ASM MP Sep 2017

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IN THIS ISSUE SEPTEMBER 2017
VOL. 56, NO. 9
CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE
28 42
SPECIAL FEATURES
28 Protecting Concrete Infrastructure from Corrosion

Wesley Fawaz
60 9th Annual Company Showcase
CATHODIC PROTECTION
34 Coupons for Cathodic Protection Evaluation
of Mixed-Metal Piping Systems
Douglas E. Gilroy About the Cover
The Arthur Ravenel Jr. Bridge, which spans the Cooper
River in Charleston, South Carolina, is the third longest
cable-stayed bridge in the Western Hemisphere with a
COATINGS & LININGS main span of 1,546 ft (471 m). The largest local contract
secured 250,000 m3 (326,988 yd3) of concrete for the
38 Plasma Electrolytic Oxidation Coatings for Aluminum Alloys
Y. Zhang, W. Fan, H.Q. Du, and Y.W. Zhao structure. Concrete is the most widely used construction
material in the world. According to www.concretehelper.
42 Hydrogen Sulfide Tube Failure in a Seawater Heat Exchanger
Hanan Farhat and Roy Johnsen
com, about 10 billion tons (9,072 billion kg) of concrete are
produced every year. In this issue of MP, several articles
discuss concrete structure corrosion and how to mitigate
47 Coatings & Linings Essentials
degradation of the reinforcing steel that gives concrete
higher tensile strength. Alkaline conditions in concrete form
a passive film on the surface of the steel reinforcement
that prevents or minimizes corrosion. Reduction of the pH
CHEMICAL TREATMENT caused by the ingress of chlorides or carbonation causes
the passive film to degrade and allows the reinforcement
52 Electrochemical Approach for Screening Concrete Corrosion
Inhibitors
to corrode in the presence of oxygen and moisture. A key
way to minimize corrosion is to design for durability and
I-Wen Huang, Fred Goodwin, and Frank Apicella employ the most appropriate prevention technologies and
techniques available.
MATERIALS SELECTION & DESIGN

56 Rust Layer Characterization of a Buried Drinking Water Pipe
Zhanjun Guo and Zhiliang Chen
2 SEPTEMBER 2017 MATERIALS PERFORMANCE NACE INTERNATIONAL: VOL. 56, NO. 9

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IN THIS ISSUE SEPTEMBER 2017
VOL. 56, NO. 9
CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE
6 17 47
DEPARTMENTS
6 Up Front
8 What’s Online @ www.materialsperformance.com

Coming Next Month:
10 From the Editor’s Desk
CORROSION 2018 The MP Blog

11
Advance Program 14 Material Matters
14. Study Evaluates Chloride Limits for Structural Reinforced Concrete
17. Florida Tests Cathodic Protection Solutions on High-Resistance Concrete
MP (Materials Performance) is published monthly by NACE International

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UP FRONT
Seawater Reactions The work was supported by the U.S. aluminum anode corrodes, it can be replaced
Strengthened Ancient DOE’s Office of Science (Washington, DC) at low cost.
and the National Science Foundation With their system, OWP says UUVs can
Concrete
(Arlington, Virginia). launch from shore and without a need for
For more information, visit www.lbl.gov. service ships. To that end, the group is work-
ing with the U.S. Navy (Washington, DC) to
replace batteries in acoustic sensors
‘Seawater-Drinking’ Battery designed to detect enemy submarines. In
Could Power Underwater mid-2017, a pilot was launched to use the
Surveys UUVs for surveys. Currently, these UUVs can
travel ~100 nautical miles (185 km), but OWP
believes it can raise the distance to ~1,000
nautical miles (1,852 km).
For more information, visit news.mit.edu.
Samples from this ancient Roman pier in
Italy were studied with x-rays at Berkeley
Lab. Photo by J.P. Oleson. High-Tech Sensing Illuminates
Concrete Stress Testing
A new look inside 2,000-year-old concrete—
made from volcanic ash, calcium oxide
(CaO) (also known as lime), and seawater—
is helping explain the chemistry that has
allowed ancient structures to withstand the
test of time. The research is also inspiring a
Batteries that “drink” seawater are being
hunt for the original recipe so that modern developed to power underwater vehicles.
concrete manufacturers can do as the Photo courtesy of MIT. The coating can create a candle-like “flame,”
Romans did. that highlights shear stress distribution in a
Researchers at the U.S. Department of Massachusetts Institute of Technology concrete beam. Photo courtesy of the
Energy’s (DOE) Lawrence Berkeley National (MIT) (Cambridge, Massachusetts) spinout University of Leeds.
Laboratory (Berkeley Lab) (Berkeley, Cali- Open Water Power (OWP) is developing an
fornia) used x-rays to study samples of aluminum-water power system that it says Scientists at the University of Leeds (Leeds,
Roman concrete from an ancient pier and is safer, cheaper, and more durable for United Kingdom) and the University of Qatar
breakwater sites. Their earlier work found unpiloted underwater vehicles (UUVs) than (Doha, Qatar) discovered a new way to mea-
that crystals of aluminous tobermorite, a lithium-ion batteries. sure the strength of modern concrete com-
layered mineral, could play a key role in While many UUVs use lithium-based posites and the points when it could fracture.
strengthening concrete. Now, this study is batteries, OWP says these batteries are Their approach involves applying a light-
piecing together how and where it formed— flammable, have limited energy density, and refracting coating, designed to display stress
namely, in the centers of partially dissolved must be encased in expensive metal pres- positions, to the surface of concrete beam
relict lime clasts. sure vessels. In contrast, their system con- samples. The epoxy coating is birefringent,
They believe the work could lead to consists of an alloyed aluminum anode, a cath- which means it can split light waves in differ-
crete manufacturing techniques with less ode alloyed with several elements (primarily ent directions in proportion to any stress.
environmental impact than modern Port- nickel), and an alkaline electrolyte posi- The light reflects back to a photonic cam-
land cement processes. Also, researchers tioned between electrodes. era. The camera takes a picture showing
suggest a reformulated recipe for Roman When these UUVs are placed in the where the stress levels are most extreme,
concrete could be tested for applications on ocean, seawater is pulled into the battery before cracks or fractures occur. While the
ocean-facing structures such as seawalls, and splits at the cathode into hydroxide coating is not new, this project is the first
and could help safeguard hazardous wastes. anions and hydrogen gas. The hydroxide time it has been used to measure shear strain
According to Marie Jackson, a professor anions interact with the aluminum anode, on opaque materials rather than transparent
with University of Utah (Salt Lake City, creating aluminum hydroxide and releasing materials. With the process, the researchers
Utah) who led the study, the CaO likely electrons. Those electrons travel back believe they can prove that concrete made
reacted with volcanic ash when it was toward the cathode, donating energy to a cir- from non-traditional ingredients—such as
exposed to seawater. “Contrary to the prin- cuit along the way to begin the cycle anew. waste plastic products—can sustain service
ciples of modern cement-based concrete, Both the aluminum hydroxide and hydrogen loads without fracturing.
the Romans created a rock-like concrete gas are jettisoned as harmless waste. For more information, visit www.leeds.
that thrives in open chemical exchange with Components are only activated when ac.uk.
seawater,” Jackson says. the battery is flooded with water. Once the —Ben DuBose

ABLE ·
EAT
RE
P
I L M
·
F S
ST
S
· FA
RYK N E
D C
BLE
re
HI
u
RA
s
T D
U
a
·
Me
A C C U R AT E
Halve your DFT inspection

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WHAT’S ONLINE @ www.materialsperformance.com
Discussed this
Month
Following are just a few of the articles featured
this month on www.materialsperformance.com.
Features
Analysis of Materials for Highly
Corrosive Environments
Extra consideration is given to the coatings used
to protect sections of horizontal directional
drilling-installed pipe from corrosion; however,
the systems currently being employed may be
insufficient. (This is a Science in Action feature
with links to CoatingsPro articles.)
New Collaborative Research Project

Targets Surface Degradation
Researchers from BP and several prominent
European universities were awarded a contract to
investigate the processes that cause surface
degradation and to develop new mitigation
strategies.
Editor’s Choice
New Tantalum Alloy Resists Highly
Corrosive Environments
The results of recently completed trials show that
adding low levels of ruthenium improve the
corrosion and hydrogen enrichment resistance of
a titanium alloy in acid media.
Researchers Eye Advanced Sensors

to Monitor Buried Infrastructure
These novel advanced sensors were attached to a
hazard-resilient plastic pipeline installed
underground and tested through a simulated
fault rupture.
For even more corrosion news, visit

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

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FROM THE EDITOR’S DESK
Helping www.materialsperformance.com
Concrete EDITORIAL
MANAGING EDITOR-IN-CHIEF
EDITOR
Gretchen A. Jacobson
Kathy Riggs Larsen
Stand the TECHNICAL EDITORS Norman J. Moriber

Jack Tinnea,
Tinnea Associates, LLC
Test of Time TECHNICAL EDITOR EMERITUS

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

THE BLOG
The following are excerpts from the

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

Sulfate Electrodes
Q: Is it advisable to use drinking
mineral water mixed with
copper sulfate (CuSO 4) crystals as an
electrolyte inside the tube of a Cu/CuSO 4
electrode (CSE) to make a saturated
solution?
A: Definitely not! You should use

only distilled or demineralized
water for the make-up solution. Using any
other types of water will lead to signifi-
cant errors in the potential.
A: Distilled water must be used, and

it should be saturated with CuSO 4
crystals. Do not add any other substance
to the solution or the integrity of the CSE
will be compromised.
A:
be used.
I have heard it said that water
drops from an air conditioner can
A: If you had to do this, then mea-

sure the conductivity of the con-
densate. When an air conditioner or de-
humidifier is run after it has not been on
for a while, the condensate will be unsuit-
able because it has washed accumulated
dust and salts from the coils. Once it has
been used for several weeks, the conden-
sate conductivity will typically be <12 µS,
which is quite adequate for reference
electrodes. Much of the commercial-
NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 11

January 23-26, 2018 | Las Vegas, Nevada, USA
Visit www.concrete.org
to register
Learn more about
ACI’s publications,
education, and
certification.
Other features:
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THE BLOG
Continued from page 11
shift of ca. –100 mV. Refer to “Factors

Affecting the Accuracy of Reference
Electrodes” by F. Ansuini and J. Dimond, Mentors Make a Difference
November 1994 MP, p. 14.
Intergranular Cracking of
Find a mentor. Be a mentor.
Low CS Stack Casing
www.nace.org/BeAMentor
Q: The stack casing of fired heaters
in a catalytic reformer unit has
been cracking. The fired heaters burn fuel
oil, fuel gas, and natural gas. The stack
casing is a welded structure of ¼-in
(6.3-mm) thick low carbon steel (CS)
(A285 Grade A, 0.05%C/60 HRB). The cas-
ings have cracked in the refractory-lined
regions. Cracks occurred within 2 in
(51 mm) of welds, mostly parallel to but
some through the welds and some in the
heat-affected zones. The cracking initi-
ated on the inside surface and propagated
through the plate thickness to the outside
surface. The cracking is almost com-
pletely intergranular, some extensively
branched. I am looking for possible corro-
dents responsible for the intergranular
stress corrosion cracking (IGSCC). The
only thing I can think of is ammonium
nitrate in acidic condensates, with the
ammonium coming from the air intake.
The stack casing material that failed
has 0.05% C, which was reported to be
sensitive to IGSCC of CS in nitrate (e.g.,
CORROSION 2007 paper no. 485). How-
ever, few have reported on nitrate crack-
ing in fired heaters and boilers. I wonder
if this is because nitrogen oxides (NO x)
are so prevalent in combustion products.
Do you have any suggestions or simi-
lar experiences with fired heater/stack
casing cracking?
A: If the cracking is occurring in the

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

Middle East. Most of the furnace
stacks in one refinery cracked. It was
blamed on nitrates, as I remember.
A: Would it be possible to insulate

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

MATERIAL MATTERS
Study Evaluates Chloride Limits for

Structural Reinforced Concrete
D
isintegrating and deteriorat- dent of Tourney Consulting Group, LLC tive passive layer breaks down and corro-
ing concrete is a key issue for (Kalamazoo, Michigan). The research, sion starts. Rust forms, which takes up
structures worldwide. A conducted at NRMCA and Tourney labo- more space than the original steel, and
major contributing factor is ratories, established a relationship causes the concrete cover to crack and
the presence of chloride ions in the con- between the initial calculated total chlo- spall. While external chloride ions from
crete, which causes the reinforcing steel ride content of the concrete’s constituents the environment (e.g., seawater and deic-
inside to corrode. Recently, a research and the measured water-soluble chloride ing salts) migrate through concrete over
project1 on chloride limits for reinforced content in aged, hardened concrete. time and eventually reach the reinforcing
concrete was completed by the National According to the researchers, con- steel, internal chlorides that originate
Ready Mixed Concrete Association crete’s highly alkaline environment pro- from materials used to produce the
(NRMCA) (Silver Spring, Maryland) in tects the reinforcing steel from corro- concrete are present when the concrete
collaboration with NACE International sion. When chlorides concentrate on the is cast.
member Neal Berke, FNACE, vice presi- steel reinforcement, however, its protec- ACI 318-142 prescribes limits on inter-
nal water-soluble chlorides for concrete,
which are determined based on the
weight of Portland cement in the con-
crete. The reason for the chloride limits,
explains Karthik Obla, vice president,
technical services with NRMCA, is to pro-
tect the reinforcing steel against corro-
sion initiation. According to NRMCA, 3
corrosion initiates when the concentra-
tion of chlorides exceeds a threshold con-
centration at the reinforcing steel.
Although these chloride concentration
values can vary, they are typically in the
range of 0.05 to 0.1% of the weight of the
concrete—~2 to 4 lb/yd 3 (1.2 to 2.4 kg/ m 3),
or ~0.4 to 0.8% of the weight of cement
(based on the assumption of ~500 lb/yd 3
[297 kg/m3] of cement).
Chloride limits set by ACI 318-14 tar-
get various atmospheric exposures. For
exposure class C1—concrete that is
exposed to moisture but not to external
sources of chlorides—the maximum
internal water-soluble chloride ion con-
tent (by weight of cement) in concrete is
0.3% for reinforced concrete and 0.06% for
prestressed concrete. For exposure class
C2—concrete that is exposed to moisture
as well as an external source of chlo-
rides—the maximum internal water-solu-
ble chloride ion content is 0.15% for rein-
forced concrete and 0.06% for prestressed
concrete. Typical sources of water-soluble
chloride ions include water, aggregates,

Information on corrosion
control and prevention
For chloride testing, concrete samples are cast and then ground into powder. Photo courtesy of
Karthik Obla.
cementitious materials, and admixtures. pores. Between 50 and 75% of the total
Obla notes that concrete producers chloride content in concrete is estimated
conduct a water-soluble chloride test (per to be water soluble and a contributor to
ASTM C1218 4) on concrete specimens reinforcing steel corrosion. 3
that have cured between 28 and 42 days With an aim to reduce the time and
after casting to determine if concrete cost added to a concrete job for chloride
mixtures used for buildings comply with testing, the researchers implemented the
the ACI 318-14 chloride limit. If the test first phase of a project to evaluate chlo-
results exceed the chloride limit criterion, ride limits for reinforced concrete. In this
he says, the concrete producer must phase, the researchers worked to estab-
adjust one or more of the ingredients in lish a relationship between the total
the concrete mixture and then repeat the amount of chlorides in concrete calcu-
test. If concrete has been poured prior to lated from the chloride levels in the indi-
the availability of the chloride test vidual concrete constituents and the level
results, the viability of the concrete of chlorides measured by the ASTM C1218
placed may be questionable. water-soluble chloride test.
Not all chlorides in concrete contrib- Berke explains that total chloride con-
ute to corrosion, says Berke. Some chlo- tent in a concrete mixture can be estab-
rides are chemically bound in the cement lished when the mixture proportions are
matrix and supplementary cementitious being developed for a concrete building
materials and cannot be extracted by project. The total chloride content is
water. This means they are not available determined based on measured chloride
to cause corrosion of the reinforcing steel. content of the individual materials used
Some aggregates also contain chlorides and the proportion of these materials in
that are trapped and probably unavail- the concrete mixture. NRMCA’s Technol-
able to cause corrosion. Water-soluble ogy in Practice (TIP) 13 3 discusses
chlorides, however, are not bound and sources of internal chlorides and calcu-
can move through the concrete’s capillary Continued on page 16 Coating Thickness Material Analysis Microhardness Material Testing

MATERIAL MATTERS
lating chloride content in concrete from cement, Class C and Class F fly ash, silica initial calculated chloride content and
the mixture ingredients. fume, and slag cement, with varying the measured acid-soluble chloride con-
The researchers propose that if the water/cementitious material ratios and tent for each mixture, and <60% of the ini-
initial calculated total chloride content is aggregate types. Chloride in various dos- tial calculated chloride content for mix-
less than the chloride limit specified by ages was also added to the freshly mixed tures that had no chlorides added. This
ACI 318-14, then the water-soluble chlo- concrete. The initial total chloride con- supports the researchers’ proposal that if
ride level measurement for the hardened tent was calculated for the samples and the initial calculated total chloride con-
concrete will be lower than the initial cal- then verified using the acid-soluble chlo- tent of concrete mixtures is less than the
culated chloride total and comply with ride content measurement method in specified limits for water-soluble chloride
the building code—and water-soluble accordance with ASTM C1152. 6 The content in hardened concrete, then the
chloride testing may be avoided. If the ini- water-soluble chlorides were measured concrete mixture will comply with code
tial calculated total chloride content when the samples had aged between 28 requirements for chloride limits. Added
exceeds the specified limit, the concrete and 42 days in accordance with ASTM time and project costs could be avoided if
producer can then adjust the proposed C1218, as required by ACI 318-14. the requirement for a water-soluble chlo-
concrete mixture up front to ensure code Study results showed that for most of ride content test could be waived.
requirements are met rather than deal the mixtures, the ratio of the initial cal- This phase of the research work was
with out-of-spec water-soluble chloride culated total chloride content and the funded by the RMC Research & Education
level test results during the project. measured acid-soluble chloride was close Foundation and the ACI Concrete Foun-
In the year-long study, the researchers to 1.0, which indicated the calculated dation. The complete report can be down-
tested more than 500 samples of concrete total chloride content and the measured loaded at www.nrmca.org/lab.
mixtures, says Obla. Concrete mixtures total chloride content were reasonably
included numerous combinations of consistent. Also, the measured water- References
ASTM C1505 Type II and Type V Portland soluble chloride content was less than the 1 K. Obla, C. Lobo, R. Hong, N. Berke, “Evalua-
tion of Chloride Limits for Reinforced Con-
crete Phase A,” RMC Research & Education
Foundation, Project 14-01, July 2017.
2 ACI 318-14, “Building Code Requirements for
Structural Concrete and Commentary ”
(Farmington Hills, MI: ACI, 2014).
3 NRMCA TIP 13, “Chloride Limits in Con-
crete” (Silver Spring, MD: NRMCA).
4 ASTM C1218/C1218M-17, “Standard Test
Method for Water-Soluble Chloride in Mor-
tar and Concrete” (West Conshohocken, PA:
ASTM, 2017).
5 ASTM C150/C150M–17, “Standard Specifica-
tion for Portland Cement” (West Consho-
hocken, PA: ASTM International, 2017).
6 ASTM C1152/C1152M-04 (2012) e1, “Stan-
dard Test Method for Acid-Soluble Chloride
in Mortar and Concrete” (West Consho-
hocken, PA: ASTM International, 2012).
—K.R. Larsen
Read
MP Online
NACE International members have free
access to MP Online, with back issues to
2005.
Access the digital issues of MP at

www.materialsperformance.com/magazine.

Information on corrosion control and prevention
Florida Tests Cathodic Protection Solutions

on High-Resistance Concrete
T he ease and practicality of installa-

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

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

MATERIAL MATTERS
To address this, FDOT’s corrosion

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

Information on corrosion control and prevention
The measurements were recorded at the CP current.” According to Lasa, the FDOT team explains. At the moment,
various points on each bridge over the crucial variable is that the second system FDOT says neither system is completely
last few years. While the precise results can be installed via pumping—whereas ready for full-scale installation as a CP
showed some variance based on the exact the first system requires hand troweling. standard on their bridges. However, sig-
geometry, location, and condition of the “Hand trowel requires more time for nificant knowledge of each system’s per-
bridges, the second CP system showed the application,” says Matthew Duncan, cor- formance and an understanding of their
most consistent success. On one particu- rosion mitigation technologist at FDOT current distribution mechanisms on
lar bridge with the Type 2 CP system, the and a co-author of the paper. “When high-resistance concrete were acquired
footing steel directly beneath the jacket applying the mortar by trowel, if the oper- through the study.
was also protected from corrosion. That ation is not done fast enough, the mortar “Additional testing and subsequent
additional protection extended up to 305 first applied may have already started the modifications to each system to improve
mm (12 in) away from the bottom of the setting process when the panel is put in performance is certainly promising,
protective jacket onto the footing, place. In addition, if sufficient mortar is along with the development of better
according to Mohammad Islam, co- not placed on the panel, there may be installation procedures,” Lasa says.
author and also a scientist with FDOT. voids at the anode-concrete interface
“Of the two systems installed, the when the panels are placed against the Reference
Type 2 system appears to be providing the concrete.” 1 I.R. Lasa, M. Islam, M. Duncan, “Galvanic Ca-
best CP polarization, whereas the Type 1 “On the other hand, pumping is faster thodic Protection for High Resistance Con-
system is providing CP for less than 50% and it completely fills the annular space crete in Marine Environments,” CORROSION
of the areas covered,” Lasa says. “The between the anode and the concrete,” 2017, paper no. 9700 (Houston, TX: NACE
lesser performance of the Type 1 system is Duncan adds. International, 2017).
attributed at this time to the poor bond Future system installations may
—Ben DuBose
between the anode and the concrete sur- include a manufacturer’s representative
faces, which impedes a uniform flow of to oversee the initial installation, the
ATTENTION Looking for Rehab and

ENGINEERS Lining Speciﬁcations?
Design guidelines Tanks Lift Stations

for water and wastewater
infrastructure Manholes Pipe Systems
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COMPANY NEWS
Redesigned Web Site for to further developing the range of fire pro- series of projects, including two designed
Concrete Corrosion Inhibitors tection coatings, as well as expanding a to improve corrosion resistance in aircraft
global R&D network. parts. The award recognizes a group of
Applied to structural steel in large five, including lead materials engineer
buildings and industrial oil and gas instal- Jack Benfer, senior chemist Ruben Prado,
lations, the PFP coatings expand to form engineer technician Rodney Williamson,
an insulating layer of carbon char when materials engineer Peter Sheridan and
exposed to high temperatures. This chemical engineer Luzmarie Youngers.
enables the steel to maintain its load-bear- Two of their accomplishments came in
ing capacity for up to four hours longer the development of new methods to fight
during a fire, giving people time to escape corrosion, FRCSE explains, including an
the building and for firefighters to extin- advanced anodizing line aimed at provid-
The site offers tips to extend the life of concrete guish the fire. The new R&D facility ing better protection to aircraft alumi-
structures. Photo courtesy of Cortec Corp.
focused on PFP coatings will enable the num. The team also introduced a new
A redesign of the Mitigating Corrosion company to further expand its PFP prod- zinc-nickel plating line for steel aircraft
Inhibitors (MCI†) web site by corrosion uct range, including the development of components. The “active” coating works
control technologies group Cortec® Corp. PFP coatings for hydrocarbon fires— by releasing electrons in the event a steel
(St. Paul, Minnesota) offers a fresh look at which are encountered in the oil and gas part is scratched or nicked, to keep the
extending the service life of concrete industry. component from corroding. Parts outfit-
structures. On the web site, the company “Our 15 R&D centers around the globe ted with the new coating are currently
offers its products within a vastly all work together as one organization to deployed on a Navy aircraft carrier to
improved online user experience and con- ensure that our customers get best-in- confirm its durability.
nects visitors to industry news, learning class solutions and technical support,
resources, and more. Visitors can browse whether they are global, multinational, or Distribution of Elastomeric
newsletters, read the latest news releases local,” says CEO Henrik Andersen. “PFP Polyurethane Coatings
about the products, or watch videos on the coatings are a key element in our strategy, Expands to Canada
effects of corrosion and potential protec- and the new PFP-focused R&D center will Global paints and coatings group Akzo-
tion solutions—such as the company’s ensure we remain at the leading edge of Nobel (Amsterdam, The Netherlands) has
inhibitors. These inhibitors can extend the this important technological area.” extended the existing distribution agree-
service life of new structures by proac- ment for its Polibrid coatings to now
tively delaying the onset of corrosion and U.S. Navy Honors Projects include Canada. The original worldwide
keeping rates low after initiation. In reha- Designed to Prevent Aircraft distribution pact was crafted in 2016. This
bilitation projects, the application of these Corrosion expanded agreement will enable access to
inhibitors can penetrate a considerable the coating range throughout North Amer-
distance to significantly reduce the corro- ica as part of the company’s international
sion rate by up to 80%. The products main- brand portfolio of protective coatings and
tain structural integrity, rehabilitate vul- linings. The range includes high-build,
nerable structures, and also alleviate low-odor, two-component elastomeric
environmental concerns. polyurethane lining options designed to
protect concrete and steel in severe
New R&D Hub in Spain for immersion environments, while also being
Fire Protection Coatings free of volatile organic compounds
Hempel A/S (Lyngby, Denmark) is invest- FRCSE scientists and engineers inspect a piece (VOCs). Fast curing times, easy applica-
of aircraft aluminum that will go through an tion, and flexible, crack-resistant proper-
ing in a new research and development
advanced anodizing line to receive a corrosion- ties make the range ideal for use in corro-
(R&D) center focused solely on passive fire resistant coating. Photo by Clifford Davis,
protection (PFP) coatings. Located just sive wastewater treatment, potable water,
U.S. Navy.
outside Barcelona, Spain, the center will and other immersion applications such as
open in late 2018 and employ 35 experi- Scientists and engineers with the U.S. penstocks, dam gates, manholes, and pipe-
enced technicians and scientists. The Navy’s Fleet Readiness Center Southeast lines, where exposure to hydrogen sulfide
investment demonstrates a commitment (FRCSE) ( Jacksonville, Florida) were pre- (H2S) and microbiologically influenced
sented with the 2016 Delores M. Etter Top corrosion (MIC) is prevalent.
†
Trade name. Scientists and Engineers Award for a

Executive Vice President include managing the group’s oil and gas nearly $1 million in overall funding allo-
Named for Oil, Gas team in Atlanta, Georgia, and Houston, cated for more than 20 institutions and
Engineering Division Texas. The company’s team entails more educational programs across North Amer-
Architecture, than 80 engineers specializing in the oil ica. The foundation funds programs across
engineering, and gas division, which also includes the the continent each year, providing hands-
planning, and sectors of natural gas, midstream, fuel, on learning opportunities in areas from
construction corrosion control, and environmental ser- robotics and thermodynamics to design
group Pond & vices. Despite an overall downturn in the and materials development. Since 2001,
Co. (Peachtree oil and gas sector, the company notes that the foundation has advanced the auto
Corners, Geor- it recently opened two new offices in industry through grants to colleges and
gia) has named Houston. universities and by providing students
Lorraine A. with technology, tools, and experiences
Green as execu- Corrosion Control Group similar to that of the professional work-
Lorraine A. Green. Photo
tive vice presi- Issues Education Grants to place The proposal process for these edu-
courtesy of Pond & Co.
dent of its oil Develop Trade Workforce cation grants is by invite only, and all pro-
and gas division. Green has more than 30 The Denso North America Foundation posals are evaluated based on technical
years of experience providing engineering (DNAF) philanthropic arm of corrosion merit, student experience, and alignment
and environmental consulting services to protection group Denso North America with industry needs.
the industry, according to the company, (Houston, Texas) recently confirmed its
which adds that her responsibilities will 2017 college and university grants, with Continued on page 22
AXALTA COATING SYSTEM
QUALITY & PROTECTION

YOU CAN RELY ON
The leading choice for rebar application for concrete
structures and bridges that meet or exceed the
performance standards set by ASTM and AASHTO.
Benefits:
» Excellent corrosion and cathodic disbondment
resistance
» Superior chloride permeability resistance – particularly
de-icing salts
» DOT approved by all qualifying states
» Reclaimable - near 100% utilization
axalta.us/powder
800.247.3886

COMPANY NEWS
New Web Site for product manufacturers will find the com- dential, light commercial, and high-per-
Architectural Metal Coatings pany’s product information organized by formance coatings. The site also hosts pro-
PPG (Pittsburgh, Pennsylvania) has coatings type—coil or extrusion—as well files and data sheets for nearly two dozen
launched a new web site for architectural as by finished end-use or performance of the company’s metal coatings. A “where
metal coatings that features a streamlined requirement. Coil coatings are searchable to buy” section links visitors to members
appearance, intuitive navigation, and by roofing, panel, and industrial applica- of the company’s certified applicator pro-
enhanced access to popular coatings spec- tions, while extrusion coatings are sorted gram network, a select group of excep-
ification tools. Architects, specifiers, and according to industry standards for resi- tional extrusion coatings applicators, as
well as a list of company-approved coil
coaters around the world. Additional con-
tent includes an automated sample
request system, project case studies, and a
project photo gallery.
Corrosion Inhibitor Chemical

Earns European Regulatory
Approval
Rivertop Renewables (Missoula, Montana)
announced that its sodium glucarate
chemical has achieved registration under
the European Chemical Agency’s (ECHA)
(Helsinki, Finland) Registration, Evalua-
tion, Authorization, and Restriction of
Chemicals (REACH) regulation. REACH
registration opens the door for the com-
mercial deployment of products derived
from sodium glucarate in markets across
Europe, including its Waterline CI and
Headwaters corrosion inhibitors.
The registration confirms the health
and safety characteristics of sodium gluca-
rate for manufacturers, customers, regula-
tors, and non-governmental organizations
in Europe. Sodium glucarate, based on
glucaric acid (C6H10O8), only recently
became available in commercial quanti-
ties due to Rivertop’s oxidation technology
that transforms simple plant sugars into
renewable chemicals. The company plans
to develop additional applications for
sodium glucarate in marine corrosion and
rust removal.
—Ben DuBose
MP welcomes submissions of
Company News. Please send photos
and information to Ben DuBose, NACE
International; tel: +1 281-228-6414;
email: [email protected].

12 – 15 November 2017 | Sydney, Australia
PROUDLY PRESENTED BY:
MAJOR SPONSOR:
THE Destination - Sydney

Sydney is also home to world-class meeting
Known the world over as Australia’s ‘Harbour City’,
infrastructure and accommodation options.
Sydney is blessed with stunning natural landscapes and
Just as importantly, it offers easy accessibility
a near-perfect climate. Living is serious business in
between the airport, conference facilities and the
Sydney which is fun loving and full of energy. Delegates
city centre, and is a safe and stable destination
will have the opportunity to choose from the many
for international visitors and locals alike.
attractions that Sydney and the surrounds have to
offer, with activities to suit all tastes ranging from fine Sydney ticks all the boxes!
restaurants, arts and culture, shopping, family attractions,
visiting the Iconic Sydney Opera House or Sydney Check it out:
Harbour Bridge, pristine beaches or Taronga Zoo. www.sydney.com
THE Preliminary Program is available on the

conference website now AND The final program
for C&P2017 will be available in September 2017
To register go to
conference.corrosion.com.au
PRODUCT SHOWCASE
Expanded Marine
Polyaspartic Coatings Coatings Line
for Quicker Turnarounds
Paints and coatings company PPG
(Pittsburgh, Pennsylvania) introduced
its Kwikspar 600 (full gloss) and Kwik-
spar 600SG (semi-gloss) polyaspartic
coatings. The coatings represent a new
line of corrosion-resistant, direct-to-
metal coatings formulated with
advanced film-build and fast-curing characteristics to improve efficiency. In highly Ship owners and operators can now enjoy
corrosive environments, both coatings can be overcoated on AMERCOAT 370 or a new level of flexibility and expand the
SIGMAFAST 278 epoxy primers to provide an ultrafast-drying alternative to tradi- options available for cost-effective
tional three-coat systems. In low to moderately corrosive environments, one coat of onboard maintenance following the
either coating can replace traditional two-coat epoxy/urethane systems. Formu- launch of a new multipurpose, one-pack
lated from 73% solids, the coatings cure up to eight times faster than standard poly- primer from the marine coatings business
urethane coatings in a 4-mil (25.4-µm) thickness on a low-temperature substrate. of AkzoNobel (Amsterdam, The Nether-
They also exhibit strong durability, flexibility, and abrasion resistance, making lands). The Interstores Alkyd Primer is the
them ideally suited for steel building and structural components that require cor- latest addition to the company’s Inter-
rosion resistance, weathering, and gloss and color retention. Tel: 1 888-977-4762, stores range and is compatible with most
web site: www.ppgpmc.com. AkzoNobel marine coatings topcoat
options. Specifically created with the
needs of the crew in mind, it is specially
formulated for brush and roller applica-
tion and is suitable for all substrates
above the waterline. Compatible with all
existing coatings systems and formulated
for ease of application, the Interstores
range has been sold to more than 3,000
Don’t let corrosion stop you vessels since its launch. Tel: +1 312-544-
7000, web site: www.akzonobel.com.
from getting here to there... Corrosion-Inhibiting
Packaging Boxes
Cortec® Corp. (St. Paul, Minnesota) intro-

We have the solution to help you duced custom-made CorrTainer boxes at
Protect those Assets! its coated products facility in Eau Claire,

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

The Latest Tools for
Fighting Corrosion
machine allows the company to make any

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

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

PRODUCT SHOWCASE
PVC-Coated Sealing Locknut trical system it contains and to prevent

The polyvinyl chloride (PVC) coated con- corrosion from sabotaging the system’s
duit division of Plasti-Bond (Gilmer, structural integrity. One of the most com-
Texas) released its new PVC-Coated Seal- mon exposure areas are the threads of
ing Locknut to protect conduit systems conduit connections into outlet boxes,
against water, oils, and other liquids. The conduit bodies, and other fittings. To pre-
primary function of a PVC-coated conduit vent thread exposure, the company devel-
system is to maximize the life of the elec- oped a simple, detachable sleeve that pro-
vides a consistent seal over exposed

conduit threads at the point of connec-
tion. Other features of the patent-pending
locknut include a built-in gasket, extra-
thin construction, and a simple design to
allow for easy installation and tightening
over conduit threads at joints throughout
the system. Tel: +1 903-843-5591, web site:
www.plastibond.com.
Portable Flaw Detector

for Difficult Inspections
GET BETTER PERFORMANCE

FROM THERMAL INSULATION
Nondestructive testing (NDT) technolo-
gies group Olympus (Waltham, Massachu-
setts) announced the launch of its EPOCH
6LT flaw detector, designed to meet the
ULTRA-LOW RESISTS CORROSION WORKSITE SAFETY CONDENSATION HIGHER BUILD & requirements of challenging ultrasonic
HEAT TRANSFER UNDER INSULATION & PROTECTION CONTROL FASTER APPLICATION
inspections. Optimized for single-handed
operation, the flaw detector combines an
ergonomic design with powerful ultra-
AEROLON’S ADVANTAGES
sonic functionality in an instrument built
for rope access and high portability appli-
STAND OUT FROM THE REST cations, such as inspections of offshore oil
platforms, in-service wind turbines, avia-
tion, bridges, and structural steel. Addi-
Aerolon® thermal insulating coating from tional key features include hands-free
Tnemec has raised the level of performance for operation; easy navigation; a strong resis-
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FEATURE ARTICLE
Protecting Concrete
Infrastructure from
Corrosion
Corrosion of Steel in Concrete Can Be
Accelerated in Harsh Environments—Such
as Coastal, Tropical, or Desert—with High
Salt Levels and/or Extreme Temperatures
Wesley Fawaz, Executive Officer, Australasian Corrosion Association
C
Corrosion continues to impose a massive cost on as- managers who operate and maintain concrete infra-
set owners and industry. NACE International reports structure face different corrosion challenges depend-
the global cost of corrosion is estimated to be US$2.5 ing on the industry sector in which they operate. The
trillion, which is equivalent to 3.4% of the global concrete degradation in the football pitch-size stor-
gross domestic product (as reported in 2016). By age sheds operated by Queensland Sugar Limited
using available corrosion control practices, it is esti- (QSL) (Brisbane, Queensland, Australia) differs from
mated that savings of between 15 and 35% of the cost that of the bridges maintained by VicRoads (Kew,
of corrosion could be realized (i.e., between US$375 Victoria, Australia).
and $875 billion annually) on a global basis.1 Harsh environments—especially coastal, tropical,
As concrete infrastructure ages, owners and oper- or desert with high salt levels and/or extreme temper-
ators are being challenged to find better ways to atures—can accelerate the rate of corrosion of steel in
maintain the integrity of their assets. Factors that concrete. Usually the most exposed elements deterio-
need to be considered include how long the asset is rate first, although it can take from five to 15 years for
expected to remain in operation and if a shorter ser- the effects of reinforcing steel corrosion to become
vice life is acceptable if maintenance must be fre- visibly noticeable.
quently repeated. Corrosion prevention needs to be Alkaline (high pH) conditions in concrete form a
cost effective as well as practical. passive film on the surface of the steel reinforcing
Monitoring the impact of corrosion on concrete bars that prevents or minimizes corrosion. The pas-
infrastructure such as storage sheds, wharves, and sivity provided to steel reinforcement by the alkaline
bridges is a critical aspect of ensuring structural environment of concrete may be lost if the pH of the
integrity and durability performance. A key way to concrete pore solution falls because of carbonation or
minimize corrosion is to design for durability and if aggressive ions such as chlorides penetrate the con-
employ the most appropriate technologies and pre- crete in sufficient concentration to reach the steel
vention techniques available. reinforcement surface. Carbonation of concrete
Corrosion of concrete-reinforcing steel is a world- occurs as a result of atmospheric carbon dioxide
wide problem that causes a range of economic, aes- (CO2), atmospheric sulfur oxide (SOx), and nitrogen
thetic, and utilization issues. Asset owners and oxide (NOx) gases neutralizing the concrete pore

Monitoring concrete structures such as bridges, jetties, and piers in Australia’s coastal environments detects conditions such as chloride ingress that can speed up
corrosion of reinforcing steel.

FEATURE ARTICLE
the state that face degradation from a enable appropriate corrective measures to
range of sources. be taken,” Andrews-Phaedonos says.
“Current estimates suggest that a pro- The traditional method of concrete
portion of Australia’s bridges are structur- repair is to remove the cracked, delami-
ally or functionally deficient and require nated, and spalling concrete to a depth of
major rehabilitation, strengthening, 20 to 30 mm behind the reinforcing bars to
improvement, or replacement to bring fully expose the rusted material and remove
them to current design standards,” the contaminated concrete from the steel.
Andrews-Phaedonos says. “The iconic West Once the corrosion-affected material is
Gate Bridge carries massive loads in addi- taken out, the steel is either treated or
tion to being subject to high winds and salt replaced and then special concrete repair
spray,” he adds. mortars are applied and the surface refin-
QSL operates and maintains a range of ished. Polymer-modified repair mortars are
assets, the major ones being its storage a modern development that improves
sheds and wharves where raw sugar is adhesion and resists further ingress of con-
loaded onto ships. According to David taminants. Coatings are commonly used in
Edelman, project engineer at QSL, the com- combination with patch repairs to reduce
pany’s massive storage sheds—some of further entry of chlorides or CO2.
which are 45-m (148-ft) wide and 400-m
(1,312-ft) long—also face a slow-acting but “Without a proactive
pervasive threat.
Raw sugar is poured onto the concrete floor of “Sugar makes a mildly acidic solution approach, the first sign of a
that can slowly eat away at the concrete
a QSL bulk sugar storage shed. Photo
courtesy of ACA. floors and walls of the sheds,” Edelman
problem with a structure is
says. “This damage leads to a potholed, typically when a piece of
uneven surface and breaking of the con-
water (lowering its pH to 9) and thereby crete at joints, which adds to the difficulty
concrete falls off due
destroying the passive film. Leaching of cal- of washing the floors in addition to present- to corrosion.”
cium hydroxide [Ca(OH)2] as well as ing hazards to workers. The sugar forms a
sodium hydroxide (NaOH) and potassium sticky, unsafe coating that builds up over Edelman comments that when the QSL
hydroxide (KOH) from concrete also lowers time and makes work inside the sheds diffi- jetty at Lucinda was built, an alkali-silica
pH to cause corrosion of steel reinforce- cult, meaning the floors have to be washed reaction later developed, which caused
ment. Stray electrical currents, most com- periodically.” concrete cracking. Chlorides then pene-
monly from electrified traction systems, To minimize the damage caused by the trated the concrete and caused premature
can also break down the passive film and sugar attack, the walls and floors of the corrosion of the reinforcing steel on parts of
cause corrosion of steel-reinforced and pre- company’s storage sheds are coated with a the structure. Where parts of the structure
stressed concrete elements. sealer. Deeper holes and cracks are filled were highly exposed, this corrosion caused
As reinforcing bars rust, the corrosion with epoxy, and joints are maintained to extensive damage and elements had to be
products increase the volume of the steel— prevent sugar attacking deeper into the repaired or replaced. However, in large sec-
up to six times its original size—and put slabs. In addition to this chemical attack, tions of the jetty structure, the chlorides in
increasing pressure on the surrounding the continual operation of large, front-end the concrete have not yet reached a concen-
material, which slowly cracks the concrete. loaders moving hundreds of thousands of tration where corrosion is initiated.
Over the course of several years, the cracks tons of raw sugar through the sheds and “The chloride concentrations have been
eventually appear on the surface and the onto conveyor belts and ship loaders dam- monitored over many years and they are
concrete starts to flake off or spall. ages the concrete surfaces. slowly increasing,” Edelman says. To coun-
Inspections of the many concrete cul- Similar to VicRoads’ coastal concrete ter this, QSL started applying an impregnat-
verts and low road bridges along the hun- structures, QSL’s port assets also degrade in ing silane coating to the underside of the
dreds of kilometers of country highways the aggressive maritime environment. For 5.7-km (3.5-mi) long jetty to prevent further
in Australia have shown that their effec- QSL, this is exacerbated by its location in ingress of chlorides. “By putting this rela-
tive operational life is being reduced as the tropics as well. The wharves and associ- tively inexpensive protection in place now,
the size of interstate road trucks ated infrastructure at Lucinda, Bundaberg, we can extend the life of the structure,”
increases. Many structures were designed and Cairns in Queensland are all under states Edelman. “If we wait another 10 or
for vehicles half the size and weight of threat of chloride attack in addition to 15 years, the chlorides levels will have
modern trucks. Fred Andrews-Phaedonos, damage from tropical storms and cyclones. increased, corrosion will have started, and
principal engineer—concrete technology “Correct interpretation of observations it will be too late. The square-meter cost of
at VicRoads, says the government road and testing is essential to a correct diagno- a simple protective coating like silane is as
authority has a range of assets throughout sis and prognosis of the problem, and thus little as one hundredth of the cost of a con-

Protecting Concrete Infrastructure from Corrosion
Installation of the CP system at QSL’s Lucinda wharf includes drilling holes in the concrete (left) and inserting anodes (right). Photos courtesy of ACA.
crete patch repair, but it is only effective are beginning to crack and fail after less tems with proper installation can achieve a
before corrosion starts.” than 10 years.” One of the limitations of 30-year or longer operational life.
Monitoring chloride levels through core patch repair is that it is often necessary to One of the QSL conveyor tunnels has an
sample testing allows a proactive approach. remove large quantities of sound concrete ICCP system installed, and the company is
All asset managers should know the chlo- to solve the problem, which causes exten- preparing to add the technology to a sec-
ride and carbonation profile of their con- sive disruption and can cost ~$3,000/m2. tion of the Lucinda jetty that is subject to
crete, particularly if that concrete is aging One of the alternative methods of pro- near-constant wetting from waves. “In this
and located in coastal environments. tection used on concrete, especially in section, chlorides have reached a level
“Without a proactive approach, the first marine environments, is cathodic protec- where corrosion has begun and some spall-
sign of a problem with a structure is typi- tion (CP). One type, impressed current CP ing has occurred,” Edelman states.
cally when a piece of concrete falls off due (ICCP), mitigates corrosion by passing a “Cathodic protection is a more cost-effec-
to corrosion,” says Edelman. “At that point small, permanent current through the con- tive option compared to allowing the corro-
it may be too late for a coating to protect crete to the reinforcing steel. Electrical sion to continue and having to carry out
the remainder of the structure, and you cabling and a permanent direct current constant repairs.” He adds that there will be
may be up for some very large repair bills.” (DC) power supply are required. Anodes are long-term cost savings that help with the
Several of QSL’s assets have experienced inserted into the concrete at set spacing total annual spend for concrete repair and
significant corrosion and spalling of con- and electrically attached to the positive ter- protection, which is ~$1 million across the
crete over the years due to chloride ingress. minal of a DC power supply (transformer/ six terminals.
Traditional patch repair has been used, rectifier). The negative terminal is electri- During the past 30 years, much
with replacement of corroded reinforce- cally connected to the reinforcing steel. The research has been done on replacing some
ment in many cases, but results have been CP current passivates the steel reinforce- of the Portland cement used in concrete
inconsistent. “We have some patch repairs ment and restores an alkaline (high pH) with alternative binders such as fly ash,
that are pushing 30-years old and remain in environment in the concrete around the blast furnace slag, silica fume, polymers,
great condition,” Edelman says, “but others steel reinforcement. Well-designed CP sys- recycled car tires, and fibers. One area of

FEATURE ARTICLE
research is in the field of geopolymer con- mation on all the latest technologies that
crete that utilizes alkali-activated binding yield a suite of proactive and reactive pro-
agents. Some of this research has been cesses and procedures to maximize the
published through the Australasian Corro- effectiveness of reinforced and prestressed
sion Association, Inc. (ACA) (Kerrimuir, concrete. “If you have all the appropriate
Victoria, Australia). Fly ash is a by-product specialists involved at the design stage, it is
from burning coal at a power station, and very possible to have a design life of 100
incorporating fibers into a concrete mix is years or more,” says NACE International
similar to the old practice of adding horse member Warren Green, a partner and cor-
hair to wet plaster. rosion engineer at Vinsi Partners Consult-
The enhanced characteristics of fiber- ing Engineers (North Ryde, New South Scaffolding for concrete repair works is
reinforced polymer (FRP) concrete include Wales, Australia). erected around a mooring dolphin at QSL’s
Cairns bulk sugar terminal. Photo courtesy of
increased flexural and shear capacity of By incorporating the byproducts of
ACA.
beams and slabs, says Andrews-Phaedonos. other processes into the concrete mix, it
FRP concrete is now regularly specified by has been possible for different types of con-
VicRoads for repairing and strengthening crete to qualify for “Green Star” credits—an stressed concrete panels, under factory
works. “The material is thinner, lighter, internationally known sustainability rating conditions, permits a far greater degree of
noncorrosive, and easier and quicker to system that recognizes reductions in green- quality control. “Advances in admixtures
install,” he comments. “It also has increased house gas emissions, resource use, and means that we can build almost anything
axial load, bending, shear, and confinement waste. In addition to new materials being out of concrete these days,” Green notes.
capacities.” incorporated into the concrete mix, other “The Australian standards for concrete
Research into concrete additives has additives have created self-compacting and work give basic guidance for normal situa-
provided construction companies and engi- self-leveling concrete that can save both tions, but in aggressive environments such
neering consultancies with access to infor- time and cost. Off-site construction of pre- as tropical, coastal, acid-sulfate soils, etc.,
a structure will not necessarily achieve its
design life if simply designed and con-
NACE NEW ORLEANS SECTION

structed to comply with the standards,”
says Green. To complement the standards
(e.g., AS 51002) and support designing for
19TH ANNUAL EDUCATION WEEK maximum durability in specific situations,
the Concrete Institute of Australia (North
DECEMBER 4-9, 2017 • NEW ORLEANS AIRPORT HILTON Sydney, New South Wales, Australia) is
nace.org/nolaedu to register for NACE Section Local Courses developing a range of recommended prac-
tice guidelines. “VicRoads was the first
NACE NEW ORLEANS SECTION COURSES DATES PRICE INSTRUCTOR
state road authority in Australia to publish
Corrosion in Oil and Gas Production (COG) December 4-6 $400 Charlie Speed, Consultant standard specifications for concrete main-
Corrosion Under Insulation (CUI) December 4-6 $500 Peter Bock, CUI Consultant tenance work and has made a significant
contribution to the preparation of stan-
Rectifier School (RS) December 4-5 $250 Jim Bradford, Corrpro
dards such as 5100, Part 8,” adds
Oilfield Operator Chemical School (OOCS) December 7-8 $300 Charlie Speed & 15 Other Experts Andrews-Phaedonos.
The ACA is a membership association
GENERAL NACE EDUCATION COURSES DATES PRICE NACE CERTIFIED INSTRUCTORS
that works with industry and academia to
Basic Corrosion (BC) December 4-8 Raul Castillo P.E. research and disseminate information on
For pricing
Designing For Corrosion Control (DCC) December 4-8 and to register Jerry Byrd corrosion and its prevention through the pro-
for these vision of training courses, seminars, confer-
Corrosion in Refining Industry (CCRI) December 4-8 NACE General Ray Quinter
Education ences, publications, and other activities.
Protective Coatings Specialist (PCS-1 BASIC) December 4-6 courses, go to Kat Coronado For more information, visit membership.
nace.org/ corrosion.com.au.
Protective Coatings Specialist (PCS-2 nolacourses
December 7-9 Kat Coronado
ADVANCED)
References
Students are responsible for hotel reservations. Contact the New Orleans Airport Hilton at
+1 504-469-5000 or 1 800-445-8667 and ask for the NACE Event Rate Code: NAC. Room rate is $133/night. 1 G. Koch, et al., “International Measures of
Prevention, Application, and Economics of
Corrosion Technologies Study,” NACE Inter-
For pricing and to register for NACE General Education For questions, call Charlie Speed at +1 504-400-7878
courses, go to nace.org/nolacourses
national, March 1, 2016.
2 AS(/NZS) 5100:2017 Series, “Bridge design”
For information about New Orleans Section Events, (Sydney, NSW, Australia: Standards Australia,
go to nace.org/nola INTERNATIONAL
2017).

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CATHODIC PROTECTION
Coupons for Cathodic

Protection Evaluation of
Mixed-Metal Piping Systems
Douglas E. gilroy, Bechtel Oil, Gas and The measurement and interpretation tures that are within the influence of closely
Chemicals, Inc., Houston, Texas, USA of cathodic protection (CP) data in coupled impressed current anodes. These
plants or other complex facilities and other factors present inherent
present inherent challenges where challenges with regard to CP measure-
ments and the interpretation of data.
mixed metals are electrically continu-
Depending on the complexity and
ous within the protected structures’
nature of the facility and equipment, estab-
CP system. Often there is no attempt lishing and maintaining electrical isolation
to electrically isolate the buried steel can be impractical on networks of steel pip-
piping networks from other metals in ing systems within plants. Safety and prac-
the facility for safety and practical tical considerations are the key reasons for
considerations. Coupons can be used avoiding electrical isolation devices in clas-
to assist in the evaluation of CP levels sified areas, including the possibility for
on buried steel piping in mixed-metal arcing, reducing touch voltage hazards,
circuits; however, the present industry and minimizing the propensity for CP
practice of disconnecting the coupon downtime, since the failure of a single iso-
from the mixed-metal circuit to mea- lation device in a system can result in com-
plete loss of protection. In critical double
sure the potential and polarization,
containment piping systems, where fabri-
without other considerations, raises
cation requires 100% welded construction,
concerns because the instant discon- mechanical fittings often are not permit-
nect condition may not be a true rep- ted. In these situations, the CP system is
resentation of the protection status. designed to account for the mixed-metal
circuit, often using closely coupled
A
impressed current anodes that are distrib-
Although coupon usage has long been uted throughout the piping network.
recognized as a valuable tool for evaluating When coupons are used in this type of
cathodic protection (CP) conditions on system, the coupon is also within the zone
buried piping systems, their use in plants of influence of the anode gradients. Cou-
and other complex facilities can increase pon size and placement are critical for col-
confusion and raise additional questions lecting meaningful data. The coupon size is
on the CP status. Plant facilities frequently selected to match the surface area of a typi-
include extensive buried networks of bare cal coating holiday that is anticipated at a
conductors, including copper, steel-in- specific location, and proper coupon place-
concrete, mixed-metal circuits, different ment can reduce voltage drop errors. It is
fill materials, and protected buried struc- also important that the coupon be exposed

to the same local environment (including
any select fill or controlled density fill) that
is in contact with the pipe steel at coating
holiday(s). Accordingly, it is essential to
collect data at sufficient locations so they
are representative of conditions through-
out the facility.
Coupons are commonly used when the
CP current sources cannot be interrupted;
thus, the “current applied—coupon discon-
nected” (Vc-a-d) is frequently the accepted
measurement. However, the voltage drop
(sometimes called IR drop) in the measure-
ment can be significant when the coupon is
located within the gradient of closely cou-
pled anode systems. Further, the discon-
nected coupon potential may not be repre-
sentative of the normal piping condition in
a mixed-metal circuit. When it is possible FIGURE 1 Coupon-to-soil potentials (vs. CSE) in a mixed-metal circuit.
to interrupt the impressed current CP
sources for buried piping, coupon “on” and technically correct, and during current ing the cycle. It includes four coupon-to-
“off ” potentials can be measured while con- interruption, secondary voltage drops from electrolyte potentials, as described in
nected and disconnected. circulating galvanic currents can cause NACE SP0104-2014:
The literature on coupons is extensive; errors in the measurements on structures • Current applied—coupon connected
however, many questions arise on their with characteristic potentials that can vary (Vc-a-c)
proper use when evaluating the CP status widely. A suggested approach is to acquire • Current applied—coupon discon-
of buried piping in a mixed-metal circuit: these measurements while locally disconnected (Vc-a-d)
• Is the coupon instant-disconnect necting the coupon from the structure. The • Current interrupted—coupon con-
potential measurement an accurate question remains whether the disconnected (Vc-i-c)
representation? nected coupon’s potential measurement is • Current interrupted—coupon dis-
• How can the 100 mV polarization CP a true representation of the actual mixed- connected (Vc-i-d)
criterion be used to satisfy NACE metal circuit condition. As shown in Figure 1, the potential of a
International SP0169-2013?1 Simultaneous interruption of all con- CS coupon can become more negative
• Is it appropriate to leave the CP sys- nections between the carbon steel (CS) when it is disconnected from CS piping
tem energized during the coupon piping and the bare copper grounding con- that remains connected to bare copper.
instant-disconnect potential mea- ductors (not a realistic concept) would not When this behavior is observed, it suggests
surement? be a valid representation of the CS piping a greater accuracy concern as compared to
• How can coupon current measure- condition when in the mixed-metal circuit. the impact of secondary voltage drops from
ments be used to evaluate CP status? The pipe-to-soil potential would be circulating currents during CP current
• Are other CP criteria appropriate for expected to become more negative when interruption. The Vc-i-c potential repre-
the location? the more noble metal (i.e., copper) is dis- sents the coupon’s mixed-metal circuit
connected. Depending on the level of polarized potential and is considered to be
Instant-Disconnect polarization of the mixed-metal circuit, a necessary measurement for CP evalua-
Potential Measurements similar behavior can be seen on a coupon tion. The current applied and interrupted
NACE SP0104-2014,2 Section 3.11, dis- when it is disconnected. instant-disconnect potentials are also con-
cusses the use of coupons in complex pip- Figure 1 is a plot of coupon-to-soil sidered to be required measurements. The
ing environments where mixed metals are potentials in a mixed-metal circuit that native and disconnected depolarized
electrically continuous with the protected includes bare copper grounding conduc- potentials are also important.
piping. NACE Publication 35201 3 also tors and a closely coupled anode system.
addresses the use of coupons in detail, stat- These potentials were measured with the 100 mV Criterion
ing that the application of polarized poten- rectifiers cycling on and off, and with the In complex facilities, the use of alter-
tial or polarization criteria is not always coupon connected and disconnected dur- nate protection criteria may be advanta-

CATHODIC PROTECTION
geous, including the 100 mV polarization polarized potential; or, by allowing the cou- was more positive than –850 mV vs. CSE,
criterion. Correct interpretation in mixed- pon to fully depolarize, reestablish its OCP the 100 mV criterion can be evaluated by
metal circuits, however, is critical. Simply for comparison to the coupon’s mixed- comparing Vc-i-c to the OCP of the coupon.
measuring depolarization from the mixed- metal polarized potential. If the fully depo- The coupon’s native potential that was
metal polarized potential could result in an larized disconnected coupon potential is established before it was connected to the
improper conclusion that CP is effective if desired, the CP system may have to be de- mixed-metal circuit can be referenced as
this is 100 mV or more. Would this indicate energized for a prolonged time period the OCP for evaluating the degree of polar-
protection if the mixed-metal polarized where coupons are in the zone of influence ization during the initial application of CP.
potential is more positive than the open- of closely coupled anodes. The CP system While this value also could be used for sub-
circuit potential (OCP) of the CS pipe? For for CS piping in mixed-metallic circuits as sequent evaluations in the mixed-metal
example, if the mixed-metal polarized described here should continue to be ener- circuit case, it is recognized that the depo-
potential is –450 mV vs. a copper/copper gized to the greatest extent possible to larized potential can differ from the native
sulfate reference electrode (CSE) and the avoid accelerated corrosion at coating potential after CP has been applied. Using
mixed-metal depolarized potential is –350 defects on the piping because of the gal- the native potential is usually preferable to
mV vs. CSE, can it be concluded that the CS vanic couple to a massive cathode (i.e., bare de-energizing the CP system for a long
is protected if its OCP is more negative copper grounding network). duration that is sometimes necessary to
than –450 mV vs. CSE?4 measure the fully depolarized potential.
NACE SP0169-2013, Section 6.3.4, states, Voltage Drop
“In mixed-metal piping systems, CP can be The reference electrode should be Coupon Current
typically achieved at a polarized potential located as close to the coupon as is practi- A shunt with a known resistance can be
that is 100 mV more negative than the OCP cal, as described in NACE SP0104-2014, to installed in series with a coupon to deter-
of the most active metal.” Coupons can be minimize voltage drop error in the poten- mine the current magnitude and direction.
used to meet the intent of this standard by tial measurements. A coupon within the With the CP system energized, direct cur-
showing that the coupon’s mixed-metal zone of influence of an energized anode, as rent (DC) pickup can provide an important
polarized potential is 100 mV more negative is the case with closely coupled anodes, can indication of CP effectiveness at that loca-
than the OCP of the coupon. show influence from the CP system regard- tion. Protective current density can be esti-
NACE/ASTM G193-12D5 defines OCP as less of whether the coupon is connected or mated from the surface area of the coupon,
the corrosion potential—the potential of a disconnected. SP0104-2014 recognizes that however, in mixed-metal circuits with the
corroding surface in an electrolyte mea- current-applied coupon potential measure- attempt to satisfy the –850 mV CSE polar-
sured under open-circuit conditions rela- ments can include voltage drop error. In ized criterion, the observed current densi-
tive to a reference electrode (also known as this standard, “Appendix D, Coupon IR- ties can be orders of magnitude greater
electrochemical corrosion potential, free Drop Calculation Procedure” provides a than typical design CP current densities for
corrosion potential, and OCP). Typically, method to identify voltage drop error. bare CS. Current discharge from a coupon
native potentials are not measured on bur- The most common measurements are is an indication that protection is lacking
ied steel piping in plants prior to mechani- Vc-a-c and Vc-a-d. According to NACE and corrosion may be occurring at that
cal completion. Where electrical isolation SP0104-2014, in mixed-metal circuits, and location.
is not established, native potentials mea- where the voltage drop may be significant, An indication of current pickup during
sured after mechanical completion and Vc-i-c and Vc-i-d also should be measured. the “off ” portion of the rectifier cycle does
prior to applying CP are representative of The difference between Vc-a-d and Vc-i-d is not necessarily imply that CP is effective, as
the mixed-metal native state and are not the coupon voltage drop (Vc-IR). circulating currents can imply corrosion on
considered to be the OCP of the most active the piping at other locations. Currents mea-
metal. However, a native potential on a Potential Measurement sured during the off cycle also confirm the
coupon can be measured before it is con- Evaluation caution in NACE SP0104-2014. The differ-
nected to the mixed-metal circuit (after In Figure 1, Vc-a-d and Vc-i-d are more ence between the “on” and “off ” mV drops
sufficient aging and before initial CP is negative than the Vc-i-c (i.e., the mixed- across the shunt determines the net current
applied). Upon the application of CP, this metal polarized potential). In this case, on the coupon. The polarities are important
measurement provides a baseline to refer- Vc-i-d is 277 mV more negative than Vc-i-c to note in these measurements, as they indi-
ence the degree of cathodic polarization of and, therefore, not considered an accurate cate the direction of current flow.
the mixed-metal circuit. representation of the CS condition in the
After CP has been applied, the depolar- mixed-metal circuit. The same concern Conclusions
ized potential often differs from the initial applies for the Vc-a-d measurement. Vc-IR Coupon size, placement, and environ-
native coupon potential. Subsequent evalu- is ~–50 mV, which represents the voltage ment must be carefully considered to pro-
ations can identify whether the discon- drop error in the Vc-a-d measurement. vide data that are representative of struc-
nected coupon depolarizes 100 mV or more In Figure 1, Vc-i-c satisfies the polarized tural conditions at a variety of locations
positive than the coupon’s mixed-metal –850 mV CP criterion. However, if Vc-i-c throughout a facility.

Coupons for Cathodic Protection Evaluation of Mixed-Metal Piping Systems
Editor’s note: Learn more about cathodic

4 W.B. Holtsbaum, “Application and Misappli- protection (CP) for steel structures buried in
In mixed-metal circuits, the coupon’s
soil in this new Materials Performance
instant-disconnect potential alone might cation of the 100 mV Criterion for Cathodic quarterly special feature, “The Science Behind
not be representative of the actual mixed- Protection,” MP 42, 1 (2003): p. 30. It.” Now that you’ve read the MP article about
5 NACE/ASTM G193-12D, “Standard Termi- CP on mixed-metal circuits, explore the
metal condition.
science behind the corrosion problem, which
The Vc-i-c potential is considered a nology and Acronyms Relating to Corrosion”
is presented in these related CORROSION
required measurement to evaluate protec- (Houston, TX: NACE, 2013). articles:
tion status in mixed-metal circuits. D.A. Jones, “Analysis of Cathodic Protection
This article is based on CORROSION 2017
Measurements should be obtained with Criteria,” Corrosion 28, 11 (1972): pp. 421-
paper no. 8824, presented in New Orleans, 423. http://corrosionjournal.org/doi/
the coupon connected and disconnected,
Louisiana, USA. abs/10.5006/0010-9312-28.11.421.
and with th e current applied and
Y. Hosokawa, F. Kajiyama, Y. Nakamura,
interrupted. DOUGLAS E. GILROY is a principal “New Cathodic Protection Criteria
Voltage drops can be present in the engineer in the Materials Engineering Based on Direct and Alternating Cur-
Technology group at Bechtel Oil, Gas and rent Densities Measured Using Coupons
Vc-a-d measurements, especially in the
and Their Application to Modern Steel
case of closely coupled anode systems that Chemicals, Inc., Houston, Texas, USA. He Pipelines,” Corrosion 60, 3 (2004): pp. 304-
are common in plants. has 36 years of experience in onshore and 312. http://corrosionjournal.org/doi/
offshore CP design, installation, commis- abs/10.5006/1.3287735.
The 100 mV CP criterion in mixed-
sioning, and testing, and in pipeline AC G.K. Glass, “Technical Note: The 100-mV
metal circuits, referenced from the Vc-i-c Potential Decay Cathodic Protection
interference. He has a M.S. in materials
potential and the OCP of the CP coupon, Criterion,” Corrosion 55, 3 (1999): pp. 286-
engineering and is a NACE Corrosion
meets the intent of NACE SP0169-2013, 290. http://corrosionjournal.org/doi/
Specialist and CP Specialist, Fellow of the abs/10.5006/1.3283989.
Section 6.3.4. Institute of Corrosion, and a registered M.H. Peterson, “Principles and Criteria
CP response can differ in soils vs. areas Professional Engineer in Texas. He has for Cathodic Protection of Steel in Sea
backfilled with controlled density fill where been a member of NACE for 35 years. Water—A Review,” Corrosion 15, 9 (1959):
longer polarization and depolarization pp. 51-55. http://corrosionjournal.org/doi/
abs/10.5006/0010-9312-15.9.51.
durations may be observed.
CP current pickup during the Vc-a-c
condition can suggest effective protection
at that location, assuming no sources of
foreign interference currents are present.
Coupons should be allowed to age until
stable native potentials have been estab-
lished. Coupons should not be connected
to the mixed-metal circuit until their
native potential is established, and then
only when the CP system is ready to be
energized.
Acknowledgments
Acknowledgement is given to my col-
leagues within the Bechtel organization
who provided contributions to this article,
especially M. Fang, H. Acuna, and D. Chew.
References
1 NACE SP0169-2013, “Control of External
Corrosion on Underground or Submerged
Metallic Piping Systems” (Houston, TX:
NACE International, 2013).
2 NACE SP0104-2014, “The Use of Coupons for
Cathodic Protection Monitoring Applica-
tions” (Houston, TX: NACE, 2014).
3 NACE Publication 35201, “Technical Report
on the Application and Interpretation of
Data from External Coupons Used in the
Evaluation of Cathodically Protected Metal-
lic Structures” (Houston, TX: NACE, 2001).

COATINGS & LININGS
Plasma Electrolytic Oxidation

Coatings for Aluminum Alloys
y. Zhang, W. Fan, anD h.Q. Du, School Plasma electrolytic oxidation coatings oxidation—has attracted considerable
of Mechanical Engineering, Zhejiang were formed on aluminum alloys in an attention as a surface treatment technol-
Industry Polytechnic College, Shaoxing, ogy for forming ceramic coatings on the
inexpensive and convenient electro-
China surfaces of valve metals (Al, Mg, Ti, and
y.W. Zhao, Key Lab of E&M, Ministry of lyte. The effects of current density
their alloys).4-6 According to the report by
Education & Zhejiang Province, Zhejiang (CD) on corrosion resistance behavior
Li, et al.,7 the PEO process is a multifactor-
University of Technology, Hangzhou, of the coatings were studied by po-
China controlled process; and the properties of
tentiodynamic polarization and elec- PEO coatings can be influenced by factors
trochemical impedance spectroscopy such as electrolyte concentration,8 electri-
(EIS) tests. The results proved that the cal parameters, 9 and additives. 10 Many
coating produced with a CD of 10 investigations on these influencing factors,
A/dm2 showed the best anticorrosion especially additives, have been conducted
properties. The longtime EIS test in recent years so ideal coatings can be
showed that the 10 A/dm2 coating was obtained. It has been demonstrated that
capable of protecting the aluminum the presence of glycerin in the electrolyte
alloy substrate after immersion in a composition resulted in both a stable solu-
0.59-M sodium chloride (NaCl) solution and a dense, uniform coating without
any cracking. The glycerin additive was
tion, which was confirmed by the re-
also effective in enhancing the corrosion
sults of a 10-day salt solution immer-
resistance of the coating; however, this
sion test in a 2-M NaCl solution. study lacked of a full investigation on the
effect of current density (CD) on the corro-
A
sion properties of coatings formed in a
Aluminum and its alloys have been glycerin-containing alkaline electrolyte.
widely used in the aerospace and automo- In the present work, PEO of 6063 alumi-
tive industries due to their high specific num alloy (UNS A96063) was conducted in
strength, low density, good formability, and a phosphate-based electrolyte containing
nonmagnetic properties.1-2 Poor corrosion glycerin. Corrosion resistance was studied
resistance, however, greatly limits the by potentiodynamic polarization and elec-
application of aluminum alloys, particu- trochemical impedance spectroscopy (EIS)
larly the susceptibility to localized damage tests.
such as intergranular and pitting corrosion
caused by intermetallic constituent parti- Experimental Procedures
cles.3 Therefore, it is necessary to improve
the corrosion resistance of these alloys by Material and Plasma Electrolytic
surface treatments. Oxidation Treatment
Plasma electrolytic oxidation (PEO)— The substrate material used for the PEO
also referred as microarc oxidation (MAO), treatment, 6063 aluminum alloy, was com-
microplasma oxidation (MPO), and micro- prised of 0.45 to ~0.90 wt% Mg, 0.35 wt% Fe,
arc discharge oxidation (MADO) or anode 0.2 to ~0.6 wt% Si, 0.10 wt% Cu, 0.10 wt%

Mn, 0.10 wt% Cr, 0.10 wt% Zn, 0.10 wt% Ti,
and the balance Al. The 30- by 29- by 3-mm
commercially available Al alloy specimens
were ground with 1,800-grit abrasive paper,
ultrasonically degreased in pure ethanol,
cleaned in distilled water, and dried in hot
air. The electrolyte used in this study was
an aqueous solution consisting of 30 g/L of
sodium hexametaphosphate [(NaPO 3) 6],
3 g/L of potassium hydroxide (KOH), 8 g/L
of borax (Na2B4O7), and 15 g/L of glycerin in
distilled water.
The PEO device consisted of a 30-kW
bipolar pulsed power source, stainless steel
vessel, cooling system, and stirring system
to maintain the temperature below 303 °K
in all cases. To ensure proper electrical con-
tact, a 2-mm diameter threaded hole was
made in the center of the samples; and a
thin, externally threaded aluminum rod
was screwed into them. Coatings were pro-
duced after 25 min in the electrolyte at CDs
of 5, 10, 15, and 20 A/dm2. After the PEO FIGURE 1 Potentiodynamic polarization curves of uncoated and PEO-coated 6063 Al alloys in a
0.59-M NaCl solution. PEO coatings were obtained with a CD of 5, 10, 15, and 20 A/dm2.
treatment, each coated specimen was
immediately rinsed in distilled water and
dried in ambient air.
Potentiodynamic Polarization and

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

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

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

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

Plasma Electrolytic Oxidation Coatings for Aluminum Alloys
ing the corrosion resistance of the PEO A/dm 2. The photographs show the two 6 Y.W. Zhao, et al., “Improved Corrosion Resis-
coating. The coating formed with a CD of samples after a salt immersion test in a 2-M tance of Titanium Dioxide-Containing
10 A/dm2 exhibited the best anticorrosion NaCl aqueous solution for 10 days. Plasma Electrolytic Oxidation Ceramic Coat-
properties among these coatings. Although the surface of the uncoated 6063 ings,” MP 55, 11 (2016): pp. 36-39.
7 Q.B. Li, J. Liang, Q. Wang, “Plasma Electro-
aluminum alloy is almost completely cov-
lytic Oxidation Coatings on Lightweight
ered by corrosion products, the surface of
Electrochemical Impedance Metals,” Modern Surface Engineering Treat-
the PEO coating shows much less attack
Spectroscopy Analysis ments, M. Aliofkhazraei, ed. (Rijeka, Croatia:
after the 10-day immersion. No obvious InTech, Rijeka, 2013), pp. 75-99.
To understand the quantitative corro-
corrosion pits had developed on the sample 8 Y.L. Cheng, et al., Corros. Eng. Sci. Technol. 46
sion behavior of the PEO coating systems,
anodized in the electrolyte with a CD of (2011): pp. 17-23.
EIS tests were carried out to provide
10 A/dm2, confirming the improved corro- 9 R.O. Hussein, D.O. Northwood, X. Nie, Surf.
detailed information on the corrosion pro-
sion resistance of the PEO coating pro- Coat. Technol. 237 (2013): pp. 357-368.
cess at the electrolyte/electrode interface
duced under the CD of 10 A/dm2. 10 T.S. Lim, H.S. Ryu, S.H. Hong, Corros. Sci. 62
and the property changes of the electrode. (2012): pp. 104-111.
This is quite important for understanding 11 C.N. Cao, J.Q. Zhang, An Introduction to Elec-
the corrosion mechanism of the coating Conclusions trochemical Impedance Spectroscopy (Beijing,
system. 11 The Nyquist plots for the PEO- PEO coatings were fabricated under dif-
China: Science Press, 2002), p. 158.
coated 6063 aluminum alloy specimens are ferent CDs in a phosphate-based electro-
lyte with the addition of glycerine. The Y. ZHANG is a doctor at the School of
shown in Figure 2. The corresponding sim- Mechanical Engineering, Zhejiang Industry
ulated data are presented in Table 1, which effect of the application CD on corrosion
Polytechnic College, Shaoxing 312000,
shows the PEO treatment significantly properties of PEO coatings was studied. China. His research interests focus on
• The potentiodynamic polarization mechanical engineering and materials.
improved the corrosion resistance of the
bare alloy. The equivalent circuit model is test showed that the coating formed
W. FAN is a professor at the School of
shown in Figure 3 for analysis of the EIS with a CD of 10 A/dm 2 showed the Mechanical Engineering, Zhejiang Industry
best corrosion resistance among Polytechnic College, Shaoxing 312000,
results based on a reasonable fitting of the China.
experimental values. The capacitance these coatings.
behavior of the coatings and substrate can • EIS tests showed that the PEO coat- H.Q. DU is a professor at the School of
ing produced with a CD of 10 A/dm2 Mechanical Engineering, Zhejiang Industry
be better simulated by constant phase ele- Polytechnic College, Shaoxing 312000,
ment (CPE) modeling, which is represented was still able to protect the substrate
China.
by the symbol Q. The impedance formula after 72 h immersion in a 0.59-M NaCl
solution. This was confirmed by a Y.W. ZHAO is a professor at Key Lab of
for Q is described by Equation (1): E&M, Ministry of Education & Zhejiang
10-day immersion test in a 2-M NaCl
Province, Zhejiang University of Technol-
1 solution. ogy, Hangzhou, Zhejiang, China, email:
( jv)
–n
ZQ = [email protected]. Her research interests
Y0 (1) focus on mechanical engineering and
Acknowledgments materials. She is the author or coauthor of
The financial aid of Research on Public numerous journal publications and is a
In this equation, j is an imaginary unit member of NACE.
Welfare Technology Application Projects of
( j 2 = –1) and w is angular frequency
Zhejiang Province under grant no.
(w = 2pf ). The coefficient and the exponent
2017C31039, Shaoxing Research Project of
n (–1 ≤ n ≤ 1) are the parameters of CPE.
Public Welfare Technology Application
In the equivalent circuit presented in
Figure 3, R s stands for the solution resis-
under grant no. 2015B70005, and the Need reprints of MP ads,
National Natural Science Foundation of articles, or covers?
tance between the specimen and reference
China under grants no. 51275477 and
electrode; Rp is the resistance of the outer REPRINTS ARE A GREAT
61572438 are gratefully acknowledged.
porous layer (i.e., the resistance of defects INVESTMENT!
such as pores/cracks in the coating), which
References Professionally printed reprints and photo
is in parallel with a constant phase element copied reprints of all MP ads, articles, and
(Qp); and Rb denotes the inner barrier layer 1 L. Wen, et al., Corros. Sci. 52 (2010): pp. 2,687- covers are available for purchase. Reprints
2,696. can be customized with your company’s
resistance (including the resistance of the
2 H.Y. Ding, et al., Tribol. Int. 43 (2010): pp. 868- logo, additional product information, or
coating/substrate interface), which is in the magazine cover—with no limits on
875.
parallel with a constant phase element (Qb). creativity!
3 G. Bierwagen, et al., Prog. Org. Coat. 68 (2010):
pp. 48-61.
Corrosion Morphology 4 H. Fadaee, M. Javidi, J. Alloys Comp. 604
Figure 4 shows the corrosion morphol- Order your reprints today; it simply makes good
(2014): pp. 36-42.
business sense! For reprint information and
ogy of the uncoated specimen and a PEO 5 T.S. Lim, H.S. Ryu, S.H. Hong, Corros. Sci. 62 rates, call +1 2812286287.
coating sample formed with a CD of 10 (2012): pp. 104-111.

COATINGS & LININGS
Hydrogen Sulfide Tube Failure

in a Seawater Heat Exchanger
hanan Farhat, College of the North Severe tube damage was discovered Inspection History
Atlantic-Qatar, Doha, Qatar in a heat exchanger in which tubes In February 2014, the HX experienced
roy JohnsEn, Norwegian University of
made from 90/10 CuNi (UNS C70600) abnormal operation caused by a backflow
Science and Technology, Trondheim,
had thinned and collapsed. The main of propane due to leaks in some of the
Norway
cause of the failure was severe tube tubes. The tube bundle was not removed
thinning due to hydrogen sulfide and the tube conditions were not inspected.
(H2S) corrosion. Sulfur was introduced The hydrostatic pressure test was reduced
to 5.0 MPa during this inspection due to
into the shell side of the exchanger
loud noise and other tube leaks. A total of
through a diisopropanolamine solu-
34 tubes were plugged. Minor leaks were
tion carrying more than the allowable noticed after commissioning, and the oper-
percentage of H2S over a long time ator reduced the shell side pressure to 3.0
period. MPa to avoid more leaks.
In April 2014, the HX failed to operate.
D
The block valve was closed and the shell fluid
Diisopropanolamine (ADIP) is used to (lean ADIP) was drained. The tube bundle
reduce hydrogen sulfide (H 2S) in natural was pulled out to visually inspect the condi-
gas to low concentrations. Lean ADIP is a tion of the tubes. The tubes were severely
25 wt% solution of diisopropanolamine in damaged and discolored with dark black
desalinated water. The heat exchanger corrosion scale. A number of tubes were
(HX) is used to cool the lean ADIP after the compressed, similar to a drinking straw with
regeneration process. The lean ADIP is in the end closed and the air sucked out.
the shell side and exchanges heat with During the failure investigation, several
chlorinated seawater in the tube side of the inspection reports from 2009 to 2014 were
HX. The highest operating inlet tempera- found that described the leaking and plug-
ture and pressure of the shell side (lean ging of the tubes.
ADIP) were 75 °C and 5.3 MPa, respectively.
The maximum operating outlet tempera- Failure Investigation
ture and pressure of the tube side (chlori-
nated seawater) were 42 °C and 0.52 MPa, Visual Inspection
respectively. During inspection of the HX, it was
The HX was manufactured in 1977 with noted that blocked tubes were damaged in
the shell made from carbon steel and the the form of both compression and elonga-
tubes made from aluminum brass. The tion. All the plugged tubes were found com-
tubes were replaced with 90/10 CuNi (UNS pressed. The damage seemed to be located
C70600) in 1994. near the ADIP inlet in the third and fourth
The total number of tubes was 1,248— passes.
each had a diameter of 19.05 ± 0.1 mm, wall One tube was split into two parts. A
thickness of 1.63 ±0.13 mm, and average thick black corrosion scale covered the sur-
length of 4,877 mm. face. The corrosion scale had poor adhe-

FIGURE 1 A micrograph of the control sample shows the typical FIGURE 2 The microstructure of a compressed tube shows no evidence of
microstructure of 90/10 CuNi alloy. grain growth. A porous black film is shown on the outer surface.
sion and was flaking off. External discolor- 50-mL hydrochloric acid (HCl), and 100-mL calcium. The test results for all of the sam-
ation of the tubes, which was yellow, blue, water for 3 s. The micrograph of the control ples were the same, with various amounts
light reddish brown, and white, was sample (Figure 1) reveals the microstruc- of sulfur in the external corrosion scale in
observed. ture of a typical 90/10 CuNi alloy with the range of 22 wt%.
Nine tube samples from different passes twinned grains of alpha copper and an A qualitative x-ray diffraction (XRD),
were selected for examination. Each tube average grain size of 25 µm. Similar micro- shown in Figure 5, revealed two copper-
sample was cross sectioned into three sam- structure can be seen in the damaged sam- sulfur components: copper sulfide (Cu1.8S),
ples: 1) tube start, 2) tube middle, and 3) ple in Figure 2. No variation in the grain which is indigo-blue or darker, and typi-
tube outlet. In addition, three reference size was observed, indicating that the tubes cally highly irridescent with brass-yellow to
samples from an unexposed tube were were not exposed to high temperatures deep red color; and djurleite (Cu 31S 16), a
examined. that would result in grain growth. Figure 3 copper sulfide compound that is gray, blue-
shows the microstructure of the corrosion black, or black in color. Similar colors of
Measurements scale on a damaged sample. The scale has these sulfides were noticed on the tubes
The outside diameter (OD) and inside multiple brittle layers that are full of voids during visual inspection. The relative
diameter (ID) of each sample were mea- and cracks. The scale’s thickness varies amounts were 11% Cu1.8S and 89% Cu31S16.
sured to identify any external or internal within the same sample.
corrosion. In the same sample, it was found Discussion
that the wall thickness could vary. Three Surface Characterization The corrosion behavior of the 90/10
measurements were taken and the average The samples were observed under scan- CuNi alloys depends on the presence of
was calculated. The measurements did not ning electron microscopy (SEM), and oxygen and other oxidizers in the system.
show any obvious reduction in the ID (i.e., energy-dispersive x-ray analysis (EDXA) During the primary corrosion reaction, an
no internal corrosion), while the OD mea- was performed. Three main areas were adherent, protective cuprous oxide film
surements showed large reductions (i.e., checked: 1) external corrosion scale, 2) (Cu2O) is formed on the alloy surface. The
external corrosion). In some of the col- internal corrosion scale, and 3) the area in corrosion resistance of the alloy in sea-
lapsed samples, the wall thickness was as between. water is determined by this naturally
low as 0.42 mm, which was ~25% of the Consistency was seen in the results occurring protective film, which reacts
original wall thickness. from the three analyzed areas on each sam- with compounds in seawater and builds a
ple. The external corrosion scale showed multilayered oxide structure. For the corro-
Metallographic Examination high concentrations of sulfur, as illustrated sion reaction to proceed, copper ions and
The microstructure of the samples was in Figure 4; the center of the sample showed electrons must migrate through the Cu2O
documented. The samples were etched in a typical 90/10 CuNi alloy content; while the film.1-3
solution of 5-g ferric chloride (FeCl 3 ), internal corrosion scale had evidence of To achieve adequate corrosion resis-

COATINGS & LININGS
in enhanced probability of corrosion and

erosion attack.1 H2S content in the range of
200 to 300 ppm wt% in lean ADIP was mea-
sured during a six month period in 2014.
The outcome of the investigation can be
summarized as:
• Severe tube thinning.
• Dominant external corrosion.
• Formation of a poorly adherent,
thick, multilayered black corrosion
film with voids and cracks on the
external surface.
• No change in metallographic micro-
FIGURE 3 The external corrosion scale in a damaged sample has multiple layers that are full of structure and grain size between an
voids. unused and used tube.
• High concentration of sulfur in the
external corrosion film. XRD showed
two sulfate components (Cu1.8S and
Cu31S16).
• H2S content in the range of 200 to 300
ppm wt% measured in the lean ADIP.
• The internal scale consisted mainly
of calcium (typical for seawater).
These findings led to the conclusion
that corrosion caused by H 2S is the root
cause of the failure. H2S corrosion is a form
FIGURE 4 The EDXA spectrum of the external corrosion scale on a damaged sample shows a high of sulfidation that results in loss of wall
concentration of sulfur.
thickness and serious corrosion on the
external surface of the tubes. It is usually
accompanied by the formation of a sulfide
scale. The scale is about five times the vol-
ume of lost metal and may occur in multi-
ple layers. 5 Sulfide attack of CuNi alloys
typically leaves a porous nonprotective
black film on the surface. The film is poorly
adherent, and usually appears as patchy
deposits.3 Such a film can be seen in Figures
2 and 3.
The corrosion rate increased with tem-
perature and H 2S content.5 The tempera-
ture in a HX varied with the highest tem-
perature occurring during the fourth pass
(the last pass that gets cooled), followed by
the third pass, second pass, and first pass.
The severity of the damage was in the same
order, showing very severe damage in the
FIGURE 5 An XRD plot shows the results of the qualitative analysis of the external corrosion scale. fourth pass and the least severe corrosion
in the first pass.
The possible failure scenario is as fol-
tance in CuNi tubes that carry seawater, ing this protective layer is crucial for opti- lows: the Cu2O layer was previously formed
clean, oxygen-containing seawater can mum life of the tube material.4 when the tubes were installed in the
flow in the tubes for several hours, days, or In an environment containing H2S, the exchanger. The exchanger tubes were
weeks. This enables the formation of a pro- H2S reacts with Cu+ and produces a non- externally exposed to the lean ADIP aque-
tective layer that can be maintained for a protective black cuprous sulfide (Cu 2S), ous solution. No oxygen was present in the
long time period.1 Forming and maintain- which is poorly adherent, brittle, and results lean ADIP solution. During the life of the

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

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

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Application deadline for 2018 scholarships is January 1, 2018.
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COATINGS & LININGS ESSENTIALS
Investigation Indicates Osmotic inspected internally with a robotic crawler. locations the lining had peeled off adjacent
Blistering Caused Damage on The robotic inspection revealed lining to the joints. Initially, the cause of the lining
Jet Fuel Pipeline Lining damage on 35 of the flooded pipe segments. damage was thought to be caused by the
The damage included topcoat removal, ingress of water and mud, followed by the
bubbles and blisters, rust, and staining, cleaning operations. Testing and analysis
which varied at different locations within were implemented, however, to determine
the pipelines. Rust had formed on exposed the actual cause of the lining damage.
metal at the welded joints, and at some Continued on page 49
N
EW
In CORROSION 2017 paper no. 9061, “Inter-
nal Lining Damage Investigation of 24-inch
Jet Fuel Pipelines,” authors Mushaid
Nauman and David Eyre with Penspen (Sur-
Measures the concentration of soluble salts
rey, United Kingdom) discuss an investiga- on metal surfaces using the Bresle method
tion into the damage of the epoxy lining on
two 24-in (610-mm) diameter pipelines for
a new fuel hydrant system. The pipelines, n Displays test duration, sample
constructed as part of an airport expansion temperature, conductivity (µs/cm)
project, were externally coated with three- and surface density
layer polyethylene (3LPE) and internally n Easy 1-2-3 gage interface guides
lined with epoxy. The lining was applied to users through the Bresle method
ensure a clean pipeline so contamination of n Includes PosiSoft suite of software
the aviation fuel could be avoided. It was for viewing and reporting data
not intended to be an anticorrosion barrier
coating. Since heat shrink sleeves were to
be applied at the joints, the girth welds
were not lined during construction. The
lining was comprised of a two-coat amine-
cured, modified epoxy coating with high
solids content in both the primer and top-
coat (65% and 63% by volume, respectively).
The dry film thickness (DFT) for both coats
was in the range of 100 to150 µm. The mate-
Innovative PosiPatch
TM
rial data sheet for the coating material indi-

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

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resource for technical articles, in-depth topical reviews, and themed issues discussing
the most recent advances in corrosion prevention and control.
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ESSENTIALS
The mechanisms investigated as the

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

COATINGS & LININGS ESSENTIALS
interface. Here, the water encountered the open. This eventually results in the death of impulse technology is being integrated into
water-soluble material on the primer sur- the microorganisms. As the electric a new, automated, resource-efficient water
face, which was likely present due to expo- impulses impart a purely physical effect, management and plant concept for pre-
sure of the primer to moisture before the bacteria are not expected to develop resis- treatment and immersion painting. To learn
epoxy phenolic resin and amine hardener tances, as they do in the case of biocides. more, visit www.kit.edu.
had fully reacted. This indicates that the In the automotive industry, painting the Source: Karlsruhe Institute of Technology.
problem was caused by poor procedures vehicle body consumes the highest amount
during application of the topcoat. If the of water. For this reason, the electric
water-soluble materials were present on the
substrate beneath the primer, blistering and
delamination would have occurred at sub-
strate/primer interface. Records at the
T
plant that applied the lining indicated that ATABLE ·
PE
RE
F
conditions were not favorable over the
·
entire lining application period. Very low
ST
te
D
· FA
temperatures and high humidity conditions
re
nc
were observed.
co
BLE
Osmotic blistering is not expected if the
ure
on
RA
line is exposed only to aviation fuel, even
s
U
ea
with the presence of soluble material on the ·

A C C U R AT E
M
primer surface. Jet fuel transfer through the

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

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

CHEMICAL TREATMENT
Electrochemical Approach
for Screening Concrete
Corrosion Inhibitors
I-Wen Huang, Fred goodWIn, and To compare laboratory-synthesized The expansive stress induced by corrosion
Frank apIcella, BASF Construction materials for corrosion inhibition ca- product formation on the reinforcing steel
Chemicals, LLC, Beachwood, Ohio, USA can cause the concrete cover to crack and
pabilities, a new corrosion inhibitor as-
sessment methodology was intro- spall, which can cause hazardous conse-
quences such as structural failure.
duced that accounts for the onset of
One approach to protect steel from cor-
corrosion inhibition during incubation
rosion is to incorporate corrosion inhibi-
time, which often is ignored when a tors: as admixtures within the freshly
single corrosion measurement proce- placed concrete or a surface treatment
dure is used. The robust analysis applied to existing concrete. The electro-
described in this article uses a combi- chemical evaluation of corrosion inhibitors
nation of open-circuit potential, elec- used in this manner is documented in for-
trochemical impedance spectros- mer studies and standards. 3-11 However,
copy, linear polarization, and there is a lack of protocols to rapidly evalu-
potentiodynamic polarization in simu- ate the effectiveness of a corrosion-inhibit-
lated pore solution. Combining these ing admixture with unknown corrosion
electrochemical tests provides a tech- inhibition performance.
Typically, corrosion inhibitors form a
nique to monitor the corrosion inhibi-
passive film on reinforcing steel that is
tion capability as a function of time.
inert to corrosion reactions. Since this pas-
The advantages and limitations are sive film formation occurs over time, any
also discussed in this article. testing method that ignores this time
dependence may not appropriately assess
C
and compare the effectiveness of inhibi-
Concrete is the second most common tors. In addition, traditional evaluation
man-made material after potable water. 1 techniques (e.g., mass loss, surface mor-
Nearly one cubic yard of concrete per phology imaging, etc.) require weeks or
person is placed per year. Assuming a even months (e.g., outdoor exposure) to
typical service life, up to 30 times this determine the effectiveness of a corrosion
amount of existing concrete is in various inhibitor. This is not practical for screening
states of deterioration.2 Reinforcing steel a number of inhibitors.
bars are installed in concrete to support The testing protocol described in this
tensile and flexural stresses for structural article combines the use of open-circuit
design requirements. However, reinforcing potential (OCP), electrochemical imped-
steel in concrete is susceptible to corrosion ance spectroscopy (EIS), linear polarization
due to the presence of chloride ions or resistance (LPR), and potentiodynamic
reduced pH in concrete from carbonation. polarization tests to provide a rapid assess-

ment of the effectiveness of inhibitors for
protecting reinforcing steel from corrosion
in the presence of simulated concrete pore
water solution containing added chlorides.
Experimental Procedures
Corrosion behavior of reinforcing steel
was simulated using UNS G10800 carbon
steel (CS) sheets polished sequentially with
400, 800, and 1,200 grit emery paper, fol-
lowed by cleaning with methanol, and then
air dried in a ventilation hood before test- FIGURE 1 OCP measurements. FIGURE 2 EIS-Nyquist plot after 1-h exposure.
ing. Simulated pore solution (pH 12.3) was
prepared by decanting water from a 2:1 (by
mass) water/Portland cement mixture. tests was determined by the destructive-
This solution was combined with 3 wt% ness—from nondestructive to destruc-
sodium chloride (NaCl) and 1 wt% corro- tive—to retrieve the most information.
sion inhibitor. There were five water-solu- The time requirements were 20 min for
ble corrosion inhibitors included in this OCP, ~40 min for EIS, 1 min for LPR, and 9
study, numbered 1 through 5, and one con- min for polarization. This did not include
trol specimen without inhibitor. the dwelling time between each measure-
ment. The time required may vary depend-
Electrochemical Tests ing on parameter settings and potentio-
A saturated calomel electrode (SCE) stats used.
was used as a reference electrode and plati-
num mesh was used as a counter electrode Results and Discussion FIGURE 3 EIS-Nyquist plot after 24-h
in a commercial flat cell. A 20-min OCP Tests of the solution pH after the elec- exposure with an enlarged scale in the inset.
measurement was conducted prior to EIS trochemical test indicated no significant
measurements to ensure electrochemical pH change (pH 11.7), suggesting that car-
Figures 2 and 3, respectively. A clear trend
stability. Two EIS measurements were then bonation and cathodic reactions such as an
of increasing corrosion inhibition was
made: the first started immediately after oxygen reduction reaction did not signifi-
found after the 24-h exposure. Corrosion
the OCP measurements at 100 kHz to 5 cantly affect the solution pH during the
Inhibitors 1 and 2 did not show any corro-
mHz in frequency, and the second EIS mea- 24-h test.
sion inhibition after the 1-h exposure, while
surement was made after 24 h to allow the
Inhibitor 1 exhibited the best corrosion
onset of passive film formation. A typical
Open Circuit Potential inhibition after 24 h. Since the measure-
10-mV (root mean square) voltage was
Figure 1 shows the OCP results, where ments are conducted on bare CS with cor-
applied in sinusoidal fluctuation. EIS
the OCP for each specimen was measured rosion inhibitors, the corrosion inhibition
results were modeled using a simplified
in the range between –0.48 to –0.38 V vs. is simulated by a simplified Randles circuit,
Randles circuit for quantitative polariza-
SCE in the specified solution. The control assuming the corrosion inhibition only
tion resistance (Rp) results. Afterward, LPR
test sample without inhibitor showed the developed through a gradual passive film
was also used for measuring Rp from –20 to
lowest OCP among all six measurements, formation. The simulation result of R p is
20 mV vs. OCP with a relatively fast scan
indicating the most active oxidation with- shown in Figure 4, which indicates that
rate (1 mV/s). The corrosion rate (icorr) was
out inhibitor at the onset. In general, the Inhibitor 1 outperformed other inhibitors,
then calculated using the Stern-Geary
OCP reading decreased with time, which and Inhibitor 5 was the least effective.
equation,12 shown in Equation (1):
could be due to the ongoing corrosion reac-
0.022 tions at early stages. Linear Polarization
i corr =
Rp Linear polarization results, as shown in
(1)
Electrochemical Impedance Figure 5, indicate very similar results when
Afterward, polarization tests were per- Spectroscopy compared to EIS. According to Equation
formed from –50 to +450 mV vs. OCP with The EIS measurements in Nyquist plots (1), the corrosion rate (i corr ) of CS can
the same scan rate as LPR. The sequence of after 1-h and 24-h exposures are shown in be calculated where R p is polarization

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

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

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

a Buried Drinking Water Pipe
ZHanjun guo, Institute of Environmental The surface corrosion layer of a steel corrosion usually occurs on the external
& Municipal Engineering, North China water pipe buried ~30 years in a soil surface of the pipe exposed to atmospheric
University of Water Resources and conditions.
environment was investigated by con-
Electric Power, Zhengzhou, China The interior of most steel drinking
ZHIlIang cHen, Yangzhou Research ventional and synchrotron x-ray dif-
water pipes used in domestic indoor envi-
Academy of Energy and Material, fraction (XRD). The results indicate the
ronments has a buildup of steel corrosion
Chinese Academy of Sciences, surface rust layer had entered a stable
Yangzhou, China products.3 The internal surface of the steel
state with a higher amount of goethite pipe exposed to aqueous conditions usually
(α-FeOOH) and a much lower amount suffers more severe corrosion than the
of lepidocrocite (γ-FeOOH). Because external surface of the pipe that is exposed
the synchrotron XRD technique pro- to indoor atmospheric conditions. In the
duces stronger and better-defined underground soil environment, however,
peaks, it has a great advantage over the steel drinking water pipe’s external sur-
conventional XRD in evaluating the face usually suffers much more serious cor-
stability of the steel rust layer in a soil rosion attack than the internal surface
environment. because soil is a much more corrosive envi-
ronment than the indoor atmosphere.3
Studies on steel corrosion in under-
S
Steel pipes have been employed in ground soil environments are typically car-
drinking water distribution systems for ried out by placing a standard steel speci-
over five centuries.1 As the thermodynami- men at a certain depth in the soil being
cally stable form of iron in contact with studied. 4 These studies are beneficial for
oxygen is ferric iron [Fe(III)], steel pipes investigating the corrosion effect of certain
can suffer from corrosion. This process soil compositions and illustrating the cor-
releases iron into solution or results in iron rosion mechanism of steel. Reports dis-
scales. Corrosion may uniformly attack a cussing in situ corrosion investigations of
steel pipe surface (general corrosion) or steel pipe surfaces are scarce due to the dif-
may be focused at specific sites (localized ficulty of conducting these tests in the field.
corrosion). While general corrosion results In the present study, the corrosion of
in the development of uniform scales, local- one steel potable water pipe after ~30 years
ized corrosion can produce pitting. The of soil exposure was investigated with
pipe lifespan can be determined by pitting attention focused on characterizing the
corrosion, which is closely related to the surface rust layer. This investigation has
environment surrounding the steel pipe, practical and theoretical importance. First,
the composition of the drinking water, the it provides field corrosion data on buried
bacteria activity under corrosion product steel water pipelines. Moreover, it provides
tubercles, and the flow of high-pressure reference data for other locations that face
drinking water inside the pipe. 2 Uniform similar issues.

Experimental Procedures
The steel drinking water pipe that is
part of the water distribution system in
Zhengzhou, China, is made of 16Mn carbon
steel. The water pipe has been buried for
~30 years.
The rust layer on the exterior surface of
the pipe was scraped off and ground to fine
powder in a mortar using a pestle, and then
characterized by x-ray diffraction (XRD) to
determine the iron oxide phases. The com-
mon XRD measurement was carried out
using a Rigaku-D/max 2000† diffractometer
with a CuKα target under 50 kV and 250 mA
at a scanning speed of 2 degrees/min. The
synchrotron radiation XRD characteriza-
tion was performed at a wavelength of
1.2398 Å based on a bending magnet, and a
Si(111) double crystal monochromator was
used to monochromatize the beam. The
focus spot size was ~0.5 mm and the end
station was equipped with a Huber 5021†
diffractometer. A sodium iodide (Nal) scin-
tillation detector was employed for data
collection. To compare the intensity differ-
ences of the XRD samples, the amount of
rust used for each analysis was kept the FIGURE 1 Visual observation of the corroded steel water pipe with close-up photographs of
same. In this case, the intensity of certain different corrosion sites (positions).
iron oxide phases, such as goethite
(α-FeOOH), lepidocrocite (γ-FeOOH), and
magnetite (Fe 3 O 4 ), semi-quantitatively Fe3O4, and/or akaganéite (β-FeOOH), and steel water pipe. The other three samples
reflected the relative amount of the phases much greater amounts of x-ray amorphous were taken from the outside wall of the
in the iron oxide samples.5-6 substances that do not give a well-defined steel water pipe.
Bragg peak by the XRD technique. 5 The For al l th e m ea sured sampl e s,
Results and Discussion γ-FeOOH is yellow-orange in color, and α-FeOOH, γ-FeOOH, and Fe3O4 peaks were
α-FeOOH and Fe 3O 4 are dark-brown in detected. However, the β-FeOOH peak was
Surface Observation color.7 not found in any of the samples. The XRD
of the Rust Layer comparison of the surface rust layers
Figures 1(a) through (d) show the visual Common X-Ray Diffraction shown in Figures 1(a), (b), and (c) indicates
observation of the corroded steel pipe with Characterization of the Rust Layer that the rust at the site in Figure 1(a) has
close-up photographs of the pipe itself. The Common XRD was used to characterize lower amounts of α-FeOOH, γ-FeOOH, and
rust layer color is not the same at different the powdered rust scraped from the differ- Fe3O4 than the rust at the site in Figure 1(c).
positions. In general, the rust layer in Fig- ent sites on the pipe shown in Figure 1. In The rust layer at the site in Figure 1(b)
ures 1(a), (c), and (d) is a dark-brown color, Figure 2, Position (a) corresponds to the was expected to have a higher amount of
while the rust layer in Figure 1(b) is a yel- rust at the site shown in Figure 1(a); Posi- γ-FeOOH due to the rust layer’s yellow-
low-brown color. This color change relates tion (b) corresponds to the rust at the site brown color. However, it had a lower
to changes in the iron oxide phases. Usu- shown in Figure 1(b); Position (c) corre- amount of γ-FeOOH than the rust at the
ally, the rust formed during corrosion of sponds to the rust at the site shown in Fig- sites in Figure 1(a) and (c), indicating that
steel in natural environments is composed ure 1(c); and Position (d) corresponds to the yellow-brown color was brought by the
of lesser amounts of α-FeOOH, γ-FeOOH, the rust at the site shown in Figure 1(d). newly formed surface rust layer, which was
The XRD pattern of Position (d) represents a relatively small portion of the total rust
†
Trade name. the sample taken from the inside wall of the amount.

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

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

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

Rust Layer Characterization of a Buried Drinking Water Pipe
rust layer does not enter a stable state).9 rust layer. Therefore, the synchrotron XRD 7 L.L. Wang, et al., “Corrosion Analysis of a
From the XRD measurements, it can be technique has a great advantage in evaluat- Steel Drinking Water Pipe in an Indoor Envi-
concluded that the area at the site in Figure ing the stable state of the steel rust layer in ronment,” MP 51, 9 (2012): pp. 61-65.
1(a) suffered the most serious corrosion a natural environment. 8 M. Yamashita, et al., “Structure and Protec-
attack among the four sites investigated. tive Performance of Atmospheric Corrosion
Product of Fe-Cr Alloy Film Analyzed by
The galvanic effect at the steel tap may be Conclusions Mössbauer Spectroscopy and with Synchro-
responsible for this. Characterization of the surface rust
tron Radiation X-Rays,” Corros. Sci. 45 (2003):
layer on an in-service steel drinking water pp. 381-394.
Rust Layer Composition Discussion pipe after ~30 years in an underground soil
9 Y.Y. Chen, et al., “Mechanical Properties and
Usually, Fe3O4 is as conductive as iron, environment was investigated. The follow- Corrosion Resistance of Low-Alloy Steels in
whereas α-FeOOH is dielectric. From the ing conclusions can be drawn: Atmospheric Conditions Containing Chlo-
electrochemical point of view,10 γ-FeOOH is • The surface rust layer on the steel ride,” Material Science and Engineering A 398
active and α-FeOOH is thermodynamically drinking water pipe had entered a (2005): pp. 47-59.
stable and electrochemically inactive. stable state with a higher amount of 10 J. Lin, M. Ellaway, R. Adrien, “Study of Corro-
Moreover, γ-FeOOH can be reduced to α-FeOOH and much lower amount of sion Material Accumulated on the Inner Wall
Fe3O4, which can be oxidized to α-FeOOH γ-FeOOH. of Steel Water Pipe,” Corros. Sci. 43 (2001): pp.
as the corrosion process proceeds.11 Among • The stronger diffraction intensity of 2,065-2,081.
these transformations, x-ray amorphous the α-FeOOH peak with a very weak 11 T. Misawa, K. Hashimoto, S. Shimodaira,
substances may act as intermediates. or almost nonexistent γ-FeOOH peak “The Mechanism of Formation of Iron Oxide
Although β-FeOOH preferentially forms is an important index in illustrating and Oxyhydroxides in Aqueous Solutions at
in the presence of chloride ions (Cl−), it was the stable state of the rust layer. Room Temperature,” Corros. Sci. 14 (1974):
not found in the samples. It is believed that • The synchrotron XRD technique has pp. 131-149.
Cl− exists in the drinking water as well as a great advantage in evaluating the 12 K. Asami, M. Kikuchi, “In-Depth Distribution
the soil environment surrounding the steel stability of a steel rust layer in a soil of Rusts on a Plain Carbon Steel and Weath-
ering Steels Exposed to Coastal-Industrial
water pipe. Since the formation of β-FeOOH environment.
Atmosphere for 17 Years,” Corros. Sci. 45
in the presence of Cl– can be greatly affected
(2003): pp. 2,671-2,688.
by the presence of sulfate ions (SO42–) in the References
13 F. Corvo, et al., “Changes in Atmospheric
corrosion process,12 the presence of SO42– in 1 Z. Niu, et al., “Iron Stability in Drinking
Corrosion Rate Caused by Chloride Ions De-
the environment is responsible for the lack Water Distribution Systems in a City of
pending on Rain Regime,” Corros. Sci. 47
of β-FeOOH. China,” J. Environmental Sciences 18 (2006):
(2005): pp. 883-892.
As the buried steel drinking water pipe pp. 40-46.
14 I.M. Allam, J.S. Arlow, H. Saricimen, “Initial
was in service for ~30 years, it is believed 2 P. Sarin, et al., “Physico-Chemical Character-
Stages of Atmospheric Corrosion of Steel in
that the rust layer on the steel water pipe istics of Corrosion Scales in Old Iron Pipes,”
the Arabian Gulf,” Corros. Sci. 32 (1991): pp.
had entered a steady state without an obvi- Water Research 35 (2001): pp. 2,961-2,969.
417-432.
ous composition evolution difference as the 3 H.J. Jang, Y.J. Choi, J.O. Ka, “Effects of Diverse
15 M. Stratmann, K. Bohnenkamp, H.-J. Engell,
corrosion process proceeded. The relative Water Pipe Materials on Bacterial Communi-
“An Electrochemical Study of Phase-Transi-
content of α-FeOOH is an important index ties and Water Quality in the Annual Reac-
tion in Rust Layers,” Corros. Sci. 23 (1983): pp.
tor,” J. Microbiology and Biotechnology 21
for evaluating the corrosion resistance of 969-985.
(2011): pp. 115-123.
the rust layer, 13 and a higher amount of
α-FeOOH is usually observed in the rust as 4 I.S. Cole, D. Marney, “The Science of Pipe
ZHANJUN GUO is a teacher and research
Corrosion: A Review of the Literature on the
the rust layer enters a stable state.14 assistant at North China University of
Corrosion of Ferrous Metals in Soils,” Corros.
For the present investigation, it was dif- Water Resources and Electric Power,
Sci. 56 (2012): pp. 5-16.
ficult to carry out the corrosion evolution Zhengzhou City, Henan Province, 450045,
5 M. Yamashita, H. Miyuki, H. Nagano, “The China. His research focuses on environ-
time tests. By comparing the intensity of
Long Term Growth of the Protective Rust mental and municipal engineering.
the diffraction peaks, it was found that the Layer Formed on Weathering Steel by Atmo-
rust layer had entered a stable state after spheric Corrosion During a Quarter of a Cen-
the long burial time,15 with a higher amount ZHILIANG CHEN is a research manager at
tury,” Corros. Sci. 36 (1994): pp. 283-299.
Yangzhou Research Academy of Energy
of α-FeOOH and lower amount of γ-FeOOH, 6 T. Kamimura, et al., “Composition and Pro- and Material, Yangzhou City, Jiangsu
as shown in Figures 2 and 3. The synchro- tective Ability of Rust Layer Formed on Province, 225009, China. He has a Ph.D. in
tron XRD characterization confirms that Weathering Steel Exposed to Various Envi- environmental science and focuses on
the stronger diffraction intensity of the ronments,” Corros. Sci. 48 (2006): pp. 2,799- environmental protection.
α-FeOOH peak with a very weak or almost 2,812.
nonexistent γ-FeOOH peak is an important
index in illustrating the stable state of the

MATERIALS
PERFORMANCE
CORROSION PREVENTION AND CONTROL WORLDWIDE
9TH ANNUAL COMPANY SHOWCASE
This feature, published annually in the September issue of MP, highlights

participating companies involved in the corrosion control industry. The
Showcase includes an overview of each company’s products and services,
as well as location and contact information.
Carboline Company
Carboline is a leading global manufacturer of high-performance
coatings, linings, and fireproofing products. Solving customers’
problems is how we got our start, and after 70 years, it’s still our
focus at Carboline. Our goal is to meet your needs and expectations
by recommending products that provide the right solutions.
By doing this, Carboline has become the global standard of
quality when it comes to high-performance coatings, linings, and
fireproofing products. Our unwavering focus on performance,
broad industrial market experience, continuous investment in
long-term product development and testing, and our ability to meet
challenges anywhere in the world makes us a source of coatings
knowledge customers find invaluable. Our global manufacturing
and sales structure allows us to coordinate and service all phases
of construction projects, regardless of location. Put our expertise,
experience, and know-how to work for you.
Carboline Company
2150 Schuetz Rd. • St. Louis, MO 63146, USA
Tel: +1 314-644-1000
Web site: www.carboline.com

2017 COMPANY SHOWCASE
Corrpro Companies, Inc.

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

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

7000 B Hollister • Houston, TX 77040, USA
Tel: 1 866-CORRPRO • Fax: +1 713-460-6060
Web site: www.corrpro.com
Cortec® Corporation
Cortec® Corporation is trusted globally in the corrosion protection
business. Headquartered in St. Paul, Minnesota, Cortec® manufactures
environmentally friendly Vapor-phase Corrosion Inhibitor (VpCI®) and
Migratory Corrosion Inhibitor (MCI®) technologies. Our relentless dedication
to sustainability, quality, service, and support is unmatched in the industry.
Cortec® has over 400 products for construction, packaging, metalworking,
electronics, water treatment, oil and gas, and other industries that are
distributed worldwide. ISO 9001/ISO 17025/ISO 14001:2004 certified.
Cortec’s patented VpCI® technology represents a breakthrough solution
in corrosion prevention. Our VpCI® products protect metals with a
chemically adsorbed molecular layer that provides multimetal corrosion
protection. The coverage is complete—all surfaces, crevices, cavities, and
other inaccessible void areas receive total protection. The VpCI® barrier is
self-replenishing, even for packaging that’s repeatedly opened, and typically
protects for up to 24 months.
Cortec’s patented MCI® technology protects reinforcing metal in concrete
from corrosion. MCI® extends the life span of new and existing concrete
structures. Often, corroding deteriorated rebar in concrete is the cause of
costly repairs, financial losses, injuries, and even deaths; but Cortec® has the
corrosion solution. Cortec® MCI® products maintain structural integrity,
rehabilitate vulnerable structures, and alleviate environmental concerns.
Cortec® Corporation
4119 White Bear Pkwy. • St. Paul, MN 55110, USA
Tel: +1 651-429-1100 • Fax: +1 651-429-1122
Web site: www.cortecvci.com

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

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

a bespoke, expert-led service. Its locations around the globe mean
that you can always be sure of speaking to a genuine corrosion
monitoring expert, not to a third party, no matter your time zone.
By doing so, Cosasco invests in long-term relationships that extend
asset lifecycles, increase safety, and reduce cost.
Cosasco
11841 Smith Ave. • Santa Fe Springs, CA 90670, USA
Tel: 1 800-635-6898 • +1 562-949-0123 • Fax: +1 562-949-3065
Web site: www.cosasco.com
Denso North America

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

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

Farwest Corrosion Control Company

Established in 1956, Farwest Corrosion Control Company is a
premier supplier of cathodic protection (CP) and corrosion control
materials and equipment. With nine office/warehouse locations
nationwide, each staffed by knowledgable personnel, we service all
industries and are the single-source solution for all your CP and
corrosion control needs.
Visit our web site: it is the largest corrosion-related site in the world with
over 1,000 pages of products, instructions, videos, printable MSDS sheets,
and much, much more.
Products include: • Services Include:

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

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

Jennings Anodes USA is a new joint venture in America formed by
combining the manufacturing resources of two long-term global
players within the CP marketplace.
Specialist Castings UK (Jennings) and Yuxi China have over 30 years

of experience in manufacture and global supply.
We have combined our technical expertise, innovation, and know-how

to create an anode operation directly within the U.S. market. U.S.-
based in-house stock improves service levels and customer support.
We are a leading domestic supplier of anodes, including both

impressed current anodes as well as sacrificial anodes, and in the
latest third-party testing of silicon iron tubular anodes, we are shown
to outperform all other tested brands.
For further information or any queries please call, email, or visit our
web site at www.jenningsanodesusa.com.
Jennings Anodes USA

Contact: Chris Jennings
Tel: +1 713-799-3884 • Email: [email protected]
Contact: Stephanie Sanchez

Tel: +1 281-844-6560 • Email: [email protected]

MESA
MESA is proud to introduce another industry-leading customer satisfaction initiative showcasing our commitment to value-added
services. We call it our CEO Assurance Program, and are so confident in our products and customer service, we want to guarantee
them! With this program, we warranty that our material orders are:
• 100% accurate and error-free of any missed/incorrect products
• Shipped when promised and delivered to your specified location on-time in good condition
If we fall short, we will make things right with a full refund of freight charges (some exclusions apply). As an ISO 9001 certified
organization and recipient of two Malcolm Baldrige Quality awards, expect nothing less than exceptional quality and value. For
more information, visit us online @ www.mesaproducts.com or call 1 888-800-MESA(6372).
Tulsa +1 918-627-3188 | Houston +1 281-445-8700 | DFW +1 817-230-4249 | Rocky Mountains +1 720-833-7032 |

Midwest +1 614-503-1705 | Mid Con +1 405-603-6737 | Michigan +1 989-441-1500 | East Coast +1 843-628-1342 |
South East +1 850-893-9366 | West Coast +1 714-963-6202 | North West +1 425-903-4850 | Canada +1 780-453-6677
MESA
4445 S. 74th E. Ave. • Tulsa, OK 74145, USA
Tel: 1 888-800-MESA (6372) • Fax: +1 918-627-2676
Web site: www.mesaproducts.com
ROXUL Technical Insulation

Industrial Insulation Shaped By Experts!
ROXUL® Technical Insulation, a subsidiary of the international

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

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

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

Corrosion
Never Sleeps
NACE WESTERN AREA CONFERENCE
November 28 – 30, 2017 | Las Vegas, Nevada | Red Rock Casino Resort & Spa
Billions of dollars are spent each year on corrosion prevention and maintenance on oil, gas, pipeline, power generation and
other infrastructure assets. To address this issue, NACE International and the NACE Southern Nevada Section invites you
to attend the 2017 Western Area Conference. Featuring unique educational presentations, forums, and new technologies
on the exhibit hall floor, this conference will be your opportunity to learn about local corrosion issues from experienced
local experts.
Technical Program Advance Registration Ends

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

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

Registration
▪ AC Corrosion root cause and analysis caused from induced high-voltage from overhead transmission power lines
▪ AC Mitigation methods and monitoring Advanced Registration
▪ Advancements in tank bottom, both internal and external Cathodic Protection (CP) design, material selection, Ends October 28, 2017
and improved installation methods
▪ Inhibitors - Vapor Transported (VCI) and Surface Coating Rust Preventive (RP)
NACE Member: $450 USD
▪ Advancements in CP design and installation methods in urban/congested areas Nonmember: $550 USD
▪ Upcoming changes to regulations and subsequent effects on interstate and intrastate natural gas and
petroleum product pipelines
Regular Registration
▪ Underground buried pipelines – Municipal water supply, Begins: November 23, 2017
water transmission, water treatment NACE Member: $550 USD
▪ Full Cycle Corrosion Management from Conceptual Design to Decommissioning
▪ Advancements in CP design and installation methods in urban/congested areas
Nonmember: $650 USD
▪ Advancements in tank bottom, both internal and external Cathodic Protection (CP) design, material selection,
and improved installation methods
▪ Water Treatment Vs. The Economics Associated with Risk and Reliability
One Day Registration
▪ Cost Effective Corrosion Management Begins: November 23, 2017
▪ General – Corrosion issues in Hydro Electricity – Focus on corrosion
affecting the Hoover Dam Nonmember: $300 USD
▪ General - Corrosion Management, Planning, Development,
Implementation & Success
▪ General - Corrosion Issues in Military Equipment and Facilities
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Matcor, Inc.
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Chapman Engineering
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e have defined strate- three years. The plan for success provides Robert H. Chalker*
gic planning as a pro- the roadmap for how we will accomplish NACE International
Houston, TX, USA
cess that provides a our goals.
DIRECTORS
roadmap for taking Perhaps some have heard the expres-
our association from a sion, “If everything is important, nothing Debra Boisvert/2015-2018
Target Products, Ltd.
well-defined present state to a compelling is.” With a clear picture of our destination Burnaby, BC, Canada
and significantly different future state. De- in mind (i.e., where we want to be in three Richard B. Eckert/2015-2018
velopment and implementation of our plan years), the board focused on establishing DNV GL
Dublin, OH, USA
for success is what makes strategic plan- the top priorities for the next year. Each of
Darby Howard/2015-2018
ning an effective, ongoing process, as op- four teams were asked: JDH Corrosion Consultants, Inc.
posed to a once-every-three-years event 8 What are the five or six most important Concord, CA, USA
that results in lofty goals, with little thought things we need to focus on in the next Thomas Ladwein/2015-2018
on how to achieve them. year to move us toward our vision and Aalen University of Applied Science
Aalen, Germany
overarching goals?
Mohammed Al-Subaie/2016-2019
Once debated, the answers to this Saudi Aramco
question become our key strategic initia- Dhahran, Saudi Arabia
tives for the year. For each key strategy, we Jorge Cantó/2016-2019
Corrosion y Proteccion
create a brief description so that we all Hidalgo, Mexico
share a common understanding of what
Cris Conner/2016-2019
the key strategy is to address. But putting a Utility Service & Maintenance, Inc.
label on a key strategy isn’t enough. We St. Louis, MO, USA
also have to create a definition of success Andrew Haiko/2016-2019

LTK Engineering Services
that answers the question: Ambler, PA, USA
8 What must be true one year from now Eric Langelund/2016-2019
The model adopted by the Board of Directors for us to be able to look back and say, Piping & Corrosion Specialties, Inc.
to facilitate strategic planning at NACE. with any credibility, that we had a good Millersville, MD, USA
year? C. Lindsay Enloe/2017-2020

Utility Safety & Design
As illustrated in the model here, the Key strategies and associated defini- Swansea, IL, USA
plan for success has three elements: key tions of success establish in specific, mea- Michael S. O’Brien/2017-2020
strategic initiatives, implementation surable terms what must be accomplished MARK 10 Resource Group, Inc.
Richmond, VA, USA
plans, and review and reload sessions. in the next 12 months to move us toward
We’ll introduce all three steps in the plan- the overarching goals we intend to achieve Toyoji Takeuchi/2017-2020
Sumitomo Heavy Industries Marine
for-success process this month, and in three years. But annual goals must be Engineering Co., Ltd.
explore the current key strategic initiatives broken down even further to make certain Yokosuka, Japan
in detail in next month’s post. we are making continual progress, and ad- EX OFFICIO DIRECTORS
Through this point in the strategic justing our plans as circumstances evolve. Keith Perkins
planning process, we have established an The implementation plan is a spread- President, NACE International Foundation
aspirational, timeless vision statement, sheet-based tool we utilize to break down Chris Fowler, FNACE
President, NACE International Institute
and specific, measurable overarching our annual goals even further, into three to
*Executive Committee members
goals that we fully intend to achieve in five tasks that need to be accomplished for

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

Western Area
NACE San Francisco Section Holds Annual
Picnic Barbecue
Barbecue expert Billy Campbell (left) with

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

NACE NEWS
East Asia and Pacific Area

NACE Coating Inspector Program Courses in Shanghai
Instructors Phil Fouche, Lerry Li, and Amy Wong instructed a Coating Fouche, Wong, and Gary Cheung instructed the CIP Level 2 course in
Inspector Program (CIP) Level 1 course in Shanghai, China to wind power Shanghai.
industry employees.
N
ACE International recently conducted CIP Levels 1 and 2 courses in Shanghai, China. NACE holds courses all over the world
that cover corrosion control technologies for every industry and environment. For more information, see www.nace.org/
training-education.
In Memoriam
L
ongtime for CHLOR*RID was developed. During CHLOR*RID members and his son Doug-
NACE In- this time, he recognized the importance of las remain active in NACE committees,
ternational eliminating the contamination of soluble carrying on the important work in the
member James R. salts on substrates prior to coating. His protective coatings field, particularly sur-
Johnson, 75, work in this field led to his founding of face preparation addressing soluble salt
passed away on CHLOR*RID International, Inc. in the early detection and removal.
Tuesday, June 20, 1990s, specializing in soluble salt testing Jim resided in Montana semi-retired.
2017 at his home and removal products. Outside of work, his interests included
in Yaak, Montana Jim didn’t stop at just a salt remover. working on his Montana home, spending
of natural causes. There was a need to detect the presence of time with family, hunting, and contribut-
James “Jim” Johnson was born in Chi- salts so he and the other owners of ing to charities that included the victims
cago, Illinois on June 14, 1942 to Roy and CHLOR*RID developed a field test kit, as of Hurricane Katrina and particularly, can-
Pearl Johnson. He moved to Big Fork, Mon- well as other products over the years. The cer-fighting research and support. His
tana in 1967, and worked for Westmont company, still headquartered in Chandler, daughter Laurie who had contracted can-
Tractor and on the Libby Dam. In 1974, Jim Arizona, is growing, with representatives cer as a child, is still in remission. Jim was
started Johnson Lumber in Bigfork, throughout the United States. a generous contributor to St. Jude’s Chil-
Kalispell and Seeley Lake. Jim was an active member on NACE dren’s Research Hospital and other
In the 1990s, he became a protective technical committees since 1991, attended research organizations.
coatings contractor in Chandler, Arizona, numerous NACE conferences and net- Survivors include his children Jason
his largest account being Allied Signal. working opportunities over the years, and Johnson (Tricia ), Chattaroy, Washington;
Within a few coating failures, Jim had ana- presented papers. He was one of the Douglas Johnson (Pauline), Post Falls,
lyzed samples showing the cause to be sol- founders that led the coatings industry to Idaho; Laurie Johnson, Reardon, Washing-
uble salt contamination. In attempting to address soluble salt contamination—still a
solve such coating failures, the chemistry leading cause of coating failures today. Continued on bottom of next page

VOLUNTEERS SPOTLIGHT
NACE Volunteers in the Crowd

Volunteer: Jon R. Cavallo
Employer: Jon R. Cavallo PE LLC, Portsmouth,

New Hampshire, USA
Professional Role in Corrosion: Consulting engineer,

instructor for NACE International’s Coating Inspector
Program (CIP) and the Electric Power Research
Institute, and author of technical publications on
coatings and linings technology, including the recent
NACE International book, The History of Protective
Coatings in Nuclear Power Plants.
J
on Cavallo is a NACE-certified CIP Level 1, 2, and 3 Coating
Inspector with nuclear and bridge endorsements and a Reg-
istered Professional Engineer in three states. During his
more than 40 years of work in the coatings and corrosion mitiga-
tion field, Cavallo has gained a reputation as a world-renowned
coating and lining expert. His recent work has included assign-
ments in the United States, Canada, Slovenia, India, Peoples
Republic of China, Japan, and South Korea.
Cavallo has been a NACE member for 35 years, and is a NACE
volunteer. He says volunteering for NACE draws on his educa-
tional background and professional experience and has provided
him with the opportunity to increase his technical knowledge
and his visibility in the industry. “My volunteer work has permit-
ted me to meet other like-minded people from around the world sharing his high-level knowledge of coatings technology as well
and to experience aspects of the industry that I might not have as his personal and professional experience in coatings.
otherwise been exposed to,” he says. Cavallo says he was at a point in his career where he
At CORROSION 2017 in New Orleans, Louisiana, Cavallo vol- acknowledged that he has been mentored very well during his
unteered to assist the NACE Foundation with its third annual career and would like to now “pay it forward” to help assist
day-long corrosion mini-camp—CORROSION: Opportunities others who are entering the corrosion mitigation field. His most
Realized—where 50 local high school students learned about recent volunteer opportunity is assisting the NACE International
career and academic opportunities in corrosion from many of Institute in improving the examinations related to the CIP
the industry’s top leaders and professionals. His responsibilities courses.
included greeting high school students on the show floor and Browse open volunteer opportunities at volunteer.nace.org.
Continued from previous page
ton; grandchildren Cynthia Delong, Kyle 2017 at the family home in Yaak. A Cele- com. In lieu of flowers, memorials may be
Sullivan, Tiffany Johnson, Alix Johnson, bration of Life immediately followed at the made to St. Jude’s Children’s Hospital,
Sydney Johnson, and Tierra Norris; and Yaak Mercantile. Arrangements were by www.stjude.org, or to the Upper Yaak Vol-
great grandchildren Kristin, Rylan, Schnackenberg & Nelson Funeral Home in unteer Fire Department-Search and
Kayleigh, Lacey Kay, and Deegan. Libby. Online condolences and memories Rescue. It was always Jim’s wish to have a
Services were held on Saturday, July 8, may be shared at www.schnackenbergfh. search and rescue in the Upper Yaak.

NACE NEWS
NACE International Corporate Members

MP publishes the names of all Diamond and Gold Corporate Members in each issue, in addition to that month’s new
corporate members of all levels. Following are the companies that are in these categories as of August 15, 2017:
Southern California Gas Co., Los Angeles, Park Derochie, Inc., Edmonton, Alberta,
DIAMOND Canada
California, USA
Turner Industries Group, LLC, Port Allen, Petroineos, Grangemouth, Stirlingshire,
Borouge (Abu Dhabi Polymers Co.), Ruwais,
Louisiana, USA United Kingdom
Abu Dhabi, United Arab Emirates
Pipetech Corp., Ltd., Calgary, Alberta,
BP Exploration & Production Operating Co.,
Canada
Ltd., Middlesex, United Kingdom GOLD
Pluspetrol, Caba, Argentina
Carboline Company, St. Louis, Missouri,
USA Airtech Spray Systems, Houston, Texas, USA PTT Global Chemical Public Co., Ltd.,
Alpha Pipeline Integrity Services, Kemah, Bangkok, Chatuchak, Thailand
Colonial Pipeline Co., Alpharetta, Georgia,
USA Texas, USA Raven Lining Systems, Broken Arrow,
Atmos Energy, Jackson, Mississippi, USA Oklahoma, USA
Corrpro, Houston, Texas, USA
Baker Hughes, Sugar Land, Texas, USA RK&K, LLP, Charlotte, North Carolina, USA
Denso North America, Houston, Texas, USA
Bechtel Group, Inc., Houston, Texas, USA ROSEN, Lingen, Germany
DNV GL, Dublin, Ohio, USA
Brand Energy & Infrastructure Services, Southern Star Central Gas Pipeline,
Dunn-Edwards Corp., Los Angeles,
Kennesaw, Georgia, USA Owensboro, Kentucky, USA
California, USA
BSS Technologies. Dubai, United Arab Specialty Polymer Coatings, Inc., Langley,
El Paso Water Utilities, El Paso, Texas, USA
Emirates British Columbia, Canada
Elcometer, Rochester Hills, Michigan, USA
Chapman Engineering, Boerne, Texas, USA Strategic Materials, Houston, Texas, USA
Enable Midstream Partners, Bossier City,
ConocoPhillips Co., Bartlesville, Oklahoma, TransCanada Pipelines, Calgary, Alberta,
Louisiana, USA
USA Canada
Excet, Inc., Springfield, Virginia, USA
Corrosion Technology Services, LLC, Tubacex Group, Llodio, Alava, Spain
Exova, West Midlands, United Kingdom
Sharjah, United Arab Emirates United States Coast Guard, Baltimore,
Henkels & McCoy, Inc., Blue Bell, Maryland, USA
CPC Corporation, Taiwan
Pennsylvania, USA
Dominion, Bridgeport, West Virginia, USA University of Akron, Akron, Ohio, USA
HMI Technical Solutions, Blue Bell,
Dong Yang Corrosion Engineering Co., Ltd., V&A Consulting Engineers, Inc., Oakland,
Pennsylvania, USA
Seoul, South Korea CA, USA
International Union of Painters and Allied
Duke Energy, Cincinnati, Ohio, USA Weldbend, Argo, Illinois, USA
Trades, Hanover, Maryland, USA
Kuwait Oil Co., Ahmadi, Kuwait Enbridge Pipelines, Inc., Schereville,
Indiana, USA NEW CORPORATE MEMBERS
Lake Superior Consulting, Duluth,
Minnesota, USA Evraz, Inc., Regina, Saskatchewan, Canada
Parsons, Pasadena, California, USA—Silver
Magnum Energy Services, Ltd., Ft. Kent, Formosa Plastics Group (FPG), Taipei,
Taiwan Riddle’s Dehi & Chemicas Service Co., Inc.,
Alberta, Canada
dba E & P Services Group, Kilgore, Texas,
MATCOR, Inc., Chalfont, Pennsylvania, USA Galvotec Alloys, Inc., McAllen, Texas, USA
USA—Silver
MESA, Tulsa, Oklahoma, USA Haynes International, Inc., Kokomo, Indiana,
Carolina Coating Solutions & Industrial
USA
National Grid, Beijing, China Services, Inc., Morrisville, North Carolina,
HoldTight Solutions, Inc., Houston, Texas, USA—Iron
Oil & Natural Gas Corp., Ltd. (ONGC),
USA
Mumbai, India Total NACE membership was 36,036 as of
Integrated Global Services, Richmond,
Oneok Partners, Tulsa, Oklahoma, USA July 15, 2017. For more information about
Virginia, USA
Polyguard Products, Inc., Ennis, Texas, USA NACE corporate membership levels and
Interprovincial Corrosion Control, Ltd., individual member benefits, contact the
PPG Performance Coatings (Hong Kong), Burlington, Ontario, Canada FirstService department at tel: +1 281-228-
Ltd., Shanghai, China
Kuwait Pipe Industries and Oil Services Co., 6223 or email: [email protected].
Saipem SpA, San Donato, Milanese, Italy Safat, Kuwait
Sandvik AB, Gavlenorg, Sweden Marathon Pipeline, LLC, Findlay, Ohio, USA
Seal for Life Industries, Stadskanaal, The Oceaneering International, Inc., Houston,
Netherlands Texas, USA
SGS, Camberley, Surrey, United Kingdom Osmose Utility Services, Inc., Peachtree City,
Sherwin-Williams Co., Cleveland, Ohio, USA Georgia, USA

NACE NEWS
Calendar of Events
SEPTEMBER 2017 NOVEMBER 2017 OCTOBER 2018
CORROSION TECHNOLOGY PIMS LATIN AMERICA 2017 NACE NONMETALLICS

WEEK 2017 November 15-17, 2017 CONFERENCE 2018
September 10-14, 2017 JW Marriott Lima October 16-18, 2018
JW Marriott Indianapolis Lima, Peru Qatar University
Indianapolis, IN, USA More info: Lesley Martinez, NACE Doha, Qatar
More info: Lesley Martinez, NACE International, tel: +1 281-228-6413, More info: Reygie de Borja, NACE
International, tel: +1 281-228-6413, email: [email protected] International, tel: +966-13-8642040,
email: [email protected] email: [email protected]
4TH KUWAIT CORROSION
MATERIALS PERFORMANCE & CONFERENCE: PLANT MARCH 2019
WELDING TECHNOLOGIES 2017 AND PIPELINE INTEGRITY
CONFERENCE & EXHIBITION MANAGEMENT CORROSION 2019
September 11-14, 2017 November 21-23, 2017 March 24-28, 2019
Sheraton Dammam Hotel & Hilton Kuwait Resort
Nashville, TN, USA
Convention Centre Al Mangaf, Kuwait
More info: CaLae Browne, NACE
Dammam, Saudi Arabia More info: Reygie de Borja, NACE International, tel: +1 281-228-6263,
More info: web site: International, email: Reygie.deborja@ email: [email protected]
www.mpwtconference.org nace.org
CORCON 2017 MARCH 2020

FEBRUARY 2018
September 17-20, 2017
CORROSION 2020
Sahara Star LIBERTY BELL CORROSION
Mumbai, India COURSE March 15-19, 2020
More info: CaLae Browne, NACE Houston, TX, USA
February 7-8, 2018
International, tel: +1 281-228-6263, More info: CaLae Browne, NACE
Normandy Farm International, tel: +1 281-228-6263,
email: [email protected]
Blue Bell, Pennsylvania email: [email protected]
More info: David Krause, tel: +1 610-868-
OCTOBER 2017 9352, email: [email protected]
APRIL 2021
SPE/NACE WORKSHOP: APRIL 2018
CORROSION MANAGEMENT CORROSION 2021
FOR ONSHORE AND April 18-22, 2021
CORROSION 2018
OFFSHORE UPSTREAM Salt Lake City, UT, USA
OIL & GAS PRODUCTION April 15-19, 2018
INSTALLATIONS Phoenix Convention Center International, tel: +1 281-228-6263,
October 30-31, 2017 Phoenix, AZ, USA email: [email protected]
Kuala Lumpur, Malaysia
International, tel: +1 281-228-6263,
More info: CaLae Browne, NACE email: [email protected]
email: [email protected]
SEPTEMBER 2018 For the most up-to-date
CORROSION TECHNOLOGY
listing of events, click on
WEEK 2018 the Events tab at
September 16-20, 2018
Royal Sonesta Houston Galleria
www.nace.org.
Houston, TX, USA
More info: Lesley Martinez, NACE
email: [email protected] Denotes NACE International event

NACE NEWS
NACE Course Schedule
ARGENTINA CIP Peer Review
CP1—Cathodic Protection Tester Shanghai....................................................Nov 11-14, 2017
Buenos Aires..............................................Nov 6-11, 2017 COLOMBIA
CP2—Cathodic Protection Technician Basic Corrosion
Buenos Aires..............................................Nov 13-18, 2017 Bogota.......................................................Oct 9-13, 2017
Internal Corrosion for Pipelines—Basic CP Interference
Buenos Aires..............................................Nov 27-Dec 1, 2017 Barranquilla................................................Oct 9-14, 2017
AUSTRALIA CP4—Cathodic Protection Specialist
CIP Level 1 Bogota.......................................................Oct 4-9, 2017
Sydney, NSW.............................................Nov 6-11, 2017 Internal Corrosion for Pipelines—Advanced
CIP Peer Review Bogota.......................................................Nov 14-18, 2017
Sydney, NSW.............................................Nov 9-12, 2017 DOMINICAN REPUBLIC
CP1—Cathodic Protection Tester CP1—Cathodic Protection Tester
Perth, WA ..................................................Oct 9-13, 2017 Cotui..........................................................Oct 9-13, 2017
CP2—Cathodic Protection Technician
ECUADOR
Perth, WA ..................................................Oct 16-20, 2017
CIP Level 2
AZERBAIJAN Quito .........................................................Oct 16-21, 2017
Basic Corrosion
EGYPT
Baku...........................................................Oct 30-Nov 3, 2017
CIP Level 1
Corrosion Control in the Refining Industry
Cairo ..........................................................Oct 7-12, 2017
Baku...........................................................Oct 2-6, 2017
CIP Level 2
CP3—Cathodic Protection Technologist
Cairo ..........................................................Oct 14-19, 2017
Baku...........................................................Oct 9-14, 2017
CP1—Cathodic Protection Tester
CP4—Cathodic Protection Specialist
Cairo ..........................................................Dec 10-15, 2017
Baku...........................................................Oct 16-21, 2017
Designing for Corrosion Control
Cairo ..........................................................Dec 17-22, 2017
Baku...........................................................Nov 6-10, 2017
CP4—Cathodic Protection Specialist
Internal Corrosion for Pipelines—Advanced
Cairo ..........................................................Nov 11-16, 2017
Baku...........................................................Oct 23-27, 2017
Internal Corrosion for Pipelines—Advanced
Marine Coating Technology
Cairo ..........................................................Dec 3-7, 2017
Baku...........................................................Nov 13-16, 2017
PCS 1 Basic Principles
BELGIUM Cairo ..........................................................Nov 25-27, 2017
CIP Level 1 PCS 2 Advanced
Antwerp .....................................................Oct 16-21, 2017 Cairo ..........................................................Nov 28-30, 2017
CANADA GERMANY
Basic Corrosion CIP Level 1
Calgary, AB................................................Oct 16-20, 2017 Frankfurt ....................................................Nov 6-11, 2017
CIP Level 1 CIP Level 2
Edmonton, AB ...........................................Nov 12-17, 2017 Frankfurt ....................................................Nov 13-18, 2017
Halifax, NS .................................................Nov 12-17, 2017
Red Deer, AB.............................................Oct 1-6, 2017
Frankfurt ....................................................Oct 23-28, 2017
Red Deer, AB.............................................Oct 15-20, 2017
CIP Level 2 INDIA
Edmonton, AB ...........................................Nov 19-24, 2017 CIP Level 1
Montreal, QC.............................................Oct 22-27, 2017 Chennai .....................................................Oct 30-Nov 4, 2017
Red Deer, AB.............................................Oct 22-27, 2017 Chennai .....................................................Dec 4-9, 2017
CIP Peer Review Mumbai .....................................................Oct 2-7, 2017
Montreal, QC.............................................Oct 27-30, 2017 CIP Level 2
Corrosion Control in the Refining Industry Chennai .....................................................Nov 6-11, 2017
Edmonton, AB ...........................................Nov 13-17, 2017 Chennai .....................................................Dec 11-16, 2017
Mumbai .....................................................Oct 9-14, 2017
Calgary, AB................................................Nov 6-11, 2017 CP2—Cathodic Protection Technician
Mumbai .....................................................Oct 2-6, 2017
Calgary, AB................................................Nov 13-18, 2017 ITALY
Designing for Corrosion Control CIP Level 2
Edmonton, AB ...........................................Nov 6-10, 2017 Genova ......................................................Oct 22-27, 2017
Pipeline Coating Applicator Training JAPAN
Edmonton, AB ...........................................Nov 6-10, 2017 CIP Level 1
CHINA Imari...........................................................Oct 12-17, 2017
CIP Level 1 KUWAIT
Shanghai....................................................Dec 3-8, 2017 CIP Level 1
CIP Level 2 Fahaheel ....................................................Dec 2-7, 2017
Shanghai....................................................Dec 10-15, 2017

For the most up-to-date information, visit www.nace.org/eduschedule Your Association in Action
CIP Level 2 SPAIN

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

NACE NEWS
UNITED STATES CIP Peer Review

Basic Corrosion Cape Canaveral, FL ...................................Dec 15-18, 2017
Austin, TX ..................................................Oct 9-13, 2017 Houston, TX...............................................Nov 17-20, 2017
Houston, TX...............................................Oct 23-27, 2017 Houston, TX...............................................Dec 15-18, 2017
New Orleans, LA........................................Dec 4-8, 2017 Coatings in Conjunction with Cathodic Protection
Orlando, FL................................................Oct 9-13, 2017 Houston, TX...............................................Nov 6-11, 2017
San Bernardino, CA ...................................Jan 22-26, 2018 Corrosion Control in the Refining Industry
CIP Level 1 Houston, TX...............................................Oct 23-27, 2017
Aiken, SC ...................................................Nov 5-10, 2017 New Orleans, LA........................................Dec 4-8, 2017
Albuquerque, NM......................................Oct 1-6, 2017 CP1—Cathodic Protection Tester
Anaheim, CA .............................................Oct 1-6, 2017 Downey, CA...............................................Dec 11-16, 2017
Baton Rouge, LA .......................................Dec 10-15, 2017 Houston, TX...............................................Oct 2-6, 2017
Buffalo, NY ................................................Oct 29-Nov 3, 2017 Houston, TX...............................................Oct 9-13, 2017
Cape Canaveral, FL ...................................Dec 3-8, 2017 Houston, TX...............................................Oct 23-27, 2017
Charlotte, NC ............................................Dec 3-8, 2017 Houston, TX...............................................Oct 30-Nov 3, 2017
Chicago, IL.................................................Dec 10-15, 2017 Houston, TX...............................................Nov 13-18, 2017
Cincinnati, OH ...........................................Oct 1-6, 2017 Houston, TX...............................................Nov 27-Dec 2, 2017
Commerce, CA ..........................................Oct 8-13, 2017 Houston, TX...............................................Dec 11-16, 2017
Commerce, CA ..........................................Dec 10-15, 2017 Kilgore, TX.................................................Dec 18-23, 2017
Denver, CO................................................Oct 15-20, 2017 Las Vegas, NV............................................Nov 27-Dec 2, 2017
Houston, TX...............................................Oct 1-6, 2017 Plano, TX ...................................................Dec 4-9, 2017
Houston, TX...............................................Oct 8-13, 2017 Rosebush, MI .............................................Oct 16-20, 2017
Houston, TX...............................................Oct 15-20, 2017 Salt Lake City, UT ......................................Oct 30-Nov 3, 2017
Houston, TX...............................................Oct 16-21, 2017 Tulsa, OK ...................................................Oct 23-27, 2017
Houston, TX...............................................Oct 29-Nov 3, 2017 CP2—Cathodic Protection Technician
Houston, TX...............................................Nov 5-10, 2017 Akron, OH .................................................Nov 27-Dec 2, 2017
Houston, TX...............................................Nov 12-17, 2017 Houston, TX...............................................Oct 2-6, 2017
Houston, TX...............................................Nov 26-Dec 1, 2017 Houston, TX...............................................Oct 16-20, 2017
Houston, TX...............................................Dec 3-8, 2017 Houston, TX...............................................Nov 6-11, 2017
Houston, TX...............................................Dec 4-9, 2017 Houston, TX...............................................Dec 11-16, 2017
Houston, TX...............................................Dec 10-15, 2017 Salt Lake City, UT ......................................Dec 4-9, 2017
Houston, TX...............................................Dec 11-16, 2017
Houston, TX...............................................Dec 17-22, 2017
Downey, CA...............................................Jan 22-27, 2018
Jacksonville, FL..........................................Oct 30-Nov 4, 2017
Houston, TX...............................................Oct 23-28, 2017
Kansas City, MO ........................................Nov 12-17, 2017
Lanham, MD ..............................................Oct 1-6, 2017 CP4—Cathodic Protection Specialist
Lanham, MD ..............................................Dec 10-15, 2017 Houston, TX...............................................Dec 17-22, 2017
Montvale, NJ .............................................Oct 16-21, 2017 Seattle, WA................................................Oct 1-6, 2017
Montvale, NJ .............................................Jan 8-13, 2018 CP Interference
New Orleans, LA........................................Nov 5-10, 2017 Houston, TX...............................................Dec 4-9, 2017
Newington, NH .........................................Oct 8-13, 2017 Designing for Corrosion Control
Orlando, FL................................................Nov 5-10, 2017 Houston, TX...............................................Oct 2-6, 2017
Philadelphia, PA ........................................Oct 1-6, 2017 New Orleans, LA........................................Dec 4-8, 2017
San Ramon, CA..........................................Oct 23-28, 2017 San Bernardino, CA ...................................Jan 22-26, 2018
Seattle, WA................................................Nov 5-10, 2017 In Line Inspection
St. Louis, MO .............................................Oct 29-Nov 3, 2017 Houston, TX...............................................Nov 27-Dec 1, 2017
Virginia Beach, VA .....................................Nov 5-10, 2017
Waipahu, HI...............................................Oct 8-13, 2017 Internal Corrosion for Pipelines—Basic
Weston, WV...............................................Nov 5-10, 2017 Houston, TX...............................................Oct 9-13, 2017
Houston, TX...............................................Nov 27-Dec 1, 2017
CIP Level 2
Anaheim, CA .............................................Oct 8-13, 2017 Internal Corrosion for Pipelines—Advanced
Cape Canaveral, FL ...................................Dec 10-15, 2017 Houston, TX...............................................Oct 16-20, 2017
Commerce, CA ..........................................Oct 15-20, 2017 Marine Coating Technology
Denver, CO................................................Oct 22-27, 2017 Houston, TX...............................................Oct 30-Nov 2, 2017
Houston, TX...............................................Oct 8-13, 2017 Offshore Corrosion Assessment Training (O-CAT)
Houston, TX...............................................Oct 22-27, 2017 Houston, TX...............................................Oct 30-Nov 3, 2017
Houston, TX...............................................Nov 5-10, 2017 PCS 1 Basic Principles
Houston, TX...............................................Nov 12-17, 2017 New Orleans, LA........................................Dec 4-6, 2017
Houston, TX...............................................Dec 3-8, 2017
PCS 2 Advanced
Houston, TX...............................................Dec 17-22, 2017
New Orleans, LA........................................Dec 7-9, 2017
Jacksonville, FL..........................................Nov 6-11, 2017
Lanham, MD ..............................................Oct 8-13, 2017 Pipeline Corrosion Assessment Field Techniques (P-CAFT)
Lansing, MI ................................................Oct 15-20, 2017 Houston, TX...............................................Nov 13-17, 2017
New Orleans, LA........................................Nov 12-17, 2017 Pipeline Corrosion Integrity Management
Newington, NH .........................................Oct 15-20, 2017 Houston, TX...............................................Oct 30-Nov 3, 2017
Orlando, FL................................................Nov 12-17, 2017 Shipboard Corrosion Assessment Training (S-CAT)
Philadelphia, PA ........................................Oct 8-13, 2017 Houston, TX...............................................Oct 9-13, 2017
Pittsburgh, PA............................................Nov 12-17, 2017 Virginia Beach, VA .....................................Oct 9-13, 2017
San Ramon, CA..........................................Nov 13-18, 2017
Seattle, WA................................................Nov 12-17, 2017
St. Louis, MO .............................................Nov 5-10, 2017
Waipahu, HI...............................................Oct 15-20, 2017 For the complete course schedule, visit www.nace.org/eduschedule.

MAKING
CONNECTIONS
“ I’ve worked for 35 years as an inspector

in the oil & gas industry, inspecting pressure
vessels, hydrocarbon storage tanks, pipes, and
pipelines. It would be impossible to imagine my
”
career without the imprint of NACE. When I was
designing my career, I always found some course
and certification that gave more validity and
recognition.
– José Caprarulo, NACE CIP Level 2, CP1, and

Corrosion Technologist Certified, Self-Employed
NACE Career Development, your experts in

training and certification
Developed by Industry,
Globally Recognized.
nace.org/career-development
CORROSION ENGINEERING DIRECTORY
Exclusive Authorized Distributor
Belzona Western 2016 Ltd.
Calgary, Alberta Canada
Phone: 1-403-225-0474
Complete Corrosion Control Systems

Fax: 1-403-278-8898
Web site: www.belzona.ca ISO 9001-2000 certified
E-mail: [email protected] ACCESS FITTINGS ER PROBES LPR PROBES COUPONS
• • •
COUPON HOLDERS•CHEMICAL INJECTION•INSTRUMENTS
Belzona Polymeric Coatings combat erosion, corrosion and SOFTWARE•ANALYSIS•ISO 9001:2000 CERTIFIED
abrasion in high temperature immersed conditions. Rebuild
and line tanks, process vessels and plant equipment. Manufacturing & Installation
4815 Elenlak Road, Edmonton, Alberta, T6B 2N1
Tel (780) 465-1187 E-mail [email protected]
and Procedures. Fax (780) 466-4632 Web Site www.caproco.com
THE D.E. STEARNS COMPANY

Manufacturers of Worry-Free Holiday
Detectors Since 1941
COASTAL CORROSION CONTROL, INC.
800-894-2120
www.coastalcorrosion.com
For over 25 years, Coastal Corrosion Control has been
the Gulf South’s leader in cathodic protection
We offer services nationwide including:
• Construction/Installations • Pipeline - Integrity - ECDA
• Engineering & Design • Right-of-Way Maintenance
• Material Sales • Survey
• Offshore www.destearns.com
ISO-9001 Certified
Aluminum • Magnesium • Zinc
QUALITY • PERFORMANCE • RELIABILITY
Sales Office Headquarters

181 Grefer Lane 6712 S. 36th Street
Harvey, LA 70058
Tel.: (504) 362-7776
ANODES McAllen, TX 78503
Tel.: (956) 630-3500
Fax: (504) 269-1418 Fax: (956) 630-3595
[email protected]
www.galvotec.com
Pin Brazing
Easybond equipment & consumables available in
Cathodic Protection & Corrosion Engineering the USA through sole importers Galvotec Corrosion
Design • Installation • Inspection • Materials • Services Services and GMC Electrical
Pin Brazing • Retrofit Systems • On-Shore • Off-Shore Contact
Dave Johnson on 504-362-7373
300 Bark Dr., Harvey, LA
or
Tel. 504-362-7373 Fax. 504-362-7331
www.galvoteccorrosion.com
TARGET YOUR AUDIENCE Gary Matlack on 909-947-6016
To reserve your ad space,
call +1 281-228-6269.

CORROSION ENGINEERING DIRECTORY
Project Management GPS Surveys ILI Digs Phone/fax: 210/923-5999
Engineering Stray Current & Interference Analyses
Remediation SSCDA ECDA ICDA DCVG
E-mail: [email protected]
AC Mitigation
Casings
Bellhole
Excavations
& Inspections
Construction METASPEC Co.
Groundbeds Test Stations

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

Anode Manufacturing Materials
CP Solutions J Boxes
P.O. BOX 240898 r SAN ANTONIO, TEXAS 78224
we do it all. 1.888.800.MESA mesaproducts.com
Quality Control Based on Verified Data
» Full Service Materials Laboratory

» Materials Performance Evaluation
» Accelerated Life Testing
» Simulated Environments
» Root Cause Failure Analysis
724.519.9068
rjleegroup.com
ST RAT EG I C CH E M I STRY
Experienced and trusted
worldwide in Gas and Oil
Production Chemistry.
www.strategic-chemistry.com
www.tinker-rasor.com TRI-STAR INDUSTRIES PTE LTD

Website: www.tristar.com.sg
Tel: +65 6266 3636
Fax: +65 6265 3635 / 6265 2801
Specialist Manufacturer of Aluminum & Zinc

Anodes. We also provide full CP surveys, installations &
commissioning, including ICCP systems.
www.teststations.com
Plated and PTFE Coated Fasteners.
ZINGA Film Galvanizing System.
Attn. NACE Sections:

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

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

Coatings
Coatings and linings: Life cycle cost, case studies of different coatings systems used,
protection of steel and concrete infrastructures, new coating formulations, application
Registration
technologies, inspection methodologies, instrumentation and standards. Regular Registration
QCQA Nondestructive Testing
QCQA Non-Destructive Testing: Surface preparation inspection and standards, Quality Nonmember: $350 USD
control issues and optimization. New non-destructive technologies. Environmental
control and technologies. One Day Registration
Design & Selection Nonmember: $175 USD
Design & Material Selection: material selection and design for extended structure integrity
and service life
Cathodic Protection
Corrosion control method and investigation: cathodic protection, ILI, ECDA, HVAC, SCC,
HVDC, interferences, rebar in concrete, corrosion under insulation, high temperature
corrosion, case studies (municipal infrastructures, concrete structures, aboveground and
underground tanks, pipelines…etc.)
OFFICIAL MEDIA PARTNERS

AD INDEX
LISTING OF ADVERTISER CONTACT INFORMATION
Advertiser....................................Page No. Advertiser....................................Page No.
ACA – Australian Corrosion Association......................................................23 MP Annual Company Showcase

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

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

400,000 units installed.
www.borin.com ∙ (310) 822-1000

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24 Consecutive Years of Sales Growth

Innovation based. Employee owned. Expect more.

Storage tanks, especially tanks that hold petrochemicals,

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

28 Protecting Concrete Infrastructure from Corrosion

60 9th Annual Company Showcase

MATERIALS SELECTION & DESIGN

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

CORROSION PREVENTION AND CONTROL WORLDWIDE MATERIALS PERFORMANCE

8 What’s Online @ www.materialsperformance.com

CORROSION 2018 The MP Blog

MP (Materials Performance) is published monthly by NACE International

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

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

nonmembers $115; overseas nonmembers $130; libraries

subject to change. must be prepaid. All overseas

6 months of issue date filled at no charge, availability permitting. Non-

Canada or +1 281-228-6223 worldwide or email: [email protected]).

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

INSULATION FOR COMMERCIAL AND

Contact us to learn more

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

Halve your DFT inspection

New Collaborative Research Project

Researchers Eye Advanced Sensors

For even more corrosion news, visit

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

Stand the TECHNICAL EDITORS Norman J. Moriber

Test of Time TECHNICAL EDITOR EMERITUS

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

The following are excerpts from the

Water for Copper/Copper

A: Definitely not! You should use

A: Distilled water must be used, and

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

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

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

A: If the cracking is occurring in the

A: I had a similar problem in the

A: Would it be possible to insulate

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

Study Evaluates Chloride Limits for

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

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 15

Access the digital issues of MP at

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

Florida Tests Cathodic Protection Solutions

T he ease and practicality of installa-

so high that typical galvanic anodes either

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

To address this, FDOT’s corrosion

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

ATTENTION Looking for Rehab and

Design guidelines Tanks Lift Stations

NACE INTERNATIONAL: VOL. 56, NO. 9 MATERIALS PERFORMANCE SEPTEMBER 2017 19

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

AXALTA COATING SYSTEM

QUALITY & PROTECTION

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