chemically modifying the coating’s surface.1-5
However, when these surfaces are damaged,
the superhydrophobicity is usually lost and,
consequently, their inherent water-repellent
properties. Therefore, a volumetric superhy-
drophobic/water-repellent coating could
represent a breakthrough technology in the
coatings industry.
In this article, the development of a
water repellent, isocyanate-free topcoat is
described, and the effect of this topcoat is
compared to conventional coatings. Salt
spray, blister box, and aging resistance
tests 6-13 were conducted to compare the
corrosion resistance of the different coat-
ings. Adhesive and mechanical properties
of the coatings are evaluated by mandrel
flexibility, impact test, pull-off adhesion,
and thermal cycling resistance tests.
Salt spray and blister box tests were
performed to compare the corrosion resis-
tance of the water-repellent PUR coating
and the corresponding standard. The iso-
cyanate-free water-repellent topcoat has
shown excellent anti-corrosive properties
and outstanding mechanical performance,
robustness, and durability.
Experimental Procedure
Formulations Preparation
The systems to be tested are shown in
Table 1. Tests have been carried out for
both one-coat and two-coat systems. The
water-repellent PUR is an isocyanate con-
taining water-repellent topcoat and the
water-repellent non-isocyanate (NISO)
topcoat is an isocyanate-free water-repel-
lent topcoat.
Substrate and Surface Preparation
Mild steel panels of rust grade A (ISO
8501-1)14 were abrasive-blasted with iron
grit (G070 acc. ISO 11124)15 to a cleanliness
MATERIALS PERFORMANCE: VOL. 61, NO. 4
TABLE 1. ONE COAT SAMPLES PREPARED FOR TESTING
Test System Coat 1
Standard 1 Conventional polysiloxane
Standard 2 Water-repellent PUR
Prototype 1 Water-repellent NISO topcoat
Standard 3 Zinc-rich primer 1
Standard 4 Zinc-rich primer 1
Standard 5 Zinc-rich primer 2
Prototype 2 Zinc-rich primer 1
degree equivalent to Sa 2.5 (ISO 8501-1).
The surface roughness of the panels had a
Rz between 40 and 55 µm.
Testing
Salt spray tests were conducted accord-
ing to ISO 92276 for the prototypes 1 and 2
and standards 1, 2, 3, and 4 directly applied
to metal. One-coat systems were tested for
1,440 h, and two-coat systems were tested
for a period of 2,200 h. After exposure, the
degree of blistering, rust, cracking, and
flaking were assessed on both the panel
and around the scribe. Pull-off adhesion
was evaluated 24 h after the end of the
exposure. The corrosion creep from the
scribe was measured at least at nine points,
and the average width, M, was calculated
according to Equation (1), where C is the
average of the measurements and W is the
original width of the scribe.
M= C-W (1)
2 R+ t
Aging resistance testing was performed
for the two-coat systems for 4,400 h.
Thermal cycling crack resistance was
conducted under the same conditions as
NACE TM0404-2004,12 Section 9, but using
the internal test Hempel method that was
empirically proven to replicate NACE
TM0404-2004 test results. Paints are
applied by blades with different thick-
nesses of application gaps on top of steel
Coat 2 Coat 3
— —
— —
— —
Conventional —
polysiloxane
Water-repellent PUR —
Epoxy intermediate PUR
Water-repellent NISO —
topcoat
panels. (For information related to sub-
strate and surface preparation, refer to the
respective section.) When paint is applied,
uniform paint stripes of different thick-
nesses are formed on steel panels. The steel
panels with applied coatings were post
cured at 60 °C for one week and then
subjected to upper and lower temperatures
of 60 °C to -30 °C, within a 2-h period, for
three weeks. After the test period, all the
samples were examined for cracks under a
microscope.
For the mandrel flexibility tests, one
side of the steel panels was coated with the
Standards 1 and 2, and Prototype 1, and
cured for two weeks. Then, the respective
flexure strain was measured using a fixed-
radii mandrel bending machine. The flex-
ure strain, F strain, of the coating systems
material were calculated using Equation
(2):
t +c
2
Fstrain= (2)
2
where t = steel panel thickness, c = coating
system thickness, and R = mandrel radius
(mm). The deformed coatings were evalu-
ated visually and microscopically for signs
of cracking.
Results
Salt Spray Test—Directly To Metal
To evaluate the corrosion resistance of
the coatings, panels were exposed to a salt
spray test (SST) for a period of 1,440 h.
APRIL 2022 33
COATINGS & LININGS

1 2 3 4 5 6

FIGURE 1: Panels evaluated after SST for 1,440 h. Panels 1 and 2—Standard 1; Panels 3 and 4—Standard 2; Panels 5 and 6—Prototype 1.

value drop was higher, up to 30%, and the

TABLE 2. CREEP LINE VALUES, CALCULATED ACCORDING
failure mode changed from cohesive to
TO EQUATION (1), FOR THE DIFFERENT SAMPLES
adhesive. The creep line width and pull-off
Standard 1 Standard 2 Prototype 1 adhesion values for the different panels are
(100 µm) (190 µm) (95 µm)
summarized in Table 2.
Creep line (mm) 1) 1.50 3) 1.00 5) 0.30
after SST exposure 2) 2.10 4) 1.60 6) 0.20
for 1,440 h SST Two-Coat System
(Standards 3, 4, and Prototype 2)
Pull-off adhesion 1a) 4.39 3a) 6.56 5a) 8.08
SST results for Standards 3, 4, and Proto-
test values (MPa) 1b) 15.24 3b) 6.98 5b) 6.33
type 2, exposed for 2,200 h, are shown in
after SST exposure 1c) 6.06 3c) 7.20 5c) 7.51
for 1,440 h 2a) 6.58 4a) 6.60 6a) 6.42 Table 3. The panels were observed after dif-
2b) 17.89 4b) 6.63 6b) 6.75 ferent times of exposure to evaluate the
2c) 3.69 4c) 6.87 6c) 6.67 degree of blistering, cracking, rusting, and/
or flaking. No visible defects were observed
after the exposure times. For all the tested
Results are shown in the following figures. line, it is possible to observe a considerable coating systems, after 2,200 h of exposure,
For 1,440 h, Standards 1 and 2, Prototype 1 reduction in the rust area around the scribe the corrosion line is below 0.5 mm. Pull-off
showed similar results—no blistering, flak- for Prototype 1. Figures 1 and 2 show that adhesion values were quite remarkable for
ing, or cracking were observed. Regarding the pull-off adhesion strength and failure Standard 4 and Prototype 2, It was observed
the scribe line area, it is notable that the mode of Standard 2 and Prototype 1 did not that pull-off adhesion values did not
creep line width is considerably larger for change more than 10% of the initial values. decrease for Standard 4 and have increased
the Standards 1 and 2. Concerning the scribe However, the Standard 1 pull-off adhesion for Prototype 2. The increase in the values

TABLE 3. TWO-COAT SYSTEM PANELS EVALUATION AFTER SST

System Standard 3 Standard 4 Prototype 2
Dry film thickness (DFT) (µm) Primer: 105 Primer: 100 Primer: 100
Topcoat: 195 Topcoat: 290 Topcoat: 220
Observations Blistering: 0(S0) Blistering: 0(S0) Blistering: 0(S0)
Rusting: Ri0 Rusting: Ri0 Rusting: Ri0
Flaking: 0(S0) Flaking: 0(S0) Flaking: 0(S0)
Cracking: 0(S0) Cracking: 0(S0) Cracking: 0(S0)

Corrosion line, M average (mm) M = 0.31 M = 0.01 M = 0.10

Pull-off adhesion average (MPa) 5.93 6.90 9.40
Adhesion failure 100% adhesion primer/steel 100% cohesive within the topcoat 100% cohesive within the topcoat
Reference (non-exposed) Reference (non-exposed) Reference (non-exposed)
Pull-off adhesion average (MPa) 9.50 7.10 7.8
Adhesion failure mode 100% cohesion within the topcoat 100% cohesion within the topcoat 100% cohesion within the topcoat

34 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Isocyanate-Free Water-Repellent Topcoat for Offshore Protection

can be explained by further curing of the

TABLE 4. PANELS EVALUATION AFTER BLISTER BOX TEST FOR 1,440 H
coating system in the high-temperature con-
ditions of SST (35 °C). Meanwhile, the pull- System Standard 1 Standard 2 Prototype 1
off adhesion values of Standard 3 have DFT (µm) 90 190 90
decreased up to 40% of the initial values.
Observations Blistering: 0(S0) Blistering: 0(S0) Blistering: 0(S0)
Blister Box Test—One-Coat System Rusting: Ri0 Rusting: Ri0 Rusting: Ri0
(Standards 1 and 2, Prototype 1) Flaking: 0(S0) Flaking: 0(S0) Flaking: 0(S0)
After 1,440 h of blister box test exposure, Cracking: 0(S0) Cracking: 0(S0) Cracking: 0(S0)
both prototype and standards showed no Pull-off adhesion 11.7/12.2 7.3/6.67 7.83/8.76
signs of blistering, rusting, flaking, or crack- average before/after
ing (Table 4). Pull-off adhesion values of blister box test (MPa)
Standard 2 slightly decreased after the test; Adhesion failure mode 100% cohesion 100% cohesion 100% cohesion within
on the other hand, pull-off adhesion values within the coating within the coating the coating
of Standard 1 and Prototype 1 slightly
increased. It can be explained by further cur-
ing of the coating system in the high-tem- decreased after the test (15 to 20% ing of the coating at different ranges of DFT.
perature conditions of the SST (40 °C). decrease), while pull-off adhesion values of Standard 2 did not show cracks at DFT
Standard 5 have decreased more signifi- above 900 µm. Prototype 1 cracked in the
Aging Cycling Resistance cantly (45% decrease). It was observed that range of 500 to 600 µm, which is at least
Test—Two-Coat System water-repellent two-coat systems (Stan- three times above the recommended appli-
(Standards 4, 5, and Prototype 2) dard 4 and Prototype 2) outperformed the cation DFT. Standard 1 cracked in the range
After 4,200 h of aging cycling resistance conventional three-coat system (Standard of 200 to 250 µm, which is two times higher
test exposure, both standards and the pro- 5) in the aging cycling resistance test, both than the recommended DFT. Refer to the
totype showed no signs of blistering, rust- in rust creepage and pull-off adhesion Experimental Procedure section for details
ing, flaking, or cracking (Table 5). It was retainment criteria. of paint application and testing regime.
observed that the corrosion line is signifi-
cantly higher for Standard 5. Standard 4 Mechanical Performance Flexibility Test
and Prototype 2, despite having fewer Standards 1, 2, and Prototype 1 were
coats, have shown better corrosion propa- Thermal Crack Resistance Test bent over different radii available mandrel.
gation resistance. Pull-off adhesion values The one-coat systems (Standards 1, 2, Standard 2, at 275 µm, had no observable
of Standard 4 and Prototype 2 slightly and Prototype 1) were examined for crack- cracks and a flexural strain of 7.8%. Stan-

TABLE 5. TWO- AND THREE-COAT SYSTEMS PANELS EVALUATION AFTER AGING CYCLING RESISTANCE TEST
System Standard 4 Standard 5 Prototype 2
DFT (µm) Primer: 95 Primer: 60 Primer: 70
Topcoat: 180 Intermediate: 120 Topcoat: 100
Topcoat: 80
Observations Blistering: 0(S0) Blistering: 0(S0) Blistering: 0(S0)
Rusting: Ri0 Rusting: Ri0 Rusting: Ri0
Flaking: 0(S0) Flaking: 0(S0) Flaking: 0(S0)
Cracking: 0(S0) Cracking: 0(S0) Cracking: 0(S0)
Corrosion line, M average (mm) M = 0.43 M = 2.53 M = 0.41
Pull-off adhesion average (MPa) 5.9 7.5 6.9
Adhesion failure 90% cohesive within the topcoat 100% adhesive between the 90% cohesive within the topcoat
and 10% adhesive between the primer and steel surface and 10% adhesive between the
primer and steel surface primer and steel surface

Reference (non-exposed) Reference (non-exposed) Reference (non-exposed)

Pull-off adhesion average (MPa) 7.0 12.9 8.7
Adhesion failure mode 100% cohesion within the topcoat 100% cohesion within the topcoat 100% cohesion within the topcoat

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 35

COATINGS & LININGS
dard 1 at 100 µm has 1.5% flexural strain
and Prototype 1 at 120 µm has 3.8% flexural
strain. It can be concluded that both sys-
tems are highly flexible. Flexural strain and
DFT values are presented as averages of six
measurements.
In both one- and two-
coat test cases, the coating
systems retained good
appearance, and no
blistering, cracking, rust,
or other visible defects were
observed on all test panels.
Conclusions
In this work, we evaluated the potential
of the isocyanate-free water-repellent top-
coat. The SST results of the one-coat sys-
tems indicated that the prototype topcoat
can reduce the corrosion creep and pre-
serve the adhesion to the substrate. SST
results of the two-coat system prototype
showed that rust creep is close to zero and
adhesion failure mode is cohesive within
the topcoat. In both one- and two-coat test
cases, the coating systems retained good
appearance, and no blistering, cracking,
rust, or other visible defects were observed
on all tested panels.
Blister box test results of one-coat sys-
tems indicated that the isocyanate-free
water-repellent topcoat possesses water
permeation resistance properties and did
not undergo degradation under constant
humid conditions. No visible defects were
observed for both prototypes.
Aging cycling resistance tests have indi-
cated that two-coat systems with water-
repellent topcoats, both PUR and polysilox-
ane, perform better than conventional
three-coat systems. The two-coat system
with zinc primer and the isocyanate-free
water-repellent topcoat have passed aging
cycling resistance tests without any visual
degradation, with low rust creep and
retained pull-off adhesion values, indicat-
ing robust anticorrosive properties of the
36 APRIL 2022
coating system.
When it comes to the mechanical test
results, the isocyanate-free topcoat showed
good performance. The thermal crack resis-
tance test and mandrel flexibility test
results indicated that the prototype has
high crack resistance and flexibility that is
higher than conventional polysiloxane top-
coats possess.
In conclusion, the results of this study
indicate that the isocyanate-free water-
repellent topcoat has a strong potential to
improve anticorrosive properties as com-
pared to the corresponding standard mate-
rial, both when applied directly to metal
and in the two-coat system with the zinc-
rich primer. In conclusion, the observed
outstanding anticorrosive and mechanical
properties of the two-coat system indicate
that this coating can be considered as a
viable candidate for areas exposed to
aggressive offshore environments.
References
1 https://industrialfinishes.com/the-isocya-
nate-problem.
2 B. Bhushan, et al., “Nanostructures for Super-
hydrophobicity and Low Adhesion,” Soft
Matter. 4 (2008): pp. 1,799-1,804.
3 B. Bhushan, et al., “Natural and Biomimetic
Artificial Surfaces for Superhydrophobicity,
Self-Cleaning, Low Adhesion, and Drag Re-
duction,” Progress in Materials Science 56
(2011): pp.1-108.
4 M. Ma, et al., “Superhydrophobic Surfaces,”
Current Opinion in Colloid & Interface Science
11 (2006): pp. 193-202.
5 Z. Guo, et al., “Superhydrophobic Surfaces:
From Natural to Biomimetic to Functional,” J.
of Colloid and Interface Science 353 (2011): pp.
335-355.
6 ISO 9227:2017, “Corrosion tests in artificial
atmospheres—Salt spray tests” (Geneva,
Switzerland: ISO, 2017).
7 ISO 6270-1:2017, “Paints and varnishes—De-
termination of resistance to humidity—Part
1: Condensation (single-sided exposure)”
(Geneva, Switzerland: ISO, 2017).
8 ISO 12944-9:2018, “Paints and varnishes—
Corrosion protection of steel structures by
protective paint systems—Part 9: Protective
paint systems and laboratory performance
test methods for offshore and related struc-
tures” (Geneva, Switzerland: ISO, 2018).
9 ISO 4624:2016, “Paints and varnishes—Pull-
off test for adhesion” (Geneva, Switzerland:
ISO, 2016).
10 ISO 6272-2:2011, “Paints and varnishes—
Rapid-deformation (impact resistance)
tests—Part 2: Falling-weight test, small-area
indenter” (Geneva, Switzerland: ISO, 2011).
11 NACE TM0304-2004, “Offshore Platform At-
mospheric and Splash Zone Maintenance
Coating System Evaluation” (Houston, TX:
NACE International, 2004).
12 TM0404-2004, “Offshore Platform Atmo-
spheric and Splash Zone New Construction
Coating System Evaluation” (Houston, TX:
NACE, 2004).
13 ISO 9227:2017, “Corrosion tests in artificial
atmospheres—Salt spray tests” (Geneva,
Switzerland: ISO, 2017).
14 ISO 8501-1:2007(en), “Preparation of steel
substrates before application of paints and
related products—Visual assessment of sur-
face cleanliness—Part 1: Rust grades and
preparation grades of uncoated steel sub-
strates and of steel substrates after overall
removal of previous coatings” (Geneva, Swit-
zerland: ISO, 2007).
15 ISO 11124-5:2019, “Preparation of steel sub-
strates before application of paints and re-
lated products—Specifications for metallic
blast-cleaning abrasives—Part 5: Cut steel
wire” (Geneva, Switzerland: ISO, 2019).
RIFNUR LATIPOV is the protective coatings
technology manager at Hempel A/S, Lyn-
gby, Denmark, email: rila@hempel.com.
Latipov has a solid technical background
with experience in product development,
project management, people manage-
ment, plus the skills and track record of
selling technical solutions to internal and
external customers. Over the last five
years, he gained experience in product
development within formulation of coat-
ings for corrosion protection, icing preven-
tion, and with added water-repellent and
self-cleaning effects. Latipov is experi-
enced in setting up collaborations with
numerous inter nal and exter nal
customers and technical presentations
for both technical and non-technical
audiences.
DAVID MORTON is the R&D manager CUI/
HH coatings at Hempel A/S, email: dmor@
hempel.com. He has 35 years of R&D coat-
ings experience in protective, marine, and
decorative coatings. Morton has been
working with Hempel A/S in Denmark for
the last nine years. He earned a Ph.D. in
chemistry from Saint Andrews University in
Scotland and has been a member of NACE
International (now AMPP) for eight years.
WWW.MATERIALSPERFORMANCE.COM
COATINGS & LININGS ESSENTIALS
Field Joint Coatings

Engineering and selecting the most adequate external corrosion recorded as significant fac- tors and the public, and fines for negligence
and appropriate pipeline coating depends tors in pipeline coating failures. Significant have cost hundreds of millions of dollars. The
upon a multitude of factors. Careful analysis catastrophic failures recorded in recent history criticality of engineering a suitable field joint
of several critical factors must be considered, have linked corrosion failure to health, safety, coating to cope with extreme environmental
such as the pipe diameter, the service pres- and environmental consequences for opera- and service conditions is imperative.
sures or operating temperatures of the trans-
port materials, the soil conditions if installing
a landline, construction techniques for instal-
lation, cathodic protection (CP), and whether
impressed current CP or sacrificial CP will be
used. These are all factors that will determine
the material selection for pipeline protection;
and it is important to understand that the
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MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 37

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 Coating a Field Joint three-layer polyethylene coatings (3LPE), three- testing methods such as thickness checks,
In recent years there have been signifi- layer polypropylene coatings (3LPP), and three- holiday detection, peel strength, adhesion
cant changes to the way field joint coating layer polyolefin coatings (3LPO). testing, hot water immersion testing, degree
systems have been engineered. Traditionally of cure, cathodic disbondment, impact resis-
the field joint coating was often overlooked Standard for Field Joint Coatings tance, indentation resistance, oxidation
and protection for this crucial zone was All coatings have distinct advantages and induction times, and flexibility.
based upon compatibility with the mainline disadvantages, with many property and char- It is essential that the pipeline is fully pro-
coating, regardless of whether or not the field acteristic variables that should be taken into tected from corrosion so petroleum products
joint coating requirements were different. consideration. There have been many devel- are contained, and this standard is a major
Several factors differ between the main- opments in recent years regarding standards leap in achieving this.
line factory coating and the field joint coat- for field joint coating systems. In 2016, the
ing. For example, the mainline coating is second edition of ISO 21809¹ was published. References
often applied in ideal factory conditions This standard specifies the requirements for a 1 ISO 21809-3:2016, “Petroleum and natural gas
using specialized equipment, and time spent field joint coating on seamless or welded steel industries—External coatings for buried or
on surface preparation and application is not pipes for buried and submerged sections of submerged pipelines used in pipeline trans-
portation systems—Part 3: Field joint coat-
critical. Since field joint coatings are applied pipeline transportation systems used in the
ings” (Geneva, Switzerland: ISO, 2016).
in the field, they are subject to extreme envi- petroleum, petrochemical, and natural gas
2 ISO 13623:2009, “Petroleum and natural gas
ronmental factors with differences in ambi- industries, as defined in ISO 13623.²
industries—Pipeline transportation systems”
ent conditions. Historically, the application of ISO 21809 has clear definitions, scopes,
(Geneva, Switzerland: ISO, 2009).
field joint coating systems has been rushed to requirements, and recommendations for engi-
This article was originally published on the MP web
adhere to critical cycle and production times, neers to follow. For example, it elaborates on
site, www.materialsperformance.com.
which has subsequently led to quality issues surface preparation techniques; material
and premature failures. Simply put, the field selection; material testing; material field test- — Lee Wilson
joint coating system must be integrated into ing; acceptance and rejection criteria require-
the pipeline construction conditions. ments for joint preparation and repairs; and
To develop a successful field joint coating
system, the engineer needs to consider addi-
tional factors such as specifying the correct
product to ensure compatibility of the mate-
rial to the mainline coating, and the overall
coating system’s performance with respect to
pipeline operating conditions. The corrosion
rate depends on various parameters, includ-
ing but not limited to pipeline operating tem-
peratures, soil or water conductivity, external
accelerators, acids and alkalis, microbiologi-
cally influenced corrosion, chemical attack,
stray current corrosion, and pipeline stresses
that lead to stress corrosion cracking.
Based on the nature of the parent coating
or factory-applied coating, the field joint coat-
ing system may consist of single or multiple lay-
ers of selected protective coating materials.
These are applied for numerous purposes that
include corrosion control, mechanical protec-
tion, thermal insulation, and adhesion. While
there are a variety of materials used as a pipe-
line field joint coating, the following are the
most predominantly used and specified sys-
tems for pipeline protection: cold applied poly-
meric tape, polyethylene (PE) and polypropyl-
ene (PP) heat shrink sleeves used in
conjunction with or without a primer, fusion-
bonded epoxy (FBE), liquid epoxy, PP coatings
applied on FBE, PE coatings applied on FBE,
polychloroprene coatings, polyurethane (PUR),

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 39

CHEMICAL TREATMENT
Enhancing Corrosion
Mitigation via Novel Surface
Treatment Application
Sarah e. Specht, Julia heiGl,
MelinDa J. Dent, Mary lyn c. liM,
Brianne GeorGic, anD arif MuBarok,
PPG, Allison Park, Pennsylvania, USA
reBekah WilSon, U.S. Army Corps of
Engineers, Engineer Research &
Development Center, Construction
Engineering Research Laboratory,
Champaign, Illinois, USA
40 APRIL 2022
Coatings remain the most dominant
mode of protection against environ-
mental degradation across a wide
range of industries. Coating systems
used in most industries are comprised
of pretreatment followed by one or
more organic layer(s). This pretreat-
ment layer is highly effective to
enhance corrosion protection. How-
ever, when protecting infrastructure
in marine environments, a pretreat-
ment process is not traditionally uti-
lized. This is due to the size and scope
of these projects and their incompat-
ibility with traditional pretreatment
methods. In this article, we introduce
a novel surface engineering technol-
ogy and compare the performance of
conventional coatings utilizing this
C
innovative preparation against tradi-
tional preparatory methods.
Coatings remain the leading mode of
protection against corrosion for large steel
structures in many harsh environmental
conditions, such as marine environ-
ments. 1-2 Critical infrastructure in such
environments must successfully withstand
years of corrosive atmospheric exposure
between re-coatings to remain structurally
viable. 2 In such environments, the first
coating layer following surface preparation
is often a primer containing either organic
or inorganic zinc. 3 Subsequent coatings
usually include an epoxy type mid-coat and
polyurethane topcoat. These coating layers
are typically applied at very thick dry film
thicknesses (DFTs) to achieve efficient pro-
tective capacity.
Smaller steel assets that are commonly
produced in industrial or automotive mar-
kets have traditionally used a different
approach to achieve a high level of corro-
sion protection: deposition of an inorganic
pretreatment layer prior to coating applica-
tion. 4 The use of phosphate conversion
coatings or thin-film inorganic layers under
the coating system provide an added level
of protection to the steel. 4 While these
assets are not typically subjected to the
same level of corrosive atmosphere as
infrastructure in coastal or marine settings,
the pretreatment layer does provide addi-
tional corrosion mitigation leading to
reduced maintenance and coating material
required to maintain an acceptable life-
cycle. This additional protection would be
highly beneficial for marine assets as well.
However, the use of pretreatment for
large assets in marine environments is not
a trivial proposal. At present, pretreatment
layers are deposited by immersion of the
asset in a liquid solution of the desired
inorganic pretreatment or via a spray appli-
cation of the pretreatment solution at ele-
vated temperature.4 Immersion application
is prohibitive for large assets due to the
large tank size required as well as the num-
ber of tanks required for the entire process.
For example, traditional metal phosphate
(e.g., Zn or Fe) pretreatment requires sev-
WWW.MATERIALSPERFORMANCE.COM
eral stages consisting of cleaning, rinsing,
TABLE 1. COATING SYSTEMS EVALUATED IN THIS STUDY
and pretreating to achieve the final pre-
treatment layer. 4-5 Even spray application Coating Description Certification/Specification
System
would be prohibitive due to the tempera-
tures required to apply the pretreatment. 1 Epoxy DTM Meets corrosivity category requirements up to C4H
Most pretreatment applications require 2a Zn-rich primer + epoxy + Meets slip B friction coefficient requirement and
controlled temperatures greater than 100 polyurethane corrosivity category requirements up to C5H
°F (38 °C).4-5 To apply such a temperature to 2b Zn-rich primer + epoxy + Meets the highest corrosivity category
a large structure in the field in a controlled polyurethane requirements up to C5VH and CX
manner would be physically challenging
and fiscally impractical. Furthermore,
waste management for large tanks of chem-
icals in the field would incur astronomical
costs.
Due to these limitations, the use of pre-
treatment methods on large steel struc-
tures in harsh environments has not been
pursued to date. However, postulating that
there may be value gained from the use of
pretreatment technologies, we have devel-
oped a method for applying pretreatment
to large structures without adding addi-
tional steps to the coating application
method through a novel surface engineer-
ing method.6 Our method imparts the qual-
ities of a pretreatment layer to the surface
of an asset through the traditional surface
preparation method of media blasting. Typ-
ically, media blasting is used to remove old
coatings from a structure, as well as pro-
vide a rough surface profile to aid in adhe-
sion for newly applied coatings. 7 In this
article, we expand beyond the use of blast-
ing as a surface preparation to also include
corrosion inhibitor application via a novel FIGURE 1 Scribe creep values for System 1 (single coat epoxy) after 1,000 h of continuous neutral
surface engineering approach. We explored salt fog exposure for the novel surface engineering approach and traditional surface preparation
this technology with several types of sys- (abrasive blasting). Bars represent the average (mean) scribe creep from three test panels; the
tems to understand the benefits, specifi- error bars represent one standard deviation from the mean.

cally for single coat and more traditional

three-coat systems.
rich primer, epoxy mid-coat, polyurethane els were then coated by hand-spray, HVLP
The test systems were subjected to
topcoat systems designed for C5 and CX 3M Accuspray † gun application with the
accelerated corrosion testing to evaluate
exposure environments. desired coating systems (Table 1) accord-
for rust creep as a demonstration of the
ing to the manufacturer’s specifications. As
corrosion protection afforded by the novel
surface engineering method. Target perfor-
Experimental Procedure mentioned previously, a single coat system
Steel panels (12 gauge, 75 mm x 150 and two three-coat systems were selected
mance metrics were selected based on ISO
mm) were used in this study and prepared to represent the lower and upper limits for
corrosivity categories,8 specifically to dem-
by either a conventional media blasting this technology in the given tests.
onstrate the value that our novel surface
approach or by the novel surface engineer- After coating, the panels cured for one
engineering approach might bring in
ing approach to impart a 2.5-mil profile to week in ambient conditions prior to accel-
extending the lifetime for a direct-to-metal
the substrate. Blasting was performed erated corrosion testing. Panels were
epoxy designed for use in C4H environ-
using a suction-fed blast cabinet. The pan-
ments and conventional three-coat zinc- †
Trade name.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 41

CHEMICAL TREATMENT

rust along the scribe, and W is the original

width of the scribe.9

M = (C-W) / 2 (1)

Results

Single-Coat Direct-to-Metal Epoxy

The corrosion protection performance
for selected coating systems was evaluated
after exposure to ISO 12944-6 continuous
neutral salt fog. The single coat system
evaluated in this study was a direct-to-
metal epoxy coating (System 1) that was
scribed and exposed for 1,000 h. The mea-
sured scribe creep values for the System 1
are shown in Figure 1. Panels prepared
using the novel surface engineering
FIGURE 2 Scribe creep values for three-coat systems 2a and 2b after 1,500 h of salt fog exposure approach prior to coating application show
with (solid) and without (patterned) the novel surface engineering approach. Bars represent the much better performance than the tradi-
average (mean) scribe creep from three test panels; the error bars represent one standard tional media blasted approach (Figure 1),
demonstrating 0.50-mm scribe creep com-
pared to the 1.74-mm scribe creep of the
traditional approach. Such a single coat
system would be appropriate for use in
milder corrosion conditions and the use of
the novel surface engineering approach
would provide longer lifetime between
coating applications.

Three-Coat Systems
In harsher environments, multi-coat
stacks with higher overall DFTs are more
common. To demonstrate the utility of our
surface engineering approach with such a
system, we evaluated two more traditional
three-coat systems containing a zinc-rich
primer, epoxy mid-coat, and polyurethane
topcoat, Systems 2a and 2b. Both systems
contain the same mid- and topcoat and dif-
FIGURE 3 Scribe creep values for three-coat systems 2a and 2b after 15 cycles of ISO 12944-9 fer only in the Zn-rich primer; System 2a
cyclic weathering exposure with (solid) and without (patterned) the novel surface engineering contains a three-component formulation,
approach. Bars represent the average (mean) scribe creep from three test panels; the error bars while 2b contains a two-component formu-
represent one standard deviation from the mean.
lation. These types of systems are common
to high corrosivity environments, such as
C5 very high and CX type environments, in
deviation from the mean.
which coating systems will be subjected to
scribed according to ISO 12944-6 with a freezer) cyclic aging. 9-10 All panels were high humidity, aggressive industrial atmo-
2-mm wide, 25-mm long scribe. 9 Panels evaluated for scribe creep after exposure by spheres, high salinity coastal areas, or off-
were subjected to either 1,000 ( for system removing the non-adherent coating with a shore environments. The scribe creep
1) or 1,500 ( for systems 2a and 2b) h of ISO sharp edge tool and calculating the average results of these systems are shown in Figure
12944-6 continuous neutral salt spray (ISO rust creep using Equation (1), in which M is 2; the values shown are an average of three
9227) as well as 15 cycles of ISO 12944-9 the calculated rust creep, C is the average panels. Both selected three-coat systems
(QUV/condensation—neutral salt fog— of nine equidistant measurements of the demonstrate better performance with the

42 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Enhancing Corrosion Mitigation via Novel Surface Treatment Application
novel surface engineering approach com-
pared to the traditionally prepared surface.
Systems 2a and 2b show 0.64 mm and 0.65
mm less scribe creep, respectively, with the
novel surface engineering approach in
place of the traditional blasting surface
preparation.
In addition to continuous salt fog expo-
sure, resistance to cyclic corrosion expo-
sure testing is essential for coatings to be
deemed acceptable for use in harsher envi-
ronments, such as C4 high or C5 very high
exposure environments. The same three-
coat systems evaluated for continuous salt
fog were also evaluated in ISO 12944-9
cyclic weathering to determine whether
the novel surface engineering approach
can enhance the corrosion protection of
the substrate when subjected to the
harsher cyclic testing. Results of the cyclic
weathering test are shown in Figure 3 for
the same systems 2a and 2b discussed pre-
viously.
Both systems exhibit improved perfor-
mance with the novel surface engineering
approach, with System 2a exhibiting a 0.37
mm improvement in the scribe creep value
and System 2b with an even larger 1.25 mm
better scribe creep over the traditional
blasting surface preparation.
Conclusions
Th e n o v e l su r f a c e e n g i n e e r i n g
approach presented in this work shows
improved performance for three systems in
accelerated corrosion testing. When the
novel surface engineering approach is uti-
lized, it yields better corrosion perfor-
mance for a single coat epoxy DTM system
in continuous salt fog testing. The novel
surface engineering approach also exhibits
better performance in two three-coat sys-
tems comprised of zinc-rich primer, epoxy
mid-coat, and polyurethane topcoat in
continuous salt fog ISO 12944-6 and
improved performance after 15 cycles of
ISO 12944-9.
Acknowledgements
This work was supported by the U.S.
Army Corps of Engineers Engineer
Research & Development Center Construc-
MATERIALS PERFORMANCE: VOL. 61, NO. 4
tion Engineering Research Laboratory
project no. W9132T-17-C-0021. All research
took place at the PPG Coatings Innovation
Center in Allison Park, Pennsylvania, USA.
References
1 R.W. Revie, Uhlig’s Corrosion Handbook, 3rd
ed. (Hoboken, New Jersey: John Wiley &
Sons, 2011), ch. 67.
2 F.N. Jones, M.E. Nichols, S.P. Pappas, Organic
Coatings—Science and Technology, 4th ed.
(Hoboken, NJ: John Wiley & Sons, 2017), ch.
7.
3 F.N. Jones, M.E. Nichols, S.P. Pappas, Organic
Coatings—Science and Technology, 4th ed.
(Hoboken, NJ: John Wiley & Sons, 2017), ch.
33.
4 L.L. Shreir, R.A. Jarman, G.T. Burstein, Corro-
sion, 3rd ed., vol. 2 ( Jordan Hill, Oxford: But-
terworth- Heinemann, 1994), pp. 15:22-15:37.
5 J.R. Davis, Metals Handbook, Desk Edition,
2nd ed. (Materials Park, OH: ASM Interna-
tional, 1998).
6 J. Heigl, et al., “Treated Particles and Sub-
strates,” WO 2020/117931 A1.
7 W.G. Wood, Metals Handbook, 9th ed., vol. 5
(Metals Park, OH: ASM International, 1982).
8 ISO 12944-2 (latest revision), “Paints and var-
nishes—Corrosion protection of steel struc-
tures by protective paint systems—Part 2:
Classification of environments” (Geneva,
Switzerland: ISO).
9 ISO 12944-6 (latest revision), “Paints and var-
nishes—Corrosion protection of steel struc-
tures by protective paint systems—Part 6:
Laboratory performance test methods” (Ge-
neva, Switzerland: ISO).
10 ISO 12944-9 (latest revision), “Paints and var-
nishes—Corrosion protection of steel struc-
tures by protective paint systems—Part 9:
Protective paint systems and laboratory per-
formance test methods for offshore and re-
lated structures” (Geneva, Switzerland: ISO).
SARAH E. SPECHT is a research chemist at
PPG, Allison Park, Pennsylvania, USA. She
has been a research chemist at PPG since
2019. She specializes in protective and
marine coatings, with a focus on corrosion
protection. Prior to PPG, she completed
her Ph.D. in chemistry, with a focus in inor-
ganic chemistry and chemical catalysis.
JULIA C. HEIGL, formerly with PPG, is a
research chemist at Sherwin-Williams,
Pittsburgh, Pennsylvania, USA. She has
worked in a wide variety of the coating
industries that include aerospace, automo-
tive inorganic pretreatment and electro-
coat, industrial, and performance and
marine coatings. She as an M.A. in sec-
ondary education teaching science.
MELINDA DENT is a group leader at PPG.
She joined PPG as a research chemist in
2018 and has experience in fundamental
understanding of coating properties with
particular emphasis on microscopy of cor-
rosion products. She has a Ph.D. in materi-
als chemistry from the University of Wis-
consin-Madison.
MARY LYN C. LIM, formerly with PPG, is a
senior leader—corrosion at Arconic Inc.,
email: marylyn.lim@arconic.com. Her
expertise includes corrosion of aluminum
alloys, and corrosion protection of inor-
ganic and organic coatings over ferrous
and non-ferrous alloys for a wide range of
applications. She has a Ph.D. in materials
science and engineering and received the
2021 SSPC President’s Lecture Series
Award. She has been a member of NACE
(now AMPP) since 2010.
BRIANNE GEORGE is a researcher at PPG.
ARIF MUBAROK is the product develop-
ment manager at PPG, email: mubarok@
ppg.com. He is a technology leader with a
full range of technical expertise such as
corrosion protection, materials character-
ization, and metallurgical testing, with
high motivation for market driven innova-
tion. He has a Ph.D. in materials science
and engineering from the University of
Connecticut in 2011, and received the
2021 SSPC President’s Lecture Series
Award.
REBEKAH WILSON is a researcher at the
U.S. Army Corps of Engineers, Engineer
Research & Development Center, Con-
struction Engineering Research Labora-
tory, Champaign, Illinois, USA.
AMPP offers
more than 300 books
covering every aspect
of corrosion control in
all industries. For more
information, visit the
AMPP Store at
store.ampp.org.
APRIL 2022 43
MATERIALS SELECTION & DESIGN

An Engineered, Integrated
Approach to External
Corrosion Management
keith parker, Enbridge Liquid Pipelines,
Bay City, Michigan, USA
trey JohnSton, Corrpro, Houston,
Texas, USA
The Enbridge External Corrosion Pre-
vention Team is developing a unifica-
tion of corrosion monitoring and miti-
gation strategies that will minimize
and effectively manage external cor-
rosion risks. The expected outcomes
of such an approach are increased
safety and reliability of the pipeline
system along with improvements in
operating efficiency. The efforts are
consistent with general industry
trends emphasize capitalization of
extensive historical data and
increased use of analytical tools
including advanced diagnostics and
modeling to help manage the rele-

T
vant corrosion threats.
FIGURE 1 Field CP measurement.

To demonstrate acceptable levels of with risk of external corrosion. To demon-

external corrosion on a pipeline system,
traditionally a technician is required to
physically travel to test point locations
across the pipeline network to make an
electrical measurement for comparison
with established criteria, as shown in Fig-
ure 1. 1 The effort involved with this task
represents a significant risk of exposure for
personnel who cover approximately 17,000
pipeline miles (27,353 km). Before consid-
ering various environmental risks associ-
ated with performing field surveys, it is well
documented that driving is one of the riski-
est activities we undertake daily.2 Addition-
ally, regulatory requirements do not vary
strate compliance, operators must expend-
comparable effort in areas with negligible
risk of external corrosion as in those with
elevated risk. With advancements in tech-
nology and expertise in recent decades
since the traditional method was formu-
lated, the Enbridge External Corrosion Pre-
vention Team (ECPT) believes there must
be a more efficient way. Therefore, End-
bridge ECPT is developing an engineered,
integrated approach to external corrosion
management (IECM).
The goal of an engineered, integrated
approach is to capitalize on the vast exper-
tise within our organization by 1) integrat-

44 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

ing the following subject matter expert
(SME) groups:
• External Corrosion Pipeline Integrity
• Pipeline Integrity
• Reliability group
and 2) integrating all means and methods
available to assess, predict, and address
external corrosion including:
• Mechanistic modeling
• Remote monitoring
• In-line inspection (ILI)
• Close-interval survey (CIS)
• External corrosion direct assessment
(ECDA)
• Traditional cathodic protection (CP)
surveys
• Engineering data analyses
A preliminary framework for such a
program utilizes the following develop-
ment cycle: Predict, Measure, Study/Correct,
Continuous Improvement, and is shown in
Figure 2.
The IECM continuous improvement
cycle begins with a robust risk assessment
(Predict) phase aimed at quantifying rela-
tive corrosion risk across the pipeline net- FIGURE 2 Preliminary IECM framework.
work. The prediction phase begins by
reviewing the mechanistic model to deter- tistical assessment, then the pipeline seg- response resulting from risk assessment
mine suitability for an integrated approach. ment qualifies for IECM, and the process results through assorted “what-if ” simula-
continues. tions. Therefore, various IECM response
Mechanistic Modeling protocols are defined that deploy resources
The IECM approach utilizes numerical Integrity Risk Determination proportional to the determined level of
simulation software that collects environ- Integrity risk is determined as a func- risk. Specific IECM responses that may be
mental, pipeline integrity, and corrosion tion of the modeled corrosion growth rate prescribed include:
control data and employs the boundary for aligned pipelines. The pipeline is • ECDA
element method with finite element model- divided into IECM segments according to • Installation of new CP system(s)
ing to calculate pipeline potential, current variations in risk category. External corro- • Upgrades to existing CP
density distribution, and corrosion growth sion control key performance indicators • CP system output adjustments
rates in complex buried pipeline networks. (KPIs) are defined for each IECM segment, • Interference mitigation (alternating
which provide the ECPT with guidance for current [AC] or direct current [DC])
Model Alignment operating and maintaining the pipeline • CIS
Confirmation segment. Depending on the results of the • ILI
Model simulations are compared with validation (Study/Correct) phase, these • Increased surveillance (e.g., remote
corresponding real-world data for pur- KPIs are used for continuous improvement monitoring)
poses of determining the level of agreement measures that are described below. • Electrical isolation
(alignment). These data are used to statisti- • Coating repairs/rehabilitation
cally determine if the model is aligned. IECM Response The program further utilizes mechanis-
Data gap analysis and corrective action rec- (Study) Phase tic modeling to determine the effectiveness
ommendations are generated for further The premise of the IECM initiative is of these response measures prior to imple-
assessment. If the model and field mea- that safety and efficiency of pipeline opera- mentation, reducing trial-and-error cycles of
surements are aligned according to the sta- tion are maximized through measured the IECM. After deployment of IECM
responses, validation of the approach begins.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 45

MATERIALS SELECTION & DESIGN
Validation (Measure/
Correct) Phase
This phase determines if reliability
targets are being met resulting from the
responses outlined above. Each pipeline
segment will have IECM predictions ana-
lyzed against established pipeline integ-
rity reliability metrics to determine if the
pipeline is being operated safely (Mea-
sure). If the segment meets these targets,
continuous improvement activities may
begin. If targets are not met, additional
risk reduction activities must be initiated
in the short term (Correct). Expected
additional activities are as described in
the IECM response phase. After risk
reduction actions are completed, the val-
idation phase is repeated until reliability
targets are met.
Continuous
Improvement Phase
IECM segments that have met reli-
ability targets are candidates for optimi-
zation of external corrosion protection
system operation proportional with the
degree to which reliability targets are
exceeded. The effectiveness of the opti-
mization options is validated in the
numerical model prior to implementa-
tion. Examples of optimization measures
that may be recommended include:
• CP system output rebalancing
• Test point quantity adjustment
• Test point configuration adjust-
ment
• Remote monitoring
• Monitoring frequency adjustment
• AC/DC interference mitigation/
monitoring configuration changes
The Benefits
Expected general benefits of the
IECM program include increases in reli-
ability, improved operational and public
safety, and increased ef f ici ency in
resource allocation associated with
external corrosion protection. With
respect to the ECP systems and monitor-
ing facilities, we envision the following
outcomes:
46 APRIL 2022
• Reductions in the number of test
points that require annual monitor-
ing through a rigorous engineering
assessment of pipeline CP condi-
tions
• Reduced field presence associated
with ensuring compliance with
AMPP (NACE) criteria
• Reduced risk of stray current dam-
age on Enbridge structures and for-
eign facilities
• Extended CP system life
The Future
The team has planned activities in
2022 to further refine and develop all
aspects of IECM.
• Perform validation studies to con-
firm model predictions
• Quantify error(s) inherent in the
model and incorporate into risk
assessment
• Confirm statistical methodologies
for model alignment and data gap
analyses
• Utilize case study results to deter-
mine response protocols and cor-
rective actions
• Incorporate mechanistic modeling
into selection of response protocols
• Develop optimization processes
Once the technical foundation for the
program has been fully developed and
validated, the team plans to further inte-
grate the various stages into an auto-
mated process to minimize assessment
and response times. We believe the IECM
approach, once fully developed and vet-
ted, will allow our organization to push
efficiencies in operations while maximiz-
ing environmental and public safety. The
team will continue to develop and share
IECM with the industry.
References
1 NACE TM0497, “Measurement Techniques
Related to Criteria for Cathodic Protection
on Underground or Submerged Metallic
Piping Systems” (Houston, TX: NACE,
2012).
2 Centers for Disease Control and Preven-
tion, “WISQARS | Leading Causes of Death
Visualization Tool,” Centers for Disease
Control and Prevention, 2019, https://
wisqars.cdc.gov/data/lcd/home ( January
11, 2022).
Acknowledgements
The authors would like to acknowl-
edge the collaborative support of techni-
cal teams from their organizations.
Disclaimer
Any information or data pertaining to
Enbridge Employee Services Canada Inc.,
or its affiliates, contained in this paper
was provided to the authors with the
express permission of Enbridge Employee
Services Canada Inc., or its affiliates. How-
ever, this article is the work and opinion of
the authors and is not to be interpreted as
Enbridge Employee Services Canada Inc.,
or its affiliates,’ position or procedure
regarding matters referred to in this
paper. Enbridge Employee Services Can-
ada Inc. and its affiliates and their respec-
tive employees, officers, director, and
agents shall not be liable for any claims for
loss, damage, or costs, of any kind whatso-
ever, arising from the errors, inaccuracies
or incompleteness of the information and
data contained in this article or for any
loss, damage or costs that may arise from
the use or interpretation of this article.
KEITH PARKER is a senior corrosion pre-
vention advisor at Enbridge LP, Bay City,
Michigan, USA, email: keith.parker@
enbridge.com He is certified to NACE
Coating Inspector Program Levels 2 and
3 and NACE CP3. He has been a member
of NACE (now AMPP) for more than 25
years.
TREY JOHNSTON is a principal engineer
at Corrpro, Houston, Texas, USA, email:
jjohnston@aegion.com. He has 15 years
with Corrpro, with extensive experience
in CP design, monitoring, and mainte-
nance. He holds a NACE Cathodic Pro-
tection Specialist certification and P.E.
licensure in multiple states. He has been
a member of NACE (now AMPP) for 14
years.
WWW.MATERIALSPERFORMANCE.COM
AMPP. The future of
asset protection.
D l d ?

options/benefits available.
g
The Association for Materials
Protection and Performance
 MATERIALS SELECTION & DESIGN
ESSENTIALS
Polymeric Technology Helps Accelerate Decarbonization Across Multiple Industries
By Chloe Hirst, Belzona
While real progress was made at the COP26
Summit, the main conclusion drawn by the
Glasgow Climate Pact was that further emis-
sions cuts are required and need to be pro-
vided by the end of 2022. This is to ensure
that countries are on track to meet the UN
Paris Agreement’s target of net-zero by 2050.
In order to achieve these carbon reduc-
tions, the 2021 State of Climate Action Report,
authored by the world’s top climate analysis
coalition, Climate Action Tracker (CAT),
explains how, “In some industries, the technol-
ogies, practices, and approaches needed to
accelerate decarbonization are well understood
but have not yet seen the levels of investment
and political support needed to rapidly scale up
mitigation action.”
As polymeric repair composites and pro-
tective coatings fall into the bracket of technol-
ogies that can actively accelerate decarboniza-
tion, it could be argued that further investment
into these systems could help many industries
ratchet up their carbon intensity reduction
plans in line with the net-zero target.
COP26 Outcome: Further
Emissions Cuts Needed
According to data from CAT, based on the
goals made at the COP26 Summit, global
warming is projected to rise to 2.4 °C by 2050.
Polymeric systems can help many industries ratchet up their carbon intensity reduction plans.
48 APRIL 2022
Although this is an improvement on the 2.7 °C
rise that was projected prior to the conference,
it is still way off the 1.5 °C target.
To sum up the situation, the report states,
“The transitions required to avoid the worst cli-
mate impacts are not happening fast enough.”
As such, the report identifies how it is
imperative that transformations toward a net-
zero future must occur throughout every sector
of society at a pace that is far faster than recent
trends.
Indeed, as the goals set at COP26 fell short
on achieving the Paris Agreement’s net-zero
target, countries are preparing to deliver on
COP26’s request to “revisit and strengthen their
current emissions targets to 2030 in 2022.”
The Outlook for Industries
Including Power, Steel,
Cement, and Buildings
The CAT’s report goes on to share statistics
on the carbon intensity reductions that need to
be made by numerous industries including
power, steel, cement, and buildings, among oth-
ers, by 2030, in order to limit warming by 1.5 °C
by 2050.
These reductions include:
• The carbon intensity of electricity gen-
eration will need to reduce to 50 to 125
gCO2/kWh
• The carbon intensity of steel will need
to decline by 25 to 30% (relative to 2015
figures)
• The carbon intensity of cement will
need to decline by 40% (relative to 2015
figures)
• The carbon intensity of operations in
select regions will need to decline by 45
to 65% in residential buildings and by
65 to 75% in commercial buildings
(relative to 2015 figures)
Unlocking the Potential
of Polymeric Materials
for Carbon Mitigation
As part of the ever-growing arsenal of car-
bon mitigation technologies and initiatives,
industrial coatings and repair composites can
help industries, such as those outlined above, to
achieve these reductions.
With a comprehensive range of polymeric
systems, including epoxy repair composites,
high-temperature coatings, liquid waterproof
membranes, elastomeric roof coatings, and
pipe wraps, among others, these systems have
been proven to not only repair and protect
damaged assets across many different indus-
tries, but to also intrinsically improve them for
the long term as well.
The environmental implications of this are
astronomical. By bypassing the need to replace
damaged assets and instead actively improve
them, industries can make great strides in min-
imizing their carbon footprints.
Economic Benefits of Investing
in High-Performance Coatings
and Repair Composites
Not only this, the report also describes the
need for “energy and process efficiency prac-
tices [that] can be economically feasible and
help drive industrial system transitions.”
As explained through a case study later in
this article, investment into composite repair
materials and industrial coatings is also an eco-
nomically feasible option. By purchasing these
systems, this mitigates the fees that can accu-
mulate in the process of asset replacement.
These fees include the cost of the asset being
WWW.MATERIALSPERFORMANCE.COM

Source: Climate Action Tracker.
replaced; the labor required during the
removal, disposal, and installation process; and
also the downtime that can be incurred during
this procedure.
For these reasons, an increase in invest-
ment into these technologies would help many
different industries in the process of ratcheting
up their 2030 emissions reduction plans, in line
with the net-zero emissions by 2050 scenario, in
a way that is also financially advantageous.
Repair and Protection
Technology Honed over
the Course of 70 Years
For decades, companies such as Belzona,
which was first established 70 years ago, have
been developing polymeric materials to
improve the energy and process efficiency of
buildings, structures, machinery, and equip-
ment found across multiple different
industries.
Examples of polymeric systems include:
1. Products such as high-performance
coating, Belzona 1341 (Supermetal-
glide), can intrinsically improve pump
efficiency by using hydrophobic tech-
nology to repel process fluids and re-
duce turbulent flow. This can create
efficiency increases of up to 7% on new
equipment and up to 20% on refur-
bished equipment.
2. The liquid waterproof membrane, Bel-
zona 3111 (Flexible Membrane), has
MATERIALS PERFORMANCE: VOL. 61, NO. 4
High-performance coating, Belzona 1341
(Supermetalglide) improves pump efficiency.
Roof protected with liquid waterproof
membrane, Belzona 3111 (Flexible Mem-
brane).
been certified by Energy Star and ETA-
Danmark (European Technical Assess-
ment) and has proven to provide excel-
lent protection of roofs for in excess of
25 years.
3. Belzona 5871, a “cool-to-touch” ther-
mal insulation barrier, reduces the
amount of heat transfer through a
surface, increasing the efficiency of
equipment.
4. For immediate leak sealing, fast-curing
materials such as the repair composite,
Belzona 1221 (Super E-Metal), and Thermal insulation barrier, Belzona 5871,
epoxy paste, Belzona 1212 are ideal for increases the efficiency of equipment.
emergency repair situations.
5. High strength, epoxy concrete repair
products such as the epoxy repair com-
posite, Belzona 4111 (Magma-Quartz),
can quickly restore secondary contain-
ment areas and damaged concrete
while providing excellent chemical and
impact resistance, as well as compres-
sive strength. Leak stemmed with emergency repair
composite, Belzona 1221 (Super E-Metal).
How Polymeric Systems
Can Help to Mitigate the
Carbon Intensity of Steel
Another way to illustrate the carbon miti-
gation potential of polymeric materials is by
considering the carbon footprint of steel.
According to an article by Carbon Clean in 2021,
for every ton of steel that is produced, nearly Rivet tank sealed with epoxy repair
double the amount, 1.85 tons of CO2 is released composite, Belzona 4111 (Magma-Quartz).
APRIL 2022 49
MATERIALS SELECTION & DESIGN ESSENTIALS
Steel fabricator saves millions of pounds
by deploying polymeric systems on gas
pipeline.
Pits filled with 2-part epoxy repair material,
Belzona 4154 (Bulkfill Resin).
Final coat of 2-part epoxy coating, Belzona
5811 (Immersion Grade).
back into the atmosphere. To put this into per-
spective, this means that if steel was a nation, it
would be the fifth largest producer of carbon
emissions in the world. By investing in repair
and protection systems that are specially devel-
oped for application onto metal substrates,
such as the 2-part epoxy repair paste, Belzona
1111 (Super Metal), asset owners can extend
the lifespan of their steel assets. In doing so, this
significantly decreases the amount of steel that
needs to be purchased. Not only will this help
to mitigate the carbon intensity of steel, but it
also enables asset owners to make considerable
financial savings too, as demonstrated in the
following case study.
50 APRIL 2022
Steel Fabricator Saves Millions
Thanks to Polymeric Repair and
Protection Systems
These types of carbon and financial savings
were made by a steel fabricator in Scunthorpe,
U.K. Over the course of several years, the asset
owner has saved millions of pounds by deploy-
ing a series of polymeric repair and protection
systems, including epoxy repair composites
and stainless steel protective coatings, on their
gas pipeline.
Previously, the client had opted to replace
the steel pipes that were severely damaged by
corrosion. However, as each meter of pipeline
costs £8,000, this meant that to replace a
90-m section, a total expenditure of £720,000
was incurred.
In order to bypass these expensive replace-
ment fees in the future, as well as mitigate the
carbon intensity of replacing the damaged steel
in this way, the client was looking for an alter-
native solution.
Following a Belzona inspection and then
approval from the client, the following poly-
meric systems were used to repair and protect
the corroded pipeline: Belzona 1151 (Smooth-
ing Metal), Belzona 4151 (Magma-Quartz
Resin), Belzona 4154 (Bulkfill Resin), and Bel-
zona 5811 (Immersion Grade).
Starting in 2016 and continuing through
into 2022, the Belzona systems were and con-
tinue to be deployed across the pipeline to
combat the widespread corrosion, totalling a
distance of 2,030 m. This will help the fabricator
to not only minimize its carbon footprint, but
also to make approximately £16 m in financial
savings as well.
In fact, this application won the contractor
a national award for the speed in which the
repair was carried out, as well as the huge sav-
ings it allowed the client to make.
Safeguard Renewable Energy
Assets with Polymeric Materials
While the CAT Report identified many
areas that need urgent improvement, the report
also identified some positive areas of progress.
It said: “In 2020, renewables reached a new all-
time record, generating 29 percent of the
world’s electricity.”
The report goes on to say how renewable
sources of power, including hydropower, biofu-
els, and wind, among others, are now the “gen-
eration technologies of choice, accounting for
82% of new capacity installed in 2020.”
In regards to the future growth of these
technologies, the report says, “Decarbonization
will be achieved by increasing the share of
renewables, particularly wind and solar, in elec-
tricity generation.” More specifically, it outlines
the objective to: “Increase the share of renew-
ables in electricity generation to 55–90% by
2030 and to 98–100% by 2050.”
Considering the ongoing success and nec-
essary future growth of these types of renew-
able energy technologies, it is important that
investments are made into protecting vital
assets. This can be achieved through the invest-
ment of polymeric repair materials and indus-
trial coatings.
R&D Team Developing
Innovative Polymeric Products
Another way in which polymeric technol-
ogy can help industries to achieve better car-
bon intensity reductions is through the compo-
sition of the products themselves.
The Belzona Research and Development
Team is currently in the process of formulating
products made from bio-based materials that
are produced from sustainable plant-based
feedstocks, rather than the traditional fossil-
fuel based ingredients.
With their high levels of renewable carbon
content, this new line of greener, more environ-
mentally friendly products gives asset owners a
further opportunity to offset the environmental
impact of their operations.
Polymeric Systems: A Welcome
Addition to the Arsenal of Carbon
Mitigation Strategies
For these reasons, an increase in invest-
ment into industrial coatings and repair com-
posites would help countries in the process of
ratchetting up their 2030 emissions reduction
plans, in order to achieve the net-zero emis-
sions by the 2050 target. Not only this, as dis-
cussed, these technologies are also instrumen-
tal in helping asset owners across many
different industries to make significant finan-
cial savings as well.
Belzona designs and manufactures polymer
repair composites and industrial protective coat-
ings for the repair, protection, and improvement
of machinery, equipment, buildings, and struc-
tures. For more information, please visit www.bel-
zona.com.
WWW.MATERIALSPERFORMANCE.COM
G
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MARCH 19-23, 2023 | DENVER, COLORADO
CM
CORROSION MANAGEMENT
Model for Predicting
Corrosion Under Insulation
Using Nondestructive Testing
khaleD haMDan, Mechanical Engineering
Department, Universiti Teknologi
PETRONAS, Perak, Malaysia
T
52 APRIL 2022
The objective of this article is to pres-
ent the model for predicting a corro-
sion under insulation rate by using
several field nondestructive testing
(NDT) inspection data, including
stress-strain profile, surface tempera-
ture profile, and moisture content of
insulation. The backward stepwise
elimination regression method was
utilized to find the influential factor for
the model. Prior to the algorithm
selection, the unsupervised learning
analysis was performed to determine
the best algorithm for the model. The
algorithm used for the final model
was an artificial neural network that
utilizes the data and the most Influen-
tial factor from field NDT inspection.
The focus of this article is on insulated
carbon steel (CS) pipes in a process plant
with an operating temperature from -42 to
175 °C, sizes from 50 mm (2 in) and above,
and with a specific type of coating and insu-
lation. The objective is to present the model
for predicting the corrosion under insula-
tion (CUI) rate by using several field nonde-
structive testing (NDT) inspection data
sets, including stress-strain profile, surface
temperature profile, and moisture content
of the insulation.
Better detectability and prediction are
required to properly manage CUI. There are
several inspection and detection methods
and/or tools for use with protective barri-
ers still in place, such as metal magnetic
memory (MMM)1 and neutron backscatter
gamma ray. 2 Previously, only a single
method of NDT had been used for detec-
tion, that of direct assessment through
visual inspection and thickness measure-
ment that requires opening the cladding.
Every method has its advantages and limi-
tations. By integrating several more NDT
methods, we will get better detection.3
CUI is corrosion that happens when
water is caught under insulation or fire-
proofing.4 It is insidious in nature and often
found after catastrophic failure. Thus, there
is a need to mitigate CUI effectively. Cur-
rently, the industry is utilizing the risk-
based inspection (RBI) methodology in
managing CUI, which is subjective. A fur-
ther drawback with the current methodol-
ogy is it is either qualitative or semi-quanti-
tative. The prediction of CUI by NACE
SP0198-20105 relies on the temperature of
the piping or equipment when it is oper-
ated (Figure 1) and whether it is an open or
closed system with no consideration of
other factors. There is also a limitation in
detecting the CUI with its protective bar-
rier as stripping of insulation incurs high
cost and sometimes requires total shut-
down of the process plant or facility.
The algorithm used in the study was an
artificial neural network (ANN), which uti-
lizes the data and the most influential fac-
tor (MIF) from field NDT inspection data.
CUI Prediction Model
The study of CUI prediction is limited
and still requires a lot of improvement and
WWW.MATERIALSPERFORMANCE.COM
further study. Almost all studies estimate
and predict the CUI probability based on a
calculation of corrosion rate of failure Closed System (oxygen held in system)
probability of the systems. There is no sin-
gle model developed by using several NDT Open System (oxygen free to escape)
inspection data and integrated with RBI 1.0 40
assessment. Cemical Plant Measurements of
Previous Prediction Model: Corrosion Under Insulation
Adaptive Neuro-Fuzzy Inference
System
In 2016, 6 M.M Khan et al. researched
0.75 30
how to construct and then check the accu-

(mpy)
racy of an adaptive neuro-fuzzy inference
Corrosion Rate (mmy)

system (ANFIS) model along with predict-

ing CUI corrosion rate of CS based on API
data. The simulation shows that the model
effectively predicts the corrosion rates
against the CUI corrosion failure frequen-
cies given by API 5832 with a mean absolute
deviation (MAD) of 0.0006. The model is
also giving CUI corrosion rates where API
583 is showing no value for it. The results
from this model would provide the inspec-
tion engineers with a satisfactory amount
of CUI corrosion rate data that will allow
for a quantitative approach to RBI.
At the end of 2016, 7 M.M. Khan et al.
made further research for a fuzzy-based
model to estimate the CUI corrosion rate of
CS based on the API data. The fuzzy model
has five inputs, which are operating tem-
perature, type of environment, type of insu-
lation, pipe complexity, and insulation con-
dition with the output given in terms of CUI
corrosion rate. The membership functions
for both inputs and outputs will be dis-
cussed in detail. Several rules were used to
perform defuzzification. After the develop-
ment of this fuzzy logic model, its root-
mean-square error value and MAD value
against API 583 data has also been checked,
which revealed quite satisfactory results.
The results from this model would provide
corrosion engineers with enough informa-
tion about CUI corrosion rates concerning
their facility so that they will be able to
make necessary inferences in a more quan-
titative approach.
Gaussian Process Regression
Lastly, there was a study using Gaussian
process regression (GPR) for predicting the
0.5 20
0.25 10
100
0
0 20
FIGURE 1 Effect of temperature on steel corrosion in water.5
thickness of mild CS plates.8 Based on the
study, with mean absolute errors (MAE) of
0.21 mm, results show that the use of GPR
provides more accurate predictions com-
pared to the use of the decay coefficient,
whose averaged MAE is 0.36 mm. This sug-
gests that the GPR method can potentially
be used in pulse eddy current NDT applica-
tions that require fast scanning.
Rawaida in 20149 conducted a review of
the available prediction method. She con-
cluded that most of the prediction methods
available are based on local industrial data
only, which might be different based on the
plant location, environment, temperature,
and many other factors that may contrib-
ute to the difference and reliability of the
model developed.
150 200 (ºF)
40 60 80 100 (ºC)
Temperature
Along these lines, it is more dependable
if the models or techniques can be devel-
oped by incorporating several inspection
methods of NDT that predict corrosion
level and its location. The summary of the
model is shown in Table 1.
Methodology
The methodology for this study is
developing the prediction model by utiliz-
ing an ANN algorithm. For research in
which a mathematical model cannot be
established, ANNs can be employed as an
effective and alternate strategy.10
A. Prediction Model
Below are three main procedures for
the prediction model to be developed:

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 53

CM
CORROSION MANAGEMENT

TABLE 1. COMPARISON OF PREDICTION MODEL

Year Paper Prediction Location Detail of Method
Method
2009 Sigeyuki Tateno et al.6-8 K-Nearest Neighbor Japan Calculating a distance from a demanded point to each historical
data
2011 Ainul Akhmar Mokhtar and First-Order Reliability Malaysia Calculation of reliability index and failure probability. Failure
Mokhtar Che Ismail8-12 Method assessment model based on structural reliability analysis.
2012 Shigeyuki Tateno et al.13 Information Gain Japan Selection of support system that eliminates corrosion rate with high
Reliability accuracy; gain ratio and reliability
2016 M.M Khan et al.6,7 Adaptive Neuro-fuzzy Malaysia Construct and then check the accuracy of ANFIS model along with
Inference System predicting CUI corrosion rate of CS based on API data.
2016 S. Tateno et al.14 Self-Organizing Map Japan This research is using past corrosion cases, before peeling off
the heat-insulating material by performing the inspection point
decision support that will improve the inspection efficiency.
2021 Sophian A. et al.8 Gaussian Process Malaysia In this study, the use of GPR for predicting the thickness of mild
Regression CS plates has been proposed and investigated with no signal
averaging used.

Proposed Framework
tensity), iii) stress/strain (dH/dx mois-
ture content).
Risk Assessment Field Section
3. Features Algorithm: a) Extraction on
POF NDT Data Operating & Design Data features for three types of variables for
the identification features using clus-
Temperature, Pressure,
tering and regression modelling; b) crit-
MMM & NBT Data
Diameter, Thickness Data ical clusters will be used for further as-
COF
sessment.

Data Pre-processing B. Research Framework

Risk The framework of the research is shown
Regression in Figure 2.

Determine Significant Factor for CUI

Result and Discussion
There are 37 piping runs that were eval-
Comparison of model Develop
Artificial Neural Network CUI
uated with NDT including MMM, NBT, and
SCOPE OF
STUDY
Probablistic Model
thermography with a risk rating from an
Model Validation
RBI assessment. For this research, there are
2,404 data entries compiled prior to the
Determine the renaining life Inspection Strategy data cleanup as per A 1(a). Next, A 1(b) will
of piping & fitness of service (Inspection Reference Plan)
be performed. The results critical parame-
FIGURE 2 Framework of CUI prediction model with inspection NDT data integrated with RBI ters are as follows: stress profile (gradient
assessment. of magnetic intensity) with a dH more than
20 A/mm; strain profile (magnetic inten-
1. Data Collection: a) Data gathering: i) red thermography to measure tempera- sity), H more than 100 mm; stress/strain
Retrieve temperature reading from all ture profile, iv) measure temperature
(dH/dx) more than 20 (A/m)/mm; moisture
the piping temperature gauges, ii) re- profile.
content of more than 200. Table 2 shows an
trieve pressure reading from all the pip- 2. Data Analysis: a) Identification: i) Iden-
ing pressure gauges; b) Fieldwork: i) Per- abbreviated list of the NDT data (please
tification of high-stress strain areas, ii)
form detail visual inspection on the pip- contact the author if you wish to obtain the
identification of temperature change
ing, ii) for fieldwork, NDT will be distribution, iii) identification of mois- complete list).
performed on the selected insulated ture trap on the insulation material, iv)
piping to collect the data; c) The objec- identification of pressure trending, v) Analysis Result
tive of every NDT is: i) MMM: To mea- identification of operating temperature Next, A 1(c) will be performed. Firstly,
sure stress profile, ii) neutron backscat- trending; b) Critical parameters: i) the MIF will be identified.11
ter testing (NBT) to measure moisture Stress profile (gradient of magnetic in-
content (hydrogen [H2] count), iii) infra- tensity, ii) strain profile (magnetic in-

54 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Model for Predicting Corrosion Under Insulation Using Nondestructive Testing

TABLE 2. PIPING LINE THAT HAS BEEN PERFORMED WITH NDT

Pressure Temperature

Diameter Nominal Insulation

LINE_ LINE_ RISK Year of Insulation Design Operating Design Operating
No Location Product OD Thickness Material Thickness
NO DwESC RATING Constn Material (kPA) (kPA) (°C) (°C)
inch/mm mm mm

From
P-12”-
P-18”- Jetty
2131- A333 Foam
1 2065 to Low (loading Propane 34 323.9 6.35 140 1940 1760 80/-45 -41
C1109- Gr.6 glass
BLOCK pier)
(N31A)
VALVE
From
P-12”-
SPEC Jetty
2132- A333 Foam
2 BREAK to Medium (loading Butane 34 323.9 6.35 140 1940 1760 80/-10 -5w
C1109- Gr.6 glass
P-12”- pier)
(N31A)
2130
From
P-12”-
P-18”- Jetty
2136- A333 Foam
3 2065 to High (loading Propane 34 323.9 6.35 140 1940 1760 80/-45 -41
C1109- Gr.6 glass
P-12”- pier)
(N31A)
2135
From
P-12”-
SPEC Jetty
2137- A333 Foam
4 BREAK to High (loading Butane 34 323.9 6.35 140 1940 1760 80/-10 -5
C1109- Gr.6 glass
P-12”- pier)
(N31A)
2135
From
P-12”-
SPEC Jetty
2142- API 5L Foam
5 BREAK to High (loading Butane 34 323.9 6.35 75 1940 1760 80/-10 -5
D1101- Gr.B glass
P-12”- pier)
(N31A)
2140
From
P-10”- Spec Jetty
Butane/ API 5L Foam
6 2130- Break to High (loading 34 273 6.35 140 1760 530 80/-45 -41
Propane Gr.B glass
D1101- P-12”- pier)
(N31A) 2153

MIF Using Backward Stepwise TABLE 3. MODEL SUMMARY

Elimination Regression Method
S R-sq R-sq (adj.) R-sq (pred.)
Significant parameters for all data cor-
relation use the regression method as 0.0248407 82.25% 69.57% 7.21%
shown in Tables 3 and 4.
Based on the backward stepwise elimi- TABLE 4. COEFFICIENT
nating regression method,11 the significant
Term Coef. SE Coef T-Value P-Value VIF
parameters are diameter, operating tem-
perature, strain max, stress-strain, and NBT Constant 0.1711 0.0433 3.95 0.006
data. The R-sq for the model is 82.25%. b (diameter, mm) -0.000497 0.000118 -4.22 0.004 1.33
f (operating temp) 0.001726 0.000552 3.13 0.017 1.53
Unsupervised Learning (K-Means) I (strain max) -0.000082 0.000026 -3.14 0.016 3.17
Next, we explored the unsupervised
j (stress/strain) 0.000421 0.000111 3.81 0.007 3.59
learning by determining the cluster.12 After-
ward, the principal component analysis K (hydrogen count) 0.000659 0.000237 2.78 0.027 2.48
was performed to reduce the dimensional-
ity of multivariate data to trivariate/bivari-
ate (2D/3D) data. 13 Then the scatter plot down our set of features to a more useful set tri-surface plots. From the analysis, it
will be plotted to lead the hypothesis that using those we can generate as useful clus- shows that the data set is a correlation
the cluster formed has sufficient explana- ters. One way of producing such a set of fea- study and not a classification study. As a
tory power. tures is to conduct correlation analysis. conclusion, the regression is the best way to
To solve this issue, we need to bring This can be done by plotting heatmaps and analyze the data.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 55

CM
CORROSION MANAGEMENT
Supervised Learning—ANN
Lastly, an ANN was developed to have a
better prediction model, as discussed
before. The approach of regression was
then decided. Steps for ANN development
are: a) Data pre-processing: i) Splitting the
dataset in the training set and test set, ii)
feature scaling; then b) Building the ANN: i)
Adding the input layer and the first hidden
layer, ii) adding the second hidden layer, iii)
adding the output layer; c) Training the
ANN: i) Compiling the ANN, ii) training the
ANN on the training set, iii) predicting the
result of the test set, iv) evaluate the model.
The results show that the model has a
prediction with 49.30% accuracy.
Conclusions
The following conclusions are drawn
from the study on prediction of the CUI rate
with several field NDT inspection data
using artificial neural networks.
1 There are many methods in predicting
the CUI shown in Table 1. However,
there is no method of utilizing NDT in-
spection data with RBI assessment.
2 Based on regression, the significant pa-
rameters are diameter, operating tem-
perature, strain max, stress-strain and
NBT data. The R-sq for the model is
82.25%.
3 From the analysis, it shows that the data
set is a correlation study and not a clas-
sification study. As a conclusion, regres-
sion is the best way to analyze the data.
4 The results from the ANN model devel-
opment show that the model has a pre-
diction of 49.30% accuracy.
5 The model can be improved by training
with more data sets.
6 There is different technique of regres-
sion that can be deployed for this data
set to get the best accuracy.
References
1 ISO 24497 (1-3), “Non-Destructive Testing—
Metal Magnetic Memory” (Geneva, Switzer-
land: ISO, 2007).
2 API Recommended Practice 583, “Corrosion
Under Insulation and Fireproofing” (Wash-
ington, DC: API, 2021).
3 B.J. Fitzgerald, S. Winnik, “A Strategy for Pre-
venting Corrosion Under Insulation on Pipe-
line in the Petrochemical Industry,” J. of Pro-
tective Coatings & Linings 22, 4 (2005).
56 APRIL 2022
4 API Recommended Practice 571, “Damage
Mechanism Affecting Fixed Equipment in the
Refining Industry” (Washington, DC: API,
2020).
5 NACE SP0198-2010, “Control of Corrosion
Under Thermal Insulation and Fireproofing
Materials–A System Approach” (Houston,
TX: NACE International, 2010).
6 M.M Khan et al., “Prediction for Corrosion
Under Insulation Subject To Carbon Steel
Pipes Using ANFIS,” ARPN J. of Engineering
and Applied Sciences 11, 1 (2016).
7 M.M. Khan et al., “A Fuzzy-Based Model To
Determine Cui Corrosion Rate For Carbon
Steel Piping Systems,” ARPN J. of Engineering
and Applied Sciences 11, 22 (2016).
8 A. Sophian, et al., “Machine-Learning-Based
Evaluation of Corrosion Under Insulation In
Ferromagnetic Structures,” IIUM Engineering
J. 22, 2 (2021).
9 Rawaida et al., “Available Prediction Methods
for Corrosion under Insulation (CUI): A Re-
view,” MATEC Web of Conferences, vol. 13,
EDP Sciences (2014).
10 N. Tosun, L. Ozler, “A Study of Tool Life in Hot
Machining Using Artificial Neural Networks
And Regression Analysis Method,” J. Mater.
Process. Technol. 124 (2002): pp. 99–104.
11 S. Tufféry, “Exploring and Preparing the
Data,” Data Mining and Statistics for Deci-
sion Making, 1st ed., Rennes, France (Hobo-
ken, NJ: John Wiley & Sons, Ltd., 2011): p. 59.
12 S. Tufféry, “The Optimum Number of Clus-
ters,” Data Mining and Statistics for Decision
Making,1st ed., Rennes, France (Hoboken, NJ:
John Wiley & Sons, Ltd., 2011): p. 238.
13 S. Tufféry, “Principal Component Analysis,”
Data Mining and Statistics for Decision Mak-
ing, 1st ed., Rennes, France (Hoboken, NJ:
John Wiley & Sons, Ltd., 2011): p. 175.
14 S. Tateno, A.S. Khaled, “Estimation of Corro-
sion Rates for Corrosion Under Insulation in
Petrochemical Plants Using Self-Organizing
Map,” 55th Annual Conference of the Society
of Instrument and Control Engineers of
Japan (2016): pp. 1104-1109.
Khaled Hamdan is an RBI engineer at the
Mechanical Engineering Department, Uni-
versiti Teknologi PETRONAS, Perak, Malay-
sia, email: khaled_hamdan@petronas.com.
my. He has 12 years of experience in asset
integrity management specializing in
advanced NDT, RBI, and digitalization. He
has a B,S. degree in mechanical engineer-
ing and an M.Sc. in asset management and
maintenance. He is currently pursuing a
Ph.D. in mechanical engineering.
WWW.MATERIALSPERFORMANCE.COM
 

   
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 AMPP NEWS
In South Florida and Coastal Areas
Worldwide, Corrosion is a Cry for Help
By Linda E. Marquez, AMPP Surfside Collapse Task Force Chair
V
iewing the world as a corrosion
control professional is often trou-
bling. We notice things others
don’t. Rust stains tell us to look for a prob-
lem, spalling concrete says, “fix me, find
what caused me.” We are most troubled
when asset owners see these issues and
still fail to act. When corrosion is evident,
especially to even the untrained eye, it
should be considered an asset’s urgent cry
for help, and as experts in this field it is
our responsibility to provide that help.
The Association for Materials Protec-
tion and Performance (AMPP) advances
the performance of materials such as pro-
tective coatings, metals, and alloys, and
concrete, among others, to protect society,
assets, and the environment. We accom-
plish this mission through workforce edu-
cation and credentialing, contractor
accreditation, technological innovation,
and global standardization of best prac-
tices. Most importantly, we serve as a
resource for decisionmakers to ensure
public policy is developed to protect the
public and the environment.
AMPP commends a recently published
report from a Miami-Dade Grand Jury on
the Champlain Towers South Collapse.
The report includes many references to
corrosion’s role in the deterioration of
buildings, which can accelerate in salt air
environments. While the definitive cause
or causes of the collapse in Surfside are
still under investigation, corrosion can
cause such destruction, and likely contrib-
uted, especially given the seaside location
of the Champlain complex.
Corrosion isn’t just a nuisance or a cost
of doing business. It should be viewed as a
grave warning. Decisions should be based
on best practices and technical standards,
not on finances. Painting over corrosion
or patching repairs doesn’t increase asset
58 APRIL 2022
integrity or sustainability. These actions
might make a building more aesthetically
pleasing, but they do not increase safety
and in some instances may contribute to
further deterioration.
In their report, the grand jury urged
policymakers to “save lives, not just
money.” This refrain is something we’ve
heard time and time again, but unfortu-
nately, it rarely drives corrosion control
decisions. However, the two are not mutu-
ally exclusive. You can save lives and
money through proactive planning. Hav-
ing a corrosion plan from the start reduces
costs by extending an asset’s useful life. A
plan also eliminates threats to safety and
avoids costly litigation.
When Florida State Attorney Kather-
ine Fernandez Rundle called on the grand
jury to analyze the circumstances that
may have contributed to the collapse, she
instructed the jury to focus on the policies,
procedures, protocols, systems, and prac-
tices related to building design, construc-
tion, and maintenance. The jury returned
with 40 recommendations, including rais-
ing qualification standards for inspectors.
Respectfully, we suggest that inspectors
also be trained and qualified in corrosion
prevention.
A professional engineer or structural
engineer may possess some corrosion con-
trol knowledge, but a corrosion engineer
or practitioner brings focused, in-depth
experience and knowledge and can iden-
tify what must be repaired or replaced to
slow and prevent the progression of corro-
sion. In South Florida and other coastal
areas where salt air is an inevitable factor,
specialized expertise is essential.
In June, AMPP assembled a task force
of renowned experts in corrosion of rein-
forced concrete structures. The group is
engaged in analysis of the Champlain Tow-
ers South disaster to understand the root
causes of the disaster. The task force is
identifying existing technical standards or
needed new standards, guidelines, work
practices, and training requirements to
improve inspection, evaluation, and ensu-
ing repairs of concrete structures. In 2022
the task force will provide supporting
information to local, state, and federal
officials, and those tasked with investigat-
ing this disaster at the National Institute
of Standards and Technology (NIST).
The task force is completing a white
paper that will be made available to NIST
and to those updating Florida’s building
codes for consideration as part of investi-
gation efforts and the development of new
laws, codes, and standards. The group is
also compiling resources to inform HOA
management companies of red flags asso-
ciated with ignoring corrosion and other
key maintenance needs.
Sadly, the tragedy in Surfside is only
the most recent example of an asset failing
and lives lost. As a society, we’ll continue
to see these tragedies unless we reform
how we protect assets from corrosion.
AMPP is here to assist all decisionmakers
to ensure safe, long lasting, reliable infra-
structure.
WWW.MATERIALSPERFORMANCE.COM
 Your Association in Action

AMPP Releases The collection of potentiodynamic

data is a highly sensitive process that must
contractors. It may also be used by other
interested parties. National and local regu-
New, Revised, and have strict bounds such that comparisons
between samples can be made. Bounds in
lations may apply when this guide is used
outside the United States.
Reaffirmed Standards previous standards were too wide, causing A discussion of ventilation is included
large variations in the resulting data. in the guide to assist users in both control-

A
MPP Standards Committees Large deviations between data of the same ling emissions to the environment, and in
have recently released the follow- material type, treatment, and electrolyte enhancing worker protection and visibility
ing standards. chemistry hinders the ability of research- within the containment. It is important to
ers to compare data as two materials can recognize that ventilation systems alone
AMPP TM21510-2022 have widely varying results. This docu- may or may not be sufficient to fully pro-
ment serves to standardize the material tect workers when the paint being
‘Potentiodynamic Scans: Material preparation, data collection, and data removed contains lead or other toxic met-
Preparation, Data Acquisition and analysis procedures for potentiodynamic als, and additional work practice and/or
Analysis’ data, ensuring future comparisons of administrative controls and respiratory
polarization curve data is achievable. protection may be required to control
worker exposures. Requirements or evalu-
SSPC-Guide 6-2021
AMPP TM21510-2022
Approved January 18, 2022

ation methods for worker health and

safety are outside the scope of this guide.
‘Guide for Containing Surface
Preparation Debris Generated
Potentiodynamic Scans: Material During Paint Removal Operations’ NACE/PODS SP0507-2021
Preparation, Data Acquisition and Analysis
SSPC-Guide 6-2021
Approved October 27, 2021

‘External Corrosion Direct

Assessment (ECDA) Integrity Data
Exchange (IDX)’
©2022 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.
NACE/PODS SP0507-2021
Reaffirmed November 23, 2021
AMPP TM21510-2022

Guide for Containing

Surface Preparation Debris Generated
During Paint Removal Operations
This new standard provides a method
for collecting reproducible potentiody-
namic data, enabling the comparison of
External Corrosion Direct Assessment
data across various experiments and labo- (ECDA) Integrity Data Exchange (IDX)

ratories. This method is intended for those ©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.

with experience in potentiodynamic data SSPC-Guide 6-2021

collection across all of industry and aca-

demia. This method has been adapted This guide describes methods of paint
from Appendix B of MIL-STD-889. Users removal, containment systems, and proce- ©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.

interested in submitting data for accep- dures for minimizing or preventing emis- NACE/PODS SP0507-2021

tance into MIL-STD-889 shall refer to the sions from escaping the work area, and
latest version of MIL-STD-889. procedures for assessing the adequacy of The objective of this standard practice
The standard provides a procedure the controls over emissions. The contain- is the development of a new external cor-
that ensures, to the best extent possible, ment systems are categorized in up to four rosion direct assessment (ECDA) data
the uniform collection of electrochemical classes per type of paint removal method, interchange data structure that will enable
data. This standard aims to reduce vari- based on the extent to which emissions electronic integration of data and stan-
ability between measurements and allow are controlled. The guide is primarily dardize reporting of ECDA data associated
for comparisons between laboratories and intended for use with steel structures; with indirect inspection data within the
samples. It also includes information and however, some of the methods and materi- pipeline industry, to allow transfer
discussion of the reason for stringency in als may be suited for use on concrete, alu- between different software packages or
the procedures and lessons learned to help minum, wood, or other materials of computer systems. This is expected to
laboratories troubleshoot potential issues construction. It is intended for use by minimize difficulty in using various pro-
with data collection. facility owners, specifiers, designers, and grams to analyze or graph data and allow

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 59

 AMPP NEWS
for comparison of data gathered for a Sulfuric acid (H2SO4) is the largest vol-
given pipeline segment at different times, ume commodity chemical in use today. It
regardless of the software system used to plays some part in the production of
collect it. The format outlined is the com- nearly all manufactured goods. One large
monly used American Standard Code for use of concentrated sulfuric acid is used as
Information Interchange (ASCII) comma a catalyst for refinery alkylation units. In
delimited text file, which is adaptable to these units, C3-C5 olefins such as propyl-
all data processing systems. This standard ene or butylene are reacted with isobutane
is expected to serve as a template for to form gasoline-blending components
future internal corrosion direct assess- such as isoheptane and isooctane. These
ment (ICDA) and stress corrosion cracking gasoline-blending components are used to
direct assessment (SCCDA) data inter- boost octane for automobile and aviation
change standards. It presents one sug- fuels.
gested exchange format to standardize Most refineries have an alkylation unit
data transfer. that uses either hydrofluoric acid (HF) or
Data collection and testing procedures sulfuric acid as the alkylation catalyst.
shall conform to NACE SP0207, “Perform- This standard deals with spent sulfuric
ing Close-Interval Potential Surveys on acid associated with the sulfuric acid
Buried or Submerged Metallic Pipelines,” alkylation process only.
NACE Standard TM0109, “Aboveground Refineries using sulfuric acid alkyla-
Survey Techniques for the Evaluation of tion typically require tanks for the storage
Underground Pipeline Coating Condition,” of fresh (not yet used in the alkylation pro-
NACE SP0169, and other applicable rec- cess) and spent (used in the alkylation pro-
ommended NACE standards for accurate cess and in need of regeneration) acid.
ECDA pipeline integrity data. Design, fabrication, and inspection of
This standard is intended for use by fresh sulfuric acid tanks are covered in
corrosion control personnel and informa- NACE SP0294. This standard covers addi-
tion technology professionals involved tions and deviations from SP0294 that
with acquiring, analyzing, or maintaining apply to spent sulfuric acid storage tanks.
ECDA data, contractors performing ECDA, Large, vertical sulfuric acid storage
and regulatory agencies. tanks are usually built in accordance with
API Standard 6502 or API Standard 620,
NACE SP0205-2021 and horizontal cylindrical tanks are built
in accordance with the ASME(2) Boiler
‘Design, Fabrication, and and Pressure Vessel Code, Section VIII,
Inspection of Tanks for the Storage Division 1.4. Although these codes and
of Petroleum Refining Alkylation standards are sufficient for design
Unit Spent Sulfuric Acid at Ambient strength and toughness considerations,
Temperatures’ they do not address the peculiarities of
corrosion by alkylation unit spent sulfuric
NACE SP0205-2021
Reaffirmed November 8, 2021
acid service. In addition, alkylation unit
spent acid may contain dissolved hydro-
carbons and hydrogen that release into the
vapor space of these tanks and potentially
produce an explosive environment. Thus,
Design, Fabrication, and Inspection of special care must be taken to deal with
Tanks for the Storage of Petroleum Refining
Alkylation Unit Spent Sulfuric Acid at
Ambient Temperatures
vapor leakage from the vapor space of
these tanks and air intrusion into the
vapor space of these tanks.
Carbon steel corrodes moderately
©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
when in contact with alkylation unit spent
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
sulfuric acid. If tanks are properly
or otherwise) without the prior written permission of AMPP.
NACE SP0205-2021
designed and adequately maintained, use
of carbon steel is an economical option for
60 APRIL 2022
the storage of these acids at ambient tem-
peratures. However, accelerated corrosion
can occur in various forms, and a cata-
strophic failure of a spent acid tank in Del-
aware City, Delaware, USA, has focused
attention on the hazards associated with
corrosion, vapor space leakage, and hot
work on or around alkylation spent sulfu-
ric acid tanks.
SSPC-Paint 29-2021
‘Coating Standard No. 29,
Zinc-Pigmented Primer,
Performance-Based’
SSPC-Paint 29
Approved December 1, 2021
Coating Standard No. 29
Zinc-Pigmented Primer, Performance-Based
©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.
SSPC-Paint 29-2021
This standard contains requirements
for three performance levels of primer coat-
ings used to protect ferrous substrates that
contain zinc as the major pigment compo-
nent. Individual products meeting mini-
mum performance requirements of this
standard may vary in formulation, raw
materials, and application characteristics.
The specifier selects the appropriate per-
formance level. If no level is specified, Level
II becomes the default. SSPC-Paint 20 is a
formulation-based standard for inorganic
or organic zinc-pigmented coatings that
includes options for specifying higher zinc
loading levels in the dry coating film. An
example of specification language that ref-
erences both performance and composition
requirements can be found in Note 9.1.
This standard does not contain require-
ments for weldable preconstruction prim-
ers such as SSPC-Paint 30. The coating is
intended for application by spray for use by
itself or as a primer in a multi-coat system.
WWW.MATERIALSPERFORMANCE.COM
 Your Association in Action

Four New Waterjet NACE WJ-3/SSPC-SP WJ-3-2021

Correction to In-
Standards Joint Surface Preparation Line Pipe Inspection
Standard, ‘Waterjet Cleaning of
AMPP has recently released the follow- Metals—Thorough Cleaning (WJ-3)’ Standard
ing standards related to waterjetting for (SP0412)’
surface preparation.
NACE WJ-3/SSPC-SP WJ-3-2021 NACE Publication 35100

NACE WJ-1/SSPC-SP WJ-1 2021

Reaffirmed November 3, 2021
Item Number 24211
ISBN 1-57590-368-7
Approved 4-11-17
Corrected 1-14-22

Joint Surface Preparation NACE Publication 35100

Standard, ‘Waterjet Cleaning of In-Line Inspection of Pipelines

Metals—Clean to Bare Substrate

This NACE International technical committee report represents a consensus of those individual members who have reviewed this
document, its scope, and provisions. Its acceptance does not in any respect preclude anyone from manufacturing, marketing, pur-
chasing, or using products, processes, or procedures not included in this report. Nothing contained in this NACE International report
is to be construed as granting any right, by implication or otherwise, to manufacture, sell, or use in connection with any method, appa-
ratus, or product covered by Letters Patent, or as indemnifying or protecting anyone against liability for infringement of Letters Patent.

(WJ-1)’ (SP0212) Joint Surface Preparation Standard,

This report should in no way be interpreted as a restriction on the use of better procedures or materials not discussed herein. Neither
is this report intended to apply in all cases relating to the subject. Unpredictable circumstances may negate the usefulness of this re-
port in specific instances. NACE assumes no responsibility for the interpretation or use of this report by other parties.

“Waterjet Cleaning of Metals— Users of this NACE report are responsible for reviewing appropriate health, safety, environmental, and regulatory documents and for
determining their applicability in relation to this report prior to its use. This NACE report may not necessarily address all potential health

Thorough Cleaning (WJ-3)” (SP0412)

and safety problems or environmental hazards associated with the use of materials, equipment, and/or operations detailed or referred
to within this report. Users of this NACE report are also responsible for establishing appropriate health, safety, and environmental pro-
tection practices, in consultation with appropriate regulatory authorities if necessary, to achieve compliance with any existing applica-
ble regulatory requirements prior to the use of this report.

NACE WJ-1/SSPC-SP WJ-1-2021 CAUTIONARY NOTICE: The user is cautioned to obtain the latest edition of this report. NACE reports are subject to periodic review, and
Reaffirmed November 3, 2021 may be revised or withdrawn at any time without prior notice. NACE reports are automatically withdrawn if more than 10 years old.
Purchasers of NACE reports may receive current information on all NACE publications by contacting the NACE FirstService Depart-
ment, 15835 Park Ten Place, Houston, Texas 77084-5145 (telephone +1 281-228-6200).

NACE International
15835 Park Ten Place
Houston, Texas 77084-5145
+1 281-228-6200

© 2017 NACE International

©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.

NACE WJ-3/SSPC-SP WJ-3-2021

Joint Surface Preparation Standard,

“Waterjet Cleaning of Metals—
The standard, “NACE Publication
Clean to Bare Substrate (WJ-1)” (SP0212) NACE WJ-4/SSPC-SP WJ-4-2021 35100: In-Line Inspection of Pipelines” has
several corrections and the new version is
Joint Surface Preparation now available.
Standard, ‘Waterjet Cleaning of Analysis of available and emerging
©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
Metals—Light Cleaning (WJ-4)’ technologies in the field of in-line inspec-
(SP0512)
or otherwise) without the prior written permission of AMPP.

NACE WJ-1/SSPC-SP WJ-1-2021

tion tools and review their status with
NACE WJ-4/SSPC-SP WJ-4-2021
respect to characteristics, performance,
Reaffirmed November 3, 2021

range of application, and limitations. This

NACE WJ-2/SSPC-SP WJ-2-2021 is a companion guide to SP0102. The fol-
lowing corrections have been made:
Joint Surface Preparation Reference 2 on p. 20 has been revised
Standard, ‘Waterjet Cleaning of from “Specifications and Requirements for
Metals—Very Thorough Cleaning Joint Surface Preparation Standard,
“Waterjet Cleaning of Metals—
Intelligent Pig Inspection of Pipelines,
(WJ-2)’ (SP0312) Light Cleaning (WJ-4)” (SP0512) Pipeline Operators Forum (POF), http://
www.pipelineoperators.org/publicdocs/
POF_specs_2009.pdf (Rijswijk, Nether-
NACE WJ-2/SSPC-SP WJ-2-2021
Reaffirmed November 3, 2021 lands: 2009),” to “Specifications and
Requirements for Intelligent Pig Inspec-
tion of Pipelines, Pipeline Operators
©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.

Forum (POF), 2016.”

NACE WJ-4/SSPC-SP WJ-4-2021

Two citations of reference 2 in Appen-

Joint Surface Preparation Standard,
dix B (pp. 30 and 31) have been revised
“Waterjet Cleaning of Metals—
Very Thorough Cleaning (WJ-2)” (SP0312) from “…from POF document. [ref.]” to “…
from Table 2.1 of the POF document.”
Metric-to-U.S. Customary unit conver-
sions have been corrected throughout
Appendix B.
©2021 Association for Materials Protection and Performance (AMPP). All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted, in any form or by any means (electronic, mechanical, photocopying, recording,
or otherwise) without the prior written permission of AMPP.

For more information on AMPP stan-

NACE WJ-2/SSPC-SP WJ-2-2021

dards, visit ampp.org/standards.

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 61

 AMPP NEWS

AMPP Board of Directors

OFFICERS Bob Chalker Michelle Lau Ross Boyd

Secretary—Ex Officio 2021-2024 2021-2023
Sam Scaturro AMPP: Association for Materials Mach 3 Engineering Sdn. Bhd. TruQC, LLC
Chair Protection and Performance Malaysia Kirkwood, Missouri, USA
2022
Alpine Painting & Sandblasting Mitra Shahbaz Kevin Garrity Doni Riddle
Contractors Chief Financial Officer 2021-2022 2021-2023
Patterson, New Jersey, USA AMPP: Association for Materials Mears Groups The Sherwin-Williams Co.
Protection and Performance Plain City, Ohio, USA Cleveland, Ohio, USA
Amir Eliezer
Vice Chair Helena Seelinger Russell Norris
2022 Executive Director 2021-2022
CTO-TRYMER LTD. AMPP: Association for Materials Sherwin-Williams Co.
Beer-Sheve, Israel Protection and Performance Houston, Texas, USA

Tim Bieri Skip Vernon

DIRECTORS 2021-2022
Past Chair
2022 Paul Vince CLT, Inc.
BP Americas, Inc. 2021-2024 Tijeras, New Mexico, USA
Houston, Texas, USA WSP Abdullah Al-dossary
Australia 2021-2023
Cris Conner
AMPP Global Center Vice Chair— Garry Manous Saudi Aramco
Ex Officio 2021-2024 Al Khubar, Saudi Arabia
Jan. 2021-June 2022 Atsalis Bros. Painting
Utility Service & Maintenance Warren, Michigan, USA
St. Louis, Missouri, USA

AMPP Global Center Board of Directors

OFFICERS DIRECTORS Emer Flounders Ahren Olson

Joyce Wright
Chair
Jan. 2021–June 2022
Huntington Ingalls Industries—
Newport News Shipbuilding
Newport News, Virginia, USA
Cris Conner
Vice Chair
Jan. 2021–June 2022
Utility Service & Maintenance
St. Louis, Missouri, USA
Terry Greenfield
Past Chair
Jan. 2021–June 2022
CONSULEX
Cocoa, Florida, USA
Amir Eliezer
AMPP Vice Chair—Ex Officio
2022
CTO-TRYMER LTD.
Beer-Sheve, Israel
Bob Chalker
Secretary—Ex Officio
AMPP: Association for Materials
Protection and Performance
Mitra Shahbaz
Chief Financial Officer
AMPP: Association for Materials
Protection and Performance
Cynthia O’Malley
Executive Director
AMPP: Association for Materials
Protection and Performance
Greg Redick
July 2021–June 2024
Potomac Redan Associates, LLC
Williamsburg, Virginia, USA
Steve Cogswell
July 2021–June 2024
FINCANTIERI Marine Systems N.A.
Jacksonville, Florida, USA
Michael O’Brien
July 2021–June 2024
MARK 10 Resource Group, Inc.
Richmond, Virginia, USA
Arcino Quiero
July 2021–June 2024
Newport News Shipbuilding
Virginia Beach, Virginia, USA
Paul Vinik
July 2021–June 2024
GPI
Daytona Beach, Florida, USA
Kristin Leonard
Jan. 2021–June 2024
ExxonMobil Research &
Engineering Materials Engineering
Section
Spring, Texas, USA
Brian Saldanha
Jan. 2021–June 2022
Chemours Co.
Wilmington, Delaware, USA
Jan. 2021–June 2022
Pond & Co.
Dresher, Pennsylvania, USA
Leonardo Uller
Jan. 2021–June 2022
SURPLUS
Rio de Janeiro, Brazil
Doug Kellow
Jan. 2021–June 2022
Brenntag Canada, Inc.
Calgary, Alberta, Canada
Michael McLampy
Jan. 2021–June 2022
PPG Industries
Carlisle, Massachusetts, USA
Mana Al-Mansour
Jan. 2021–June 2022
Saudi Aramco
Dhahran, Saudi Arabia
Francisco Gudiel
Jan. 2021–June 2023
Geotechnical and Physical
Evaluations Engineer
Baton Rouge, Louisiana, USA
Juan Caballero
Jan. 2021–June 2023
Naval & Industrial Solutions S.A.
Panama
Alison Kaelin
Jan. 2021–June 2023
ABKaelin, LLC
Pittsburgh, Pennsylvania, USA
Jan. 2021–June 2023
Covestro, LLC
Pittsburgh, Pennsylvania, USA
Roy Fultineer
Jan. 2021–June 2023
Roberts Corrosion Services, LLC
South Charleston, West Virginia,
USA
Rolf Gubner
Jan. 2021–June 2023
Consultant
Girrawheen, Australia
Kimberly-Joy Harris
Jan. 2021–June 2023
Enbridge
Houston, Texas, USA
Cal Chapman
Jan. 2021–June 2023
Chapman Engineering
Boerne, Texas, USA
Steve Biagiotti
Dynamic Risk Assessment
Systems Inc.
Englewood, Colorado, USA
Laura Cardenas Schutz
Canadian Natural Resources Ltd.
Calgary, Alberta, Canada
Aaron Williams
Blast Abrasives Supply
Kuala Lumpur, Malaysia

62 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 See why 100,000+ have
DEVELOP YOUR choosen the NACE Coatings
Inspection Program as their
COATINGS INSPECTION foundation in a growing field
of qualified workers.
EXPERTISE WITH
This in-d p h, in iv
GLOBALLY RECOGNIZED ining p g m is b il p n
d d s f kn wl dg nd
TRAINING xp i n .

Adv n www.nace.org/cip L nm b AMPP. www.ampp.org

 The process of merging NACE International

A new year. and SSPC into AMPP, the Association for

Materials Protection and Performance,
continues with finishing touches being put

A new on a newly designed membership model.

Just as NACE and SSPC’s combined 140+ year

membership history serves as the foundation for the future

of materials protection and performance, your
member history will remain and form the basis

model. of your AMPP membership.

Leading up to the official launch, we want to

answer your most frequently asked questions
New and help you realize the many possibilities
offered by AMPP membership, built on the rich

possibilities... legacies of these two respected organizations

and their many members.

C
N AMPP M m pM l AQ
ampp.org/membership/FAQs

Check back regularly and look for the official

new AMPP model launch in early 2022!
Bookmark ampp.org/membership/FAQs
or scan the QR code.

Coming Soon: New AMPP Coating
Inspector Program
T
he new AMPP Coating Inspector
Program (CIP) is launching in April
2022. Although current certification
levels will remain the same, some changes
will happen as part of this process. A new
name and a new course for Level 1 will be
launched. The new program will combine
the best parts of NACE’s legacy CIP and
SSPC: The Society for Protective Coatings’
legacy Protective Coatings Inspector (PCI)
programs. The new program levels will be:
• Basic Coatings Inspector (Level 1)
• Certified Coatings Inspector (Level 2)
AMPP Affiliate Corporate Members
AB Sandvik Materials Technology,
Sweden
Accurate Corrosion Control, USA
Benjamin Moore & Co., USA
BP Exploration & Production Operating
Co., Ltd., USA
BSS Technologies, United Arab Emirates
CAL, Inc., USA
Carboline Co., USA
Colonial Pipeline Co., USA
Corrpro, USA
Denso North America, USA
Dunn-Edwards Corp., USA
E2G The Equity Engineering Group, Inc.,
USA
Elcometer, USA
Element Material Technology, USA
Enbridge GTM, USA
Enbridge Pipelines, Inc., Canada
Faragauss Marketing, S.A. de C.V.,
Mexico
Finishing Trades Institute (FTI), USA
Greenman-Pedersen, Inc., USA
Henkels & McCoy, Inc., USA
HII Newport News Shipbuilding, USA
HMI Technical Solutions, LLC, USA
International Union of Painters and Allied
Trades, USA
MATERIALS PERFORMANCE: VOL. 61, NO. 4
• Senior Certified Coatings Inspector
(Level 3)
All certified cardholders will be moved
to the appropriate level. For example, a
current CIP Level 2 Inspector would
become a Certified Coatings Inspector,
and a PCI Level 1 Inspector would become
a Basic Coatings Inspector.
More information will be available in
April. In the meantime, check out the
FAQs online (“Update on the new AMPP
Coating Inspector and Applicator Creden-
tials”) at www.ampp.org/education/.
JT Thorpe & Son, Inc., USA
KTA-Tator, Inc., USA
Kuwait Oil Co., Kuwait
Lake Superior Consulting, USA
Marathon Pipeline, LLC, USA
MATCOR, Inc., USA
MESA, USA
National Grid, USA
Oneok Partners, USA
Polyguard Products, Inc., USA
PPG Coatings (Kunshan) Co., Ltd., China
PPG Protective and Marine Coatings,
USA
Shanghai PT Painting Technology Co.,
Ltd., China
Sherwin-Williams Co., USA
Shinko Co., Ltd., Japan
Southern California Gas Co., USA
Turner Industries Group, LLC, USA
NEW AMPP AFFILIATE
CORPORATE MEMBERS
AirTech Spray Systems—Patron
Allen Blasting & Coating, Inc.—Associate
APEX Coating LLC—Patron
Axess-Corrosion, Inc.—Patron
Baker Gulf Coast Industrial—Patron
Your Association in Action
Ecomaterials, Inc.—Patron
Elinor Coatings—Patron
Enterprise Products—Patron
Expertise Contracting Co. Ltd—Patron
IBIX North America—Patron
KH Neochem Co., Ltd.—Patron
LFM Energy Sdn Bhd—Patron
Maguire Iron, Inc.—Patron
Markleys Precision Co. LLC—Patron
Midwest Tank Co.—Patron
NJ Reliable Coatings LLC—Patron
Peak Industrial Coatings & Linings, Inc.—
Patron
Resist-A-Line Industries, LLC—Patron
RZG Garnet, Inc.—Patron
Saffo Contractors Inc.—Patron
SAIC—Associate
Select Paint & Finishes LLC—Associate
Shanghai Great Partner Enterprise
Consulting Service Center—
Associate
Total AMPP membership was 33,442 as
of February 2022. For more information
on Affiliate Corporate Membership, visit
https://ampp.org/membership/member-
ship-types/corporate-membership.
APRIL 2022 65
 AMPP NEWS

AMPP Events Calendar

APRIL 2022 AUGUST 2022 MARCH 2023

NORTHERN AREA WESTERN 2022 DoD CORROSION AMPP ANNUAL CONFERENCE +

CONFERENCE 2022 PREVENTION TECHNOLOGY AND EXPO
April 11-14, 2021 INNOVATION SYMPOSIUM March 19-23, 2023
Edmonton, Alberta, Canada August 8-11, 2022 Denver, Colorado, USA
More info: naceedmonton.com Tucson, Arizona, USA More info: Lesley Martinez, AMPP,
More info: www.dodcorrcon.org tel: +1 281-228-6413,
email: Lesley.martinez@ampp.org
JUNE 2022
SEPTEMBER 2022
FireCORR
June 7-8, 2022 AMPP CENTRAL CONFERENCE
Pasadena Convention Center and September 26-28, 2022
Municipal Fairgrounds Tulsa, Oklahoma, USA
Pasadena, Texas, USA More info: Meghan Leyva,
More info: ampp.org/events/firecorr email: Meghan.leyva@ampp.org

JULY 2022 OCTOBER 2023

20TH INTERNATIONAL AMPP EASTERN CONFERENCE

CONFERENCE ON October 26-28, 2022
ENVIRONMENTAL DEGRADATION Tampa, Florida, USA
OF MATERIALS IN NUCLEAR More info: ampp.org/events
POWER SYSTEMS
July 17-21, 2022
Snowmass Village, Colorado, USA
More info: envdeg.nace.org

AMPP Education Course Schedule

AUSTRALIA
Coating Inspector Program (CIP) Level 1
Perth, WA ..................................................... May 2–6, 2022
Perth, WA ..................................................... Jun 13–17, 2022
Preston, VIC.................................................. May 16–20, 2022
CIP Level 2
Adelaide, SA ................................................ May 9–13, 2022
Perth, WA ..................................................... Jun 20–24, 2022
Preston, VIC.................................................. May 23–27, 2022
Cathodic Protection (CP) 1—Cathodic Protection Tester
Preston, VIC.................................................. May 2–6, 2022
CP2—Cathodic Protection Technician
Preston, VIC.................................................. May 9–13, 2022
CHINA
C7 Dry Abrasive Blast Cleaning—Nozzle
Qingpu District, Shanghai ............................ May 24–26, 2022
C12 Spray Application
Qingpu District, Shanghai ............................ May 27–29, 2022
CIP Level 1
Shangha ....................................................... May 16–20, 2022
Shangha ....................................................... Jul 18–22, 2022
CIP Level 2
Shangha ....................................................... May 22–26, 2022
Shangha ....................................................... Jul 24–28, 2022
CIP Peer Review
Shanghai....................................................... May 25–28, 2022

BELGIUM COLOMBIA
CIP Level 1 CIP Level 2
Brasschaat (Maria ter heide) ......................... May 30—Jun 3, 2022 Bogota.......................................................... Jun 21–25, 2022
CP3—Cathodic Protection Technologist
BRAZIL
Bogota.......................................................... Jun 6–10, 2022
Corrosion Under Insulation (CUI)
Marine Coating Technology
Rio de Janeiro .............................................. Jun 6–9, 2022
Bogota.......................................................... May 23–26, 2022

66 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

 Your Association in Action

EGYPT SAUDI ARABIA

Corrosion Control In The Refining Industry Basic Corrosion
Cairo ............................................................. May 15–19, 2022 Al Khobar ..................................................... May 15–18, 2022
CP2—Cathodic Protection Technician
Cairo ............................................................. Jun 19–23, 2022 SINGAPORE
CP3—Cathodic Protection Technologist CIP Level 1
Cairo ............................................................. Jun 5–9, 2022 Pioneer Junction .......................................... Jul 25–29, 2022
CP4—Cathodic Protection Specialist CIP Level 2
Cairo ............................................................. Jun 12–17, 2022 Pioneer Junction .......................................... Aug 1–5, 2022
Pipeline Corrosion Integrity Management
Cairo ............................................................. May 22–25, 2022 SOUTH AFRICA
CIP Level 1
ITALY Midrand ........................................................ May 16–20, 2022
CIP Level 1 CP2—Cathodic Protection Technician
Somma Lombardo ....................................... May 8–12, 2022 Midrand ........................................................ May 30—Jun 3, 2022

MALAYSIA SOUTH KOREA

CIP Peer Review CIP Level 1
Kuala Lumpur ............................................... Jul 5–8, 2022 Busan ............................................................ Jun 20–24, 2022
Corrosion Under Insulation (CUI)—Virtual CIP Level 2
Virtual—Malaysia Time Zone ....................... May 26–29, 2022 Busan ............................................................ Jun 27—Jul 1, 2022

MEXICO SPAIN
CIP Level 1 CIP Level 1
Cuernavaca, MOR ........................................ May 16–20, 2022 Madrid .......................................................... Jun 6–10, 2022
CIP Level 2 CP2—Cathodic Protection Technician
Cuernavaca, MOR ........................................ May 23–27, 2022 Madrid .......................................................... Jun 13–17, 2022
Madrid .......................................................... Jun 20–24, 2022
CP1—Cathodic Protection Tester
Cuernavaca, MOR ........................................ May 23–27, 2022 CP4—Cathodic Protection Specialist—Virtual
Virtual—Central Europe Time ...................... May 23–27, 2022
CP2—Cathodic Protection Technician
Cuernavaca, MOR ........................................ Jun 20–24, 2022 Internal Corrosion for Pipelines—Basic
Madrid .......................................................... May 23–27, 2022
THE NETHERLANDS Internal Corrosion for Pipelines—Advanced—Virtual
CIP Level 1 Madrid .......................................................... Jun 6–9, 2022
Ridderkerk .................................................... May 30—Jun 3, 2022
THAILAND
CIP Level 2
Ridderkerk .................................................... May 16–20, 2022 CIP Level 1
Pattaya.......................................................... May 9–13, 2022
NEW ZEALAND
TUNISIA
CP1—Cathodic Protection Tester
Auckland ...................................................... May 30—Jun 3, 2022 CIP Level 1
Sfax ............................................................... Jun 20–24, 2022
CP2—Cathodic Protection Technician
Auckland ...................................................... Jun 6–10, 2022 CP2—Cathodic Protection Technician
La Marsa ....................................................... May 16–20, 2022
PAKISTAN
TURKEY
CP3—Cathodic Protection Technologist—Virtual
Virtual—Pakistan Time Zone ........................ Jun 6–10, 2022 CIP Level 1
Kadikoy Istanbul ........................................... May 23–27, 2022
PERU
UNITED ARAB EMIRATES
CP1—Cathodic Protection Tester
Miraflores ..................................................... May 30—Jun 3, 2022 Basic Corrosion—Virtual
Virtual—Dubai (UAE) Time Zone.................. May 21–24, 2022
CP2—Cathodic Protection Technician
Miraflores ..................................................... Jun 27—Jul 1, 2022 CIP Peer Review
Dubai ............................................................ Jun 4–7, 2022

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 67

 AMPP NEWS
CP3—Cathodic Protection Technologist—Virtual
Virtual—Dubai (UAE) Time Zone.................. Jun 18–22, 2022
CP4—Cathodic Protection Specialist—Virtual
Virtual—Dubai (UAE) Time Zone.................. Jun 25–29, 2022
Internal Corrosion for Pipelines—Basic
Dubai ............................................................ Jun 11–15, 2022
Internal Corrosion for Pipelines—Advanced—Virtual
Dubai ............................................................ Jun 18–21, 2022
UNITED KINGDOM
CIP Level 1
Newcastle Upon Tyne .................................. May 9–13, 2022
CIP Level 2
Newcastle Upon Tyne .................................. May 16–20, 2022
UNITED STATES
Aerospace Maintainer Coating Application Training
Tucson, AZ ................................................... Aug 8, 2022
Basic Corrosion
Houston, TX ................................................. May 16–19, 2022
Houston, TX ................................................. Jun 27–30, 2022
Basic Corrosion—Virtual
Virtual—Eastern Time Zone ......................... Jun 6–9, 2022
BCI1 Bridge Coatings Inspector Level 1
Houston, TX ................................................. May 2–6, 2022
BCI2 Bridge Coatings Inspector Level 2
Houston, TX ................................................. May 7, 2022
C1 Virtual Fundamentals of Protective Coatings
Texas ............................................................ May 1–10, 2022
C7 Dry Abrasive Blast Cleaning—Nozzle
Houston, TX ................................................. May 14–16, 2022
C12 Spray Application
Houston, TX ................................................. May 17–19, 2022
CIP Level 1
Houston, TX ................................................. May 2–7, 2022
Houston, TX ................................................. May 9–14, 2022
Houston, TX ................................................. May 16–21, 2022
Houston, TX ................................................. May 23–28, 2022
Houston, TX ................................................. Jun 6–11, 2022
Houston, TX ................................................. Jun 13–18, 2022
Houston, TX ................................................. Jun 20–25, 2022
CIP Level 1 Blended—Virtual
Virtual—Eastern Time Zone ......................... May 3–4, 2022
Virtual—Mountain Time Zone ...................... Jun 13–14, 2022
CIP Level 2
Houston, TX ................................................. May 9–13, 2022
Houston, TX ................................................. Jun 6–10, 2022
Houston, TX ................................................. Jun 20–24, 2022
CIP Level 2 Blended—Virtual
Virtual—Eastern Time Zone ......................... May 5–6, 2022
Virtual—Mountain Time Zone ...................... Jun 21–22, 2022
Coatings in Conjunction with Cathodic Protection
Houston, TX ................................................. Jun 13–18, 2022
Corrosion Fundamentals—Half Day
Tucson, AZ ................................................... Aug 8, 2022
68 APRIL 2022
Corrosion Technical Series: Corrosion and Inspection of
Concrete Structures
Virtual—Central Standard Time ................... May 10–11, 2022
CP1—Cathodic Protection Tester
Houston, TX ................................................. May 9–13, 2022
Houston, TX ................................................. Jun 6–10, 2022
Liberal, KS .................................................... Jun 6–10, 2022
CP2—Cathodic Protection Technician
Houston, TX ................................................. Jun 13–17, 2022
Houston, TX ................................................. Jun 20–24, 2022
Liberal, KS .................................................... Jun 13–17, 2022
CP3—Cathodic Protection Technologist
Houston, TX ................................................. May 16–20, 2022
CP3—Cathodic Protection Technologist—Virtual
Virtual—Mountain Time Zone ...................... May 23–27, 2022
CP4—Cathodic Protection Specialist
Houston, TX ................................................. May 23–28, 2022
CP4—Cathodic Protection Specialist—Virtual
Virtual—Eastern Time Zone ......................... Jun 13–17, 2022
FIREAPP—Intumescent Fireproofing Coating Application
Pasadena, TX................................................ Jun 6–8, 2022
In Line Inspection
Houston, TX ................................................. May 2–5, 2022
Internal Corrosion for Pipelines—Basic
Houston, TX ................................................. May 9–13, 2022
Internal Corrosion for Pipelines—Advanced
Houston, TX ................................................. May 16–19, 2022
Internal Corrosion for Pipelines—Advanced—Virtual
Virtual—Eastern Time Zone ......................... May 23–26, 2022
Nuclear Power Plant Training for Coating Inspectors—Virtual
Virtual—Central Time Zone.......................... May 9–12, 2022
Offshore Corrosion Assessment Training (O-CAT)
Houston, TX ................................................. Jun 6–10, 2022
Pipeline Corrosion Integrity Management—Virtual
Virtual—Central Time Zone.......................... Jun 6–9, 2022
Shipboard Corrosion Assessment Training (S-CAT)
Houston, TX ................................................. Jun 20–24, 2022
VIETNAM
CIP Level 1
VongTau ....................................................... Jun 27—Jul 1, 2022
WWW.MATERIALSPERFORMANCE.COM

AMPP Headquarters Directory
To reach AMPP staff in the following areas, dial +1 281-228-6200. After the first ring, enter the desired extension number. Enter 0 to
reach the receptionist during business hours (7:00 a.m. to 4:15 p.m. CST). The fax number for staff members is +1 281-228-6300. The
fax number for all general membership inquiries and orders is +1 281-228-6329. To contact the Pittsburgh office, call +1 412-281-2331.
ADVERTISING
All Inquiries ............................................................................6219
ANNUAL CONFERENCE
General Information ...............................................................6223
Exhibits .........................................................................6227, 6242
Registration ............................................................................6223
Technical Papers .....................................................................6287
AREA AND SECTION SUPPORT–OFFICERS
Inquiries and Orders
USA and Canada ....................................................................6240
International ...........................................................................6240
AWARDS ....................................................................................6276
BOARD OF DIRECTORS/BOARD COMMITTEES
Information .............................................................................6233
BOOKS
Editorial ..................................................................................6496
Sales .......................................................................................6223
CERTIFICATION
General Information ...............................................................6223
Professional Recognition/Status
Inquiries ...........................................................................6211
Recertification ..................................................................6211
COATING INSPECTOR PROGRAM
General Information ...............................................................6223
Peer Review Scheduling
Registered Candidate ......................................................6211
Registration......................................................................1802
Update and Renewal .......................................................6211
Verify Certification ...........................................................6211
COURSES AND SEMINARS
Area/Section-Sponsored Courses ..........................................6258
General Information ...............................................................6223
Contract Courses...........................................................6230/6246
Home Study
General Information and Registration .............................1802
In-House Training ..........................................................6230/6246
Instructor Applications ...........................................................6214
Registration—All Course Types ..............................................6223
Schedules ...............................................................................6223
COMPUTER SOFTWARE
General Information ...............................................................6223
Sales .......................................................................................6223
Technical Support...................................................................6255
CORROSION
Advertising .............................................................................6219
Author’s Guide .......................................................................6223
Managing Editor-in-Chief .......................................................6260
Subscriptions/Reprints ...........................................................6223
MATERIALS PERFORMANCE: VOL. 61, NO. 4
Your Association in Action
CORROSION TECHNOLOGY WEEK
Information .............................................................................6264
Registration ............................................................................6223
EDUCATION ............................................see Courses and Seminars
EXECUTIVE OFFICE .................................................................6209
FIRST SERVICE—
Inquiries, Records/Dues .........................................................1803
Membership ...........................................................................6223
LITERATURE SEARCHES .........................................................6223
MARKETING .............................................................................6239
MATERIALS PERFORMANCE
Advertising .............................................................................6219
Author’s Guide/Inquiries ........................................................6223
Managing Editor-in-Chief .......................................................6207
Subscriptions/Reprints ...........................................................6223
NACE FOUNDATION ...............................................................6205
PUBLIC AFFAIRS
Government Activities............................................................6223
PUBLICATIONS
Sales .......................................................................................6223
PUBLIC RELATIONS/MEDIA CONTACT ................................6223
RESEARCH
Seed Grants ...........................................................................6221
Student Poster Session, Research in Progress Symposium ....6221
SALES ..................................... 1 800-797-6223 (USA and Canada) or
..................................................................... +1 281-228-6223
STANDARDS INFORMATION .................................................6221
SCHOLARSHIPS/AREAS AND SECTIONS ONLY .................6240
SYMPOSIA/TOPICAL CONFERENCES
Information .............................................................................6223
Registration ............................................................................6223
TECHNICAL ACTIVITIES/COMMITTEES
C2, N1, S, ISO, Symposia.......................................................6287
MR0175 ..................................................................................6221
C1, N2 ....................................................................................6208
Committee Membership/Inquiries, Minutes, Agendas ..........6264
Technical Coordination Committee and Subcommittees ......6221
VIDEO COURSES ......................................................................6223
15835 Park Ten Place ✥ Houston, Texas 77084-5145
www.ampp.org
APRIL 2022 69
 CORROSION ENGINEERING DIRECTORY

Complete Corrosion Control Systems

ACCESS FITTINGS ER PROBES LPR PROBES COUPONS
• • •
COUPON HOLDERS•CHEMICAL INJECTION•INSTRUMENTS
SOFTWARE•ANALYSIS•ISO 9001:2000 CERTIFIED
Manufacturing & Installation TARGET YOUR AUDIENCE
4815 Elenlak Road, Edmonton, Alberta, T6B 2N1
Tel (780) 465-1187 E-mail caproco@caproco.com To reserve your ad space,
Fax (780) 466-4632 Web Site www.caproco.com call +1 281-228-6269.

Material Sales A/C Modeling and Mitigation ISO-9001 Certified

Install
Pipeline Integrity Aluminum • Magnesium • Zinc
IMP Digs
Onshore / Offshore QUALITY • PERFORMANCE • RELIABILITY
Construction Inspections
Survey Atmospheric Inspections Sales Office Headquarters
Engineering Solar Evaluations 181 Grefer Lane 6712 S. 36th Street
Hydro Vac CIS&DCVG Surveys / ECDA
Services
Harvey, LA 70058
Tel.: (504) 362-7776
ANODES McAllen, TX 78503
Tel.: (956) 630-3500
Anode Ground Beds Fax: (504) 269-1418 Fax: (956) 630-3595
Right of Way Maintenance
anodes@galvotec.com
13764 Airline Hwy • Baton Rouge, LA 70817
225.275.6131 • coastalcorrosion.com www.galvotec.com

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Corrosion Services and GMC Electrical
Pin Brazing • Retrofit Systems • On-Shore • Off-Shore Contact
Dave Johnson on 504-362-7373
300 Bark Dr., Harvey, LA Cathodic Protection & Corrosion Engineering
or
Tel. 504-362-7373 Fax. 504-362-7331 Gary Matlack on 909-947-6016
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70 APRIL 2022 WWW.MATERIALSPERFORMANCE.COM

AD INDEX
LISTING OF ADVERTISER CONTACT INFORMATION

Advertiser ..................................... Page No. Advertiser ......................................Page No.

Anotec Industries Ltd..................................................................... 11 Inspectioneering ...............................................................................3

www.anotec.com, +1 604-514-1544 www.inspectioneering.com

BORIN Manufacturing, Inc. ...........................................................BC Loresco® International .....................................................................1

www.borin.com, +1 310-822-1000 www.loresco.com, +1 601-544-7490

Coastal Corrosion Control, Inc. ....................................................19 Metal Samples............................................................................... IFC

www.coastalcorrosion.com, +1 225-275-6131 www.metalsamples.com, +1 256-358-4202

Dairyland Electrical Industries ......................................................17 PPG Protective and Marine Coatings .............................................7
www.dairyland.com, +1 608-877-9900 www.ppgpmc.com, 1 888-9PPGPMC

DeFelsko Corporation ....................................................................37

www.defelsko.com, 1 800-448-3835 AMPP International
www.ampp.org, +1 281-228-6223
Denso North America .......................................................................5
www.densona.com, 1 888-821-2300 2022 AMPP Conferences .................................................................16
AMPP Annual Conference + Expo 2023 - Save the Date ................38
D. E. Stearns Co., The. ...................................................................39
AMPP Coatings Inspection ...............................................................63
www.destearns.com, +1 318-635-5351
AMPP CP Course ...........................................................................IBC
Electrochemical Devices, Inc. .......................................................27 AMPP Future of Protection ...............................................................47
www.edi-cp.com, +1 617-484-9085 AMPP Get Connected ......................................................................51
AMPP Membership ..........................................................................64
Fischer Technology, Inc. ................................................................13 AMPP QP Testimonial ........................................................................9
www.fischer-technology.com, 1 860-683-0781 AMPP Standards ..............................................................................56
Galvotec Alloys, Inc. ......................................................................27 MP Innovations .................................................................................57
www.galvotec.com, +1 956-630-3500 Never Again Book Series..................................................................71

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These well-read case studies are now featured in a new, multi-author e-book series from AMPP. Addressing both commercial
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Grab your copy at store.nace.org

MATERIALS PERFORMANCE: VOL. 61, NO. 4 APRIL 2022 71


CORROSION BASICS
Atmospheric Corrosion
of Iron and Steel
I
ron, in its assorted forms, is exposed
to a wide variety of atmospheric
environments. Iron tends to be
highly reactive with most of them
because of its natural tendency to
form iron oxide. When it does resist cor-
rosion, it is due to the formation of a thin
film of protective iron oxide on its surface
by reaction with oxygen in the air. This film
can prevent rusting in air at 99% relative
humidity (RH), but a contaminant such
as acid rain may destroy the passivity of
the film and permit continued corrosion.
Thicker films of iron oxide may act as pro-
tective coatings and, after the first year or
so, could reduce the corrosion rate.
Although the corrosion rate of bare
steel tends to decrease with time in most
cases, the difference in corrosivity of differ-
ent atmospheres for a particular alloy is
tremendous. In a few cases, the corrosion
rates of ferrous metals have been reported
to increase with time, and careful analy-
sis of the exposure conditions generally
reveals that an accumulation of contami-
nating corrosive agents has occurred, thus
changing the severity of the exposure.
It is generally conceded that steels
containing very low amounts of copper
are particularly susceptible to severe
atmospheric corrosion. In one test over a
3 ½-year period in both a marine and an
industrial atmosphere, a steel contain-
ing 0.01% copper corroded at a rate of 80
µm/y (3.1 mpy), whereas increasing the
copper content by a factor of five reduced
the corrosion rate to only 35 µm/y (1.4
mpy). Further additions of small amounts
of nickel and chromium reduced the corro-
sion rate to approximately 10 µm/y (0.39
72 APRIL 2022
Understanding the basic principles
and causes of corrosion
mpy). Other tests comparing grey cast
iron, malleable iron, and low-alloy steels
indicated that their corrosion resistances
were approximately the same.
Plain-cast iron appears to have a corro-
sion rate about one half that of 0.2% copper
steel in a marine atmosphere. One must
be careful in citing such comparisons to
stipulate the precise composition of the
carbon steel (CS) because the corrosion
behavior of CS is influenced so markedly
by small variations in copper and phospho-
rus content. After five years of exposure in
an industrial atmosphere, a structural CS
showed a penetration of about 20 µm (0.8
mil), a copper structural steel about 10 µm
(0.4 mil), and a low-alloy steel about 4 µm
(0.15 mil).
It is impossible to give a corrosion rate
for steel in the atmosphere without identify-
ing the composition, location, and specific
environmental factors. If one can relate
exposure conditions to those described in
the literature, a fairly good estimate can be
made of the probable corrosion behavior of
a selected material. However, all aspects of
the exposure of the metal surface must be
considered. For example, a high-strength,
low-alloy (HSLA) steel may show an advan-
tage in corrosion resistance of 12:1 over CS
when freely exposed in a mild environment.
As the severity or the physical conditions
of exposure change, the HSLA steel will
show less superiority, until in crevices or
the backside of structural forms in progres-
sively more corrosive atmospheres, it will
be no better than CS.
Very little needs to be said about the
behavior of stainless steels (Types 200 and
300), which contain high percentages of
nickel and chromium, except that they can
keep their shiny aspect without tarnishing
for many decades. The steels containing
only chromium (Type 400) as the principal
alloying constituent tend to rust superfi-
cially, but the others are relatively free from
surface atmospheric corrosion. However,
many of these alloys are susceptible to
stress corrosion cracking in many common
environments.
This article is adapted from Corrosion
Basics—An Introduction, Second Edition,
Pierre R. Roberge, ed. (Houston, TX: NACE
International, 2006), pp. 111-114.
CORROSION ENGINEERING
DIRECTORY
Located in the back of
Materials Performance, this
section promotes business/
professional services.
Browse the section for
products or services that fit
your needs.
For information on
advertising in this section,
contact Brenda Nitz,
brenda.nitz@ampp.org or
+1 281-228-6219.
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prominent methods to ensure assets are
protected against corrosion. Professionals
FUTURE WITH THE in this feld are relied on in the industry to
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INDUSTRY EXPERTS to complex corrosion concerns.

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