Steelwork Corrosion Control

by DEACON; DAVID

• ISBN13: 9780415261012
• ISBN10: 0415261015
• Edition: 2nd
• Format: Hardcover
• Copyright: 2002-10-11
• Publisher: CRC Press

Summary

Steelwork Corrosion Control is a comprehensive revision and updating of a similar book by the authors published in 1985. As with the previous book it is designed principally for engineers, architects and designers for whom the protection of structural steelwork is an important part of their professional activities. Updated to include all the changes in ISO, BS and European standards, this volume is a guide to achieving sound steel protection.

Author Biography

D.A. Bayliss and D.H. Deacon, Steel Protection Consultancy Ltd, Leighton Buzzard, UK.

Table of Contents

Acknowledgements	xiv
Introduction	1	(4)
Health and safety considerations	4	(1)
The corrosion of steel	5	(15)
Corrosion: the basic process	5	(2)
The electrochemical nature of corrosion	7	(2)
Corrosion terminology	9	(2)
Potential	9	(1)
Polarisation	10	(1)
Passivity	10	(1)
Corrosion in air	11	(3)
Steel Composition	14	(1)
Rust	14	(1)
Corrosion in water	14	(3)
Composition of water	15	(1)
Operating conditions	15	(1)
Steel composition	16	(1)
Corrosion rates of steel in water	16	(1)
Corrosion in soil	17	(1)
Bacterial corrosion	17	(1)
Health and safety considerations	18	(2)
References	19	(1)
Further reading	19	(1)
Surface preparation	20	(40)
Steel surface contaminants and conditions	21	(10)
Oil and grease	21	(1)
Millscale	21	(4)
Surface cleanlines	25	(4)
Roughness	29	(1)
Surface defects and welds	30	(1)
Surface preparation methods	31	(24)
Degreasing	31	(2)
Hand - and power - tool cleaning	33	(2)
Abrasive blast-cleaning	35	(14)
Innovative methods	49	(2)
Flame cleaning	51	(1)
Pickling	52	(2)
Iron and zinc phosphating	54	(1)
Health and safety matters	55	(5)
General	55	(1)
Open nozzle blast-cleaning	56	(1)
Pressure water jetting	57	(1)
Flame cleaning	58	(1)
References	58	(2)
Paints and paint coatings	60	(50)
General requirements	60	(2)
The nature of paint	62	(3)
Paint systems	64	(1)
Protection by paint films	65	(5)
Zinc-rich pigments	66	(1)
Inhibitive pigments	66	(1)
Barrier coatings	67	(3)
Properties of paint films	70	(5)
Adhesion	70	(1)
Flexibility	71	(1)
Hardness	72	(1)
Abrasion resistance	72	(1)
Permeability	73	(1)
Resistance to microorganisms	74	(1)
Ageing of paint films	74	(1)
Paint film formation	75	(1)
Binders	75	(7)
Oxidation type	76	(2)
Solvent evaporation type	78	(2)
Chemically reacting type	80	(2)
Pigments	82	(5)
Inhibitive pigments	83	(1)
Other pigments	84	(2)
Extenders	86	(1)
Solvents	87	(1)
Paint classification	88	(19)
Oil-based and oleo-resinous paints (oxidation drying)	88	(4)
Solvent evaporation paints	92	(3)
Chemical reaction paints	95	(6)
Zinc-rich coatings	101	(3)
Waterborne coatings	104	(1)
Compatibility of different paints	104	(1)
Heat-resistant coatings	104	(3)
Other coating materials and fillers	107	(1)
Health and safety matters	107	(3)
References	108	(1)
Further reading	109	(1)
Paint application	110	(32)
Methods of application	110	(13)
Brush application	110	(1)
Roller application	111	(2)
Airspray application	113	(1)
Airless spraying	114	(4)
Application of plural-component paints by spray	118	(2)
Electrostatic spray	120	(1)
Other application methods	121	(2)
Comparison of application methods	123	(1)
Application conditions	123	(7)
Pre- or post-fabrication	124	(1)
The painting shop	125	(1)
Ambient conditions	126	(3)
Storage of paint	129	(1)
Preparation of paint before use	129	(1)
The painter	130	(1)
Paint manufacturer's data sheets	130	(2)
Health and safety matters	132	(10)
Airless spray	132	(1)
Paint materials	133	(7)
References	140	(2)
Specialist coatings and applications	142	(26)
Coating or lining of tanks	142	(8)
Corrosion protection	142	(2)
Lining materials	144	(2)
Application of linings	146	(4)
Powder coatings	150	(2)
Application methods	151	(1)
Coil coatings	152	(3)
Wrapping tapes	155	(2)
Fire protection	157	(1)
Pipelines	158	(10)
Subsea pipelines	159	(5)
Buried pipelines	164	(2)
References	166	(2)
Metal coatings	168	(25)
Application methods	168	(9)
Hot-dipping	169	(3)
Sprayed coatings	172	(3)
Coatings produced by diffusion	175	(1)
Electrodeposited coatings	176	(1)
Other application methods	177	(1)
Corrosion mechanism of metallic coatings	177	(3)
Painting of metallic coatings	180	(2)
Performance of metallic coatings	182	(4)
Performance of zinc coatings	183	(2)
Performance of aluminium coatings	185	(1)
Performance of cadmium coatings	185	(1)
Comparison between metallic and paint coatings	186	(2)
Choice of type of metallic coating	188	(1)
Treatment of welded areas	189	(1)
Wet storage stain	189	(1)
Fasteners	190	(1)
Health and safety matters	190	(3)
Hot-dip galvanising	190	(1)
Metal spraying	190	(2)
References	192	(1)
Writing effective specifications	193	(15)
Scope of the specification	194	(12)
Scope	195	(1)
Documents	195	(1)
Pre-job conference	196	(1)
Surface preparation	196	(1)
Materials	197	(1)
Control of coating materials and samples	197	(1)
Coating application	198	(2)
Workmanship	200	(1)
Treatments of special areas	200	(2)
Handling, transport and storage	202	(3)
Remedial work	205	(1)
Inspection and quality control	205	(1)
Safety	206	(1)
Other aspects of specifications	206	(1)
International standards	206	(2)
Quality control of coating operations	208	(54)
Introduction	208	(2)
Inspection requirements	210	(1)
The approach to quality control	211	(2)
Requirements for an inspector	213	(3)
Training and certification of inspectors	214	(2)
Methods of inspection of paint coatings	216	(37)
Surface preparation	216	(17)
Testing of liquid paints	233	(1)
Coating application	233	(20)
Inspection of metal coatings	253	(2)
Hot-dip galvanising	254	(1)
Sprayed metal coatings	254	(1)
Inspection instruments	255	(2)
Reports and records	257	(3)
Health and safety matters	260	(2)
References	260	(2)
Designing for corrosion control	262	(17)
Environmental conditions	263	(1)
Materials	263	(1)
Bimetallic corrosion	264	(2)
Access for inspection and maintenance	266	(2)
Crevices	268	(4)
Ground-level corrosion	272	(2)
Entrapment of moisture and condensation	274	(1)
Geometry and shape	275	(1)
Tanks	276	(1)
Fabrication and construction	277	(1)
Corrosion of steel in contact with other materials	278	(1)
Further reading	278	(1)
Maintenance painting	279	(21)
Introduction	279	(2)
The general approach to maintenance painting	281	(1)
Planning maintenance	282	(2)
Inspections and surveys for maintenance	284	(9)
Survey procedures	285	(8)
Feasibility trials	293	(1)
Maintenance procedures	293	(4)
Surface preparation prior to repainting	293	(2)
Painting	295	(2)
Environmental conditions during repainting	297	(2)
Health and safety matters	299	(1)
References	299	(1)
Control methods other than coatings	300	(11)
Cathodic Protection	300	(5)
Basic principles	301	(1)
The application of cathodic protection	301	(1)
Sacrificial anode method	302	(1)
Impressed current method	302	(1)
Choice of method for cathodic protection	302	(1)
Practical applications of cathodic protection	303	(2)
Coatings and cathodic protection	305	(1)
Conditioning of the environment	305	(2)
Treatment of the air	306	(1)
Treatment of aqueous solutions	307	(1)
Alloy steels	307	(4)
Stainless steels	308	(1)
Low-alloy weathering steels	309	(1)
References	310	(1)
Coating defects and failures	311	(18)
Introduction	311	(1)
Surface preparation	312	(2)
Coating materials	314	(1)
Coating application	314	(3)
Transport and storage	317	(1)
Types of coating defects	317	(12)
Adhesion loss (flaking, peeling, etc.)	317	(1)
Bacterial or fungal attack	318	(1)
Bleeding	319	(1)
Blistering	319	(2)
Blooming or blushing	321	(1)
Chalking	321	(1)
Cissing, crawling and fisheying	322	(1)
Cobwebbing	322	(1)
Cracking	322	(1)
Complete or partial failure to cure of two-part materials	323	(1)
Dry spray	324	(1)
Fading	324	(1)
Lifting or pulling up	324	(1)
Orange peel	324	(1)
Pinholes and holidays	325	(1)
Pinpoint rusting	325	(1)
Runs and sags	325	(1)
Saponification	325	(1)
Skin curing	326	(1)
Spot-blast boundary breakdown	326	(1)
Thickness faults	326	(1)
Uneven gloss	327	(1)
Undercutting	327	(1)
Wrinkling	328	(1)
References	328	(1)
The selection of coating systems	329	(14)
Introduction	329	(2)
Factors influencing the selection of coating systems	331	(1)
Selection of coatings for specific environments	332	(2)
Types of coatings	334	(1)
Costs of protective systems	335	(8)
Calculating the costs of alternative protective systems	336	(5)
Initial costs of protective systems	341	(1)
Further reading	342	(1)
Protective systems for different situations	343	(24)
General steelwork exposed to the atmosphere	343	(4)
Bridges	344	(2)
Buildings	346	(1)
Storage tanks (exterior)	347	(1)
Offshore structures	347	(3)
Atmospheric zone	348	(1)
Immersed zone	349	(1)
Splash zone	349	(1)
Ships	350	(4)
Surface preparation	350	(1)
Areas to be protected	350	(1)
Underwater plating	351	(1)
Anti-fouling paints	351	(1)
Boot topping	352	(1)
Topsides and superstructures	352	(1)
Steel decks	353	(1)
Machinery, pipes, etc.	353	(1)
Cargo and ballast tanks	353	(1)
Freshwater tanks	354	(1)
Chemical plants	354	(2)
Oil refineries and installations	356	(1)
Sewage systems	356	(1)
Sheet piling	357	(1)
Jetties and harbours	358	(1)
Steel in reinforced concrete	359	(8)
Concrete	359	(2)
The corrosion of rebar in concrete	361	(2)
Types of failure with reinforced concrete	363	(1)
Corrosion control methods	364	(2)
References	366	(1)
Testing of coatings	367	(36)
Introduction	367	(2)
Test requirements	369	(3)
Laboratory testing of paint films	372	(9)
Determination of drying time	373	(1)
Gloss	374	(1)
Hiding power	374	(1)
Adhesion tests	375	(1)
Abrasion resistance	376	(2)
Physical state of the film	378	(2)
Film thickness	380	(1)
Testing of paints	381	(1)
Laboratory performance tests	382	(3)
Artificial weathering	382	(1)
Salt-spray tests	383	(2)
Humidity and condensation tests	385	(1)
Other laboratory tests	385	(1)
Instruments for specialised analysis	385	(1)
Field tests	386	(11)
Type of specimen to be used for the tests	388	(1)
The coating	388	(1)
Exposure of specimens	389	(3)
Test sites	392	(1)
Monitoring of test sites	393	(1)
Methods of measuring atmospheric pollution	394	(1)
Conduct of field tests	395	(2)
Service trials	397	(1)
Tests in water and soil	398	(1)
Formulating the test programme	399	(1)
Reporting the results of tests	399	(4)
References	400	(3)
Index	403