Spring 2005 • Volume 10 Issue 7 The Newsletter for NACE Coating Inspectors and Students

In This Issue...

Tank Lining Applications ......................1

Coatings at CORROSION/2005 ...............3

Coating Inspection Procedures During Shop-Priming Operations .........6

Coatings—A $108 Billion Opportunity ..........................................9

Thermal-Spray Metallizing Inspection—Shifting Gears ..................9

Chairman’s Corner .............................. 11

Get This! ............................................. 11

Peer Corner .........................................12

Coatings Resources—Technical Committees .........................13

Coatings Resources—Standards & Reports ........................... 16

CIP Schedule ....................................... 18

Don’t Miss Mike Ditka! ....................... 19

© 2005 NACE International 1

Supplement to Materials Performance

continued on page 2 “Tanks”

Ta n k l i n i ng appl icat ions

have always been near and dear to my heart. Inspection, documentation, weather impacts, env i ronmenta l control measures, qualified appl i-cators, the right

specifi cation, adequate equipment, proper surface preparation, proper material selec-tion, quality control, and quality assurance are just a few of the necessary considerations when taking on a tank lining project. Unlike an exterior project where you have visual access to the life of the applied coating, tank lining applications are out of sight and out of mind once they have been installed and put back into full product immersed service. Lining application failures can be catastrophic to a facility owner and cost thousands of dollars in lost revenue, not to mention the expense of the lining repairs and/or replacement. Environmental regula-tions are strict and tank storage facilities are guarded against product leakage and ground contamination.

There usually are time constraints, and of course the old client adage of “bring the cost in at or under budget” make tank lining applications very high-profi le projects. Con-sider that the lining application will no longer be visible for routine or random inspections after the manways have been secured and precious product has been introduced.

Tank Lining ApplicationsBy Wayne Pruitt, Brock Maintenance, Inc.

Why Apply Tank Linings?Every tank lining project shares a basic

need for a protective coating, whether it be for corrosion control or for product purity purposes. Makes sense? The tank I am about to describe is no different. When I think back on all of the tank lining project applications I have been involved in over the past 28 years as a coatings contractor, this one humbles me to the core. I have had many, many great experiences with storage tank lining applications over the span of my long coatings career.

Inside & OutThis most memorable project consisted of

abrasive blasting the exterior chalked and weathered coating to a NACE No. 3/SSPC-SP 6 (commercial blast) and applying an epoxy primer, epoxy intermediate, and a urethane fi nish coat to a total system fi lm thickness of 12 to 15 µm dry fi lm thickness (DFT). Easy enough. The interior had an old epoxy phenolic lining that we would abrasive blast out to a NACE No. 2/SSPC-SP 10 (near white) and apply three coats of epoxy phenolic also at 12 to 15 µm DFT. This tank was a riveted crude oil storage tank at a Houston area refi ning facility and was 120 ft wide by 48 ft high. The interior specifi cations also called for an epoxy phenolic stripe coat to all welds and seams. There was visible cor-rosion to the interior roof, side walls, and fl oor, with leakage evident around many of the seam rivets. Riveted steel storage tanks

2

continued from page 1 “Tanks”

were common and constructed back in the 1950s. Continuous weld-sealed seam storage tanks became the most common way to store liquid product in the early to mid 1960s and are still the most commonly built. A 10 ft by 10 ft door sheet was cut out of the lower tank shell course to allow scaffolding and motor-ized personnel boom lifts for access to be placed inside the tank. Most of the abrasive blasting to the interior roof and walls was done out of the boom lifts.

The A TeamI had my best team of tank lining crafts-

men and my best lining supervisor working the project. These guys had a history of be-ing very productive and providing a quality fi nished product. These craftsmen were so good that they literally went from one storage tank project to another. One of the biggest challenges on a large project like this is keeping enough blasting abrasive and lining materials on hand. Every lining project has to be estimated and budgeted properly. A crew of eight men can consume and apply a tremendous amount of these materials on a large lining project.

Documented Hold Points Are CriticalThere are many inspection hold points on

a project like this. A third-party inspector hired by the owner facility and my site quality control person would do a joint inspection on all of the hold points to verify and docu-ment the quality and approve the hold point before moving on to the next step in the surface preparation and application process. The coatings manufacturer was also doing random quality assurance to confi rm that their materials were applied properly under acceptable conditions. All of this is typical on a lining project.

Looks Great The crew completed the project as planned.

The lining application was installed accord-ing to specifi cation and looked absolutely

beautiful. Cure time on the ap-plication was complete. Every riveted seam had been caulked

and sealed to perfection. Every square inch of epoxy phenolic-coated interior surface had been jeep tested with low-voltage Tinker & Rasor sponge units and this baby was ready for the next phase. The A Team was moved to the next lining project.

What’s Next?The door sheet is installed and buttered

up (welded) and the welded seam gets the same system that was applied to the rest of the tank interior. It is common after applying a lining of this nature to fi ll the tank with water (commonly referred to as hydroing the tank) to confi rm the integrity of the lining and mechanical capabilities of the tank. This process normally takes about one week. If no leakage is found the tank is emptied, cleaned out, and product is introduced. No leakage was found.

The Call!I remember getting a most haunting

call from the client shortly after the tank had been cleaned out: “Wayne, you have got to get over here right now! The lining application has failed and visible damage is everywhere!” My fi rst reaction was “You are joking, right?” “No, I am not.” I could tell by the tone of his voice that he was on a very short fuse. The tank was just a couple of minutes away from my fi eld of-fi ce. En route to the tank my stomach was in a knot and all I could think about was what could have gone wrong. The client was standing in front of the manway as I arrived at the tank, fl ashlight in hand, with a look of disgust on his face. A hole watch was posted at the manway and permits were already posted for our entry.

Catastrophic Failure Everywhere!We climbed in through the manway to

see shocking evidence of coating failures to the bottom half of the tank shell and to much of the tank fl oor. Now I was really sick! I spent the better part of the next fi ve minutes trying to rationalize how the per-fect lining application could turn out to be such a catastrophe. After careful review I

came to the quick conclusion that this was not a coating failure at all. No, the material manufacturer was not at fault, the coatings contractor was not at fault, and the quality control process was not at fault.

The Mark of ZorroThen what? As I investigated the dam-

aged areas I noticed unusual patterns burned through the coatings as if someone had written graffi ti on the walls and fl oor. It literally looked as if Zorro himself had been turned loose in the tank to leave his mark everywhere. I guess the tell tale sign was when I discovered the words neatly burned on the fi rst shell course reading “Joe loves Mary.”

So What Happened?After further review, the following con-

tributing factors resulted in the failure:• The tank had been fi lled with fi rewater

during the hydro process, which was common and I believe still is.

• The water source (fi rewater) had left the tank shell and fl oor covered in a fi lm of heavy black contaminants.

• A tank cleaning crew had been as-signed by the client to go in and pressure wash the contaminants off the thin fi lm coatings application.

• The water source also had traces abrasive particulates.

ConclusionThe combination of too much water pres-

sure and traces of abrasive particulates cre-ated a wet abrasive blasting scenario.

Closing Comments and Lessons LearnedOf course I was relieved to fi nd that neither

I nor my A Team of craftsmen had fault in the coating failures that were evident inside the tank. However, the client still felt the same degree of discomfort since costly repairs would have to be performed and the imme-diate product service of the tank would be delayed. This true story took place very early in my coatings career and I have never taken a tank lining project lightly since. ■

3

Here are some coatings-related activites you might be interested in at CORROSION/2005, April 3-7, 2005, in Houston, Texas.

Highlighted activities are free.

Coatings-Related Activities at CORROSION/2005

Sunday, April 3Protective Coatings Specialist (PCS) Exam

Plan to take the PCS exam at CORROSION/2005. To sched-ule an exam contact Paula McCordic at 281-228-6214 or paula.mccordic@nace.org. The exam is four hours. 8 a.m. to 5 p.m.

Technical Committee Meetings■ Coating and Lining Applicator Qualifi cation (TG 320) [04]

1 to 5 p.m. ■ Coating Systems, Wax, for Underground Piping Systems:

Review of NACE Standard RP0375 (TG 296) [03] [04, 35] 2 to 3:30 p.m.

■ Fretting Corrosion Between Piping and Pipe Supports (TEG 229X) [02] 3:30 to 5:30 p.m.

Monday, April 4■ How to Avoid or Reduce Premature Coating Failures/FREE—

Mike O’Brien, Mark Ten Resource Group Inc. 1 to 5 p.m.

Symposia■ Pipeline Integrity Symposium (STG 35) 9 a.m. to 5:30 p.m.■ Marine Corrosion Symposium (STG 44) 9 a.m. to 5:30 p.m.

Technical Committee Meetings■ Pipelines: Liquid Petroleum Industry Corrosion Control

Issues Forum (TEG 314X) [35] [02, 03, 04, 05, 34] 8 a.m. to noon

■ Tank Truck Interiors: Coating and Lining Inspection (TG 069) [43] [03] 9 to 10 a.m.

■ Liners, Thermoplastic for Oilfi eld Pipelines (TEG 225X) [03] [33, 35] 9 a.m. to noon

■ Liners, Thermoplastic for Oilfi eld Pipelines (TEG 225X) [03] [33, 35] 9 a.m. to noon

■ Tank Truck Trailer Interiors: Corrosion Protection with Coatings and Linings (TG 068) [43] [03] 10 to 11 a.m.

■ Truck and Trailer Rails and Equipment: Manufacture and Coating (TG 322) [43] 11 a.m. to noon

■ Process Industry—Pulp and Paper (STG 38) 11 a.m. to noon

■ Offshore Steel Pipelines: Control of External Corrosion (TG 169) [30] [05, 35] 1 to 3 p.m.

■ Coatings, Tape for External Repair, Rehabilitations, and Weld Joints on Pipelines (TG 251) [03] [04, 35] 1 to 3:30 p.m.

■ Welding: Flue Gas Desulfurization (FGD) Techniques (TG 129) [45] 1 to 4:30 p.m.

■ Linings, Thin-Film Organic for Process Vessels (TEG 303X) [03] [34] 1 to 4 p.m.

■ Oil and Gas Production—Nonmetallics and Wear Coatings (Metallic) (STG 33) 2 to 3 p.m.

■ Railcars: Corrosion Protection and Control Program (TG 063) [43] [02, 03] 3:30 to 4:30 p.m.

■ Coatings, Liquid Epoxy for External Repair, Rehabilitations, and Weld Joints on Buried Steel Pipelines (TG 247) [03] [04, 35] 3:30 to 5:30 p.m.

■ Coatings, Liquid Epoxy for External Repair, Rehabilitations, and Weld Joints on Buried Steel Pipelines (TG 247) [03] [04, 35] 3:30 to 5:30 p.m.

Tuesday, April 5 ■ Outside Coatings Demo—Live demonstration of plural

component spray application of 100% solids material and polyurea/FREESponsored by Graco. 9 to 11 a.m.

■ Liner Based Secondary Containment for Aboveground Storage Tanks/FREE Sponsored by ILTA, presented by Timothy Dyring, Environmental Protection Services. 1 to 2 p.m.

■ CoatingsPro Perspective—A Look at Coatings and Corrosion/FREESponsored by CoatingsPro Magazine. 1 to 4 p.m.

■ Coatings Specs—The Good, The Bad, and The Ugly/FREEPresented by Ken Tator, KTA. 4 to 5 p.m.

■ Coach Mike Ditka, “Let Me Tell You About Teamwork”/FREE Mr. Ditka will speak from 5:30 to 6:15 p.m. and then be available for a “meet and greet” until 7:30 p.m.Sponsored by Sherwin-Williams, Graco, CC Technologies,Mobley, Betco, and Muenters 5:30 to 7:30 p.m.

continued on pages 4 and 5

Specifi c Technology Group (STG), Task Group (TG), and Technology Exchange Group (TEG) numbers follow the title Symposia or Technical Committee Meeting. STG numbers are two digits; TG and TEG numbers are three digits; note that TEG designations are always followed by an “X.” Two-digit numbers in brackets that follow the fi rst bracketed STG number (the administrative STG) indicate other STGs that have a direct interest in the committee's assignment. For an electronic copy of this schedule go to www.nace.org/tracker and choose coatings and linings.

4

Symposia ■ Pipeline Integrity Symposium (STG 35) Continued 9 a.m. to

6 p.m. ■ Marine Corrosion Symposium (STG 44) Continued 9 a.m. to

5 p.m. ■ New Developments in the Protection of Steel in Concrete

Symposium (STG 01) Continued 9 to 11:30 a.m.

Technical Committee Meetings ■ Railcars: Interior Protection of Railcars Hauling Sulfur (TG

067) [43] [03] 8:30 to 10:30 a.m. ■ Coatings and Linings, Protective: Atmospheric (STG 02)

Meeting to explore the issues associated with corrosion at the interface between piping and pipe supports. 9 to 10 a.m.

■ Materials, Advanced, for High-Temperature Service in the CPI (TEG 123X) [37] 9:30 to 11:30 a.m.

■ External Pipeline Coatings: Performance Requirements for High-Temperature Service (TG 336) [03] [02] 9:30 to 11:30 a.m.

■ Offshore Ballast Water Tank Coatings: Standard Test Method (TG 263) [03] [33] and Offshore Exterior Submerged Coatings: Standard Test Method (TG 264) 10 a.m. to noon

■ Transportation, Land (STG 43) 10:30 a.m. to noon ■ Offshore Steel Platforms—Corrosion Control: Review of

NACE Standard RP0176 (TG 170) [30] [02,05] 10:30 a.m. to noon

■ Pulp and Paper Mill Effl uent Treatment Systems: Standard for Materials and Repair Methods for Piping, Tanks, and Concrete (TG 221) [38] [02,03] 11 a.m. to noon

■ Pulping Liquor Corrosion (TEG 131X) [38] 1 to 3 p.m. ■ Offshore Platform Maintenance Coatings (Nonimmersion):

Standard Test Methods (TG 260) [02] [33], Offshore Platforms: Coatings for Corrosion Control of Steel (TG 313), Offshore Platforms: Coatings for Atmospheric and Splash Zone New Construction (TG 312) 1 to 3 p.m.

■ Rail Industry: Information Exchange on Coatings-Related Issues (TEG 291X) [43] 1:30 to 5:30 p.m.

■ Building Systems (STG 46) 3:30 to 5:30 p.m. ■ Pipelines: Close-Interval Potential Surveys on Buried or

Submerged Metallic Pipelines (TG 279) [35] [05] 3:30 to 5:30 p.m.

■ Nonvisible Contaminants, Identifying Specifi c Levels (TG 288) [04] 3:30 to 5 p.m.

■ Coatings and Linings, Protective: Atmospheric (STG 02 and 03) This meeting will consist of a panel discussion on “Failure Modes of Buried Pipeline Coatings,” which is intended to precede the “Oil and Gas Coating Technology” symposium scheduled for

Wednesday and Thursday. Panelists will include Jeffrey L. Didas, Colonial Pipeline Co.; Matt Dabiri, Williams Gas Pipe Line; Sylvie Le Borgne, Instituto Mexicano del Petroleo; and Colin Frayne, The Metro Group. 3:30 to 5:30 p.m.

Wednesday, April 6■ Outside Coatings Demo—Live demonstrations where the win-

ners of the Houston Coating Society will be showcased/FREESponsored by the Houston Coating Society. 9 to 11 a.m.

■ Coatings Used in Conjunction with Cathodic Protection: A Primer/FREEPresented by Richard Norsworthy, Lone Star Corrosion Services Co. 9 to 11 a.m.

■ How to Deal with the Media after an Environmental Incident/FREEPresented by Phil Fouche, Quatro Products. 10 to 11:30 a.m.

■ Coatings Under Insulation/FREEPresented by Peter Bock, International Paint, Inc. 1:30 to 3:30 p.m.

■ Tank Linings: You Want What? When?/FREEPresented by Bob Hummel, Sherwin Williams. 3 to 4 p.m.

Symposia ■ Oil and Gas Technology Symposium (STG 02 and 03)

9 a.m. to 5:30 p.m. ■ Direct Assessment Symposium (STG 35) 9 a.m. to 6 p.m. ■ Corrosion in the Pulp and Paper Industry Symposium

(STG 38) 9 to 11:30 a.m. ■ PANEL—Potential Legal Ramifi cations/Issues Arising from

Inspection Issues Symposium (STG 04) 3:30 to 5:30 p.m.

Technical Committee Meetings ■ Pipeline Coating: Aboveground Techniques for the

Underground Evaluation of Condition (TG 294) [35] [03, 05] 9 to 11 a.m.

■ Marine Vessel Corrosion (TEG 181X) [44] 9 a.m. to 5:30 p.m. ■ Coatings and Linings, Protective: Surface Preparation

(STG 04) 9 to 10 a.m. ■ Military and Aerospace Equipment: Aging Systems and

Condition-Based Maintenance (TEG 178X) [40] 9:30 to 11:30 a.m.

■ Surface Preparation of Contaminated Steel Surfaces (TG 142) [04] [02, 03, 43] 10 a.m. to noon

■ Reinforced Concrete: Design Considerations for Corrosion Control (TG 290) [01] 10:30 to 11:30 a.m.

■ Ductile and Cast Iron Pipe: Corrosion Control (TG 014) [35] [02, 03, 05, 39] 1 to 5:30 p.m.

continued from page 3

5

■ Lining, Tanks and Vessels for Immersion Service: Fabrication Details, Surface Finish Requirements, and Proper Design Considerations—Review of NACE Standard RP0178-2003 (TG 295) [04] [02, 03, 43] 1 to 3 p.m.

Thursday, April 7■ Ensuring Coating Performance—Special Session/FREE

Presented by Jeff Davis, President of Brock Maintenance, Inc.9 to 9:45 a.m.

■ Coating Condition Surveys—Special Session/FREE Presented by Terry Greenfi eld, Principal of CorroMetrics 10 to 11 a.m.

Symposia ■ Direct Assessment Symposium (STG 35) Continued 8 to

11:30 a.m. ■ Oil and Gas Technology Symposium (STG 02 and 03)

Continued 9 a.m. to 5:30 p.m. ■ AC Corrosion Mechanisms and Control Symposium

(STG 35) 1 to 4:30 p.m.

Technical Committee Meetings ■ Nonmetallic Materials of Construction (STG 10) 8 to 11 a.m. ■ Marine Corrosion and Transportation (STG 44) 8 a.m. to

noon ■ Pipelines, Tanks, and Well Casings (STG 35) 9 to 11 a.m. ■ Reinforced Concrete: Corrosion-Resistant Reinforcement (TG

057) [01] [46] 1 to 3 p.m. ■ Reinforced Concrete (STG 01) 3:30 to 5 p.m.

continued from page 4

6

The shipbuilding industry, particularly in Japan, South Korea, and Europe, has

realized many benefi ts in terms of quality, speed, and cost from the development of shop primer technology. (In the U.S., shop primer is also known as pre-construction primer.) However, some in the coating industry have not properly acknowledged the role of this coating material. Very often the shop primer is not considered as a separate layer of the coating system. In many cases, though, it does remain on the substrate beneath subsequent layers and must be applied, checked, and inspected like any other paint application. The shop primer’s nature and characteristic make the coating quite dif-ferent from other “paints.” Its formulation, application, and quality control procedures are very different from those of other coat-ings. Unfortunately, many who use these coatings are unfamiliar with these unique requirements.

Coating Inspection Procedures During Shop-Priming OperationsRoberto Malfanti (NACE Certifi ed Coating Inspector #6462)IMC engineering s.r.l., Genova, Italy

What Is Shop Primer?As the name indicates, shop primer is a

coating that is designed to provide short-term protection of steel during fabrication and before application of the remaining coating layers. It must do two things: protect steel from rusting in a typically aggressive industrial environment and assure a sound surface for subsequent coats. Choosing the right shop primer depends on many fac-tors. Some of these criteria include steel type, fabrication procedure and duration, plant technical characteristics for surface preparation and application, method and degree of secondary surface preparation, desired long-term protective coating system, budget, and health and safety rules. Though not exhaustive, this list shows that choosing the right shop primer is not easy.

A summary of the requirements that a shop primer must satisfy is as follows:1. It must not negatively infl uence speed

and quality during cutting operations. 2. It must not affect welding quality and

speed.3. It must not diminish weld strength.4. It must not emit toxic fumes during

welding and heating.5. It must be easy to apply with automatic

equipment.6. It must dry quickly, allowing one to

handle the steel plates shortly after ap-plication.

7. It must exhibit good adhesion on abra-sive-blasted steel.

8. It must resist mechanical damage and high temperatures.

9. It must provide good corrosion protec-tion.

10. In addition to being non-saponifi able, it must resist water, rain, solvents, and chemicals.

11. It must accommodate overcoating with a wide-ranging paint system.

7

Like any other coating material, a shop primer contains ingredients such as pig-ments, extenders, binders, solvents, dryers, and rheological and leveling agents. However, the demands placed on it are more similar to the desired properties of paints; hence, a shop primer is a sophisticated and techno-logically advanced product.

Paint manufacturers, particularly those serving the marine industry and under-standing its uniquely rigorous demands, have taken great strides in developing high-performance products.

Many types of shop primer have been produced over the years—polyvinyl butyral (PVB), zinc-rich, and epoxy iron oxide to name a few. The marine industry commonly uses inorganic zinc (IOZ) silicate shop prim-er, although epoxy iron oxide is still locally used and produced. This article will focus exclusively on IOZ silicate shop primer.

Recent developments in silicate technology led to the formulation of zinc silicate shop primers with lower elementary zinc concen-trations. On a practical level, the advance-ments enhanced the preservation benefi ts of zinc-rich primer and eliminated earlier defects associated with cutting and weldabil-ity. Most zinc silicate shop primers are two-component, solvent-borne, moisture-cured ethyl silicates that are applied at a dry-fi lm thickness (DFT) of 15 to 25 µm. These coat-ings exhibit excellent weather and abrasion resistance, but they offer marginal benefi t in terms of the speed and quality of welding and cutting. Thanks to their completely inorganic structure, these primers provide very good thermal stability. Furthermore, because they form only a limited number of zinc salts, the shop primers are compatible with most paint systems and may even withstand systems intended for immersion service and cathodic protection. The emission of zinc fumes falls within acceptable limits, decreasing health risk. Though zinc silicate primers do offer many benefi ts, there is, of course, room for improvement—particularly in the areas of cutting and welding speed.

Today and TomorrowModern shipbuilding techniques (block

stage methods) have translated into shorter

construction periods and the requisite faster cutting and welding processes. Not surpris-ingly, health and safety rules and require-ments have improved as well.

Prompted by the changes in shipbuilding, paint manufacturers in recent years have developed “medium zinc silicate” and “low zinc silicate” shop primers. The former have a zinc content of 38 to 40% by weight and 13 to 15% by volume; the latter have a zinc content of 24 to 30% by weight and 8 to 12% by volume. The reduced zinc levels have improved the quality and speed of cut-ting and welding operations. In addition, the medium and low primers resist heat up to temperatures of 800°C without burning; this has resulted in a drastic reduction of back-burning damages.

The future of shop primer hinges on the development of a water-based zinc silicate formulation that meets rules limiting the amount of volatile organic compounds in the coating. In spite of paint manufacturers’ efforts to develop and formulate this type of shop primer, the goal has proved elusive. Much work remains in terms of research and testing before a suitable and effective water-based shop primer becomes a reality.

Application and ControlThe range of applications for shop primer

is very wide. These coatings are used in virtually every case in which steel is used as a construction material. Not surprisingly, questions abound regarding the correct application on myriad plates, pipes, and pro-fi les. Although small workshops may apply shop primers manually, this article focuses on the automatic machine application of these coatings.

In a shipyard, a conveyor carries steel stock to the site’s shop-priming equipment. The prefabrication workshop, where plates and profi les are cut, sits on the side of the equipment opposite the conveyor. The prin-cipal components of this “production chain” include the preheater, centrifugal blasting enclosure, paint chamber with mixing site, drying oven, abrasive silo, and separator with fi lters. A continuous hydraulic press may also be positioned at the entrance. From an application standpoint, it is essential to prop-

erly clean the surface and obtain the correct fi lm thicknesses. Because the shop-priming process is almost completely automated, setting the machinery to follow the correct parameters is critical; this process alone can take days to complete.

The specifi ed degree of preparation fol-lows ISO 8501-1 Sa 2,5 (NACE No. 2/SSPC-SP 10) in nearly all cases. The standard calls for the use of reusable steel abrasive in various sizes—generally a mixture. Not only must the abrasive remove mill scale and rust, but it must also produce a suitable anchor pattern. Shipyards commonly use only steel shot in an attempt to reduce turbine blade wear. In fact, this practice fails to achieve the scour-ing action of grit and produces an incorrect anchor pattern. An airless blast-cleaning machine basically comprises an electric motor, a turbine (blasting wheel), and a V-belt transmission. A 40- to 70-hp (30- to 52-kW) electric motor usually supplies the motive power, but units with power outputs ranging from 15 to 100 hp (11 to 75 kW) can be used. In addition to power output, the number of revolutions (i.e., speed) is an important consideration. Because kinetic energy is directly proportional to particle speed, increasing the particles’ velocity markedly improves both production rate and blasting quality. Blasted steel is transported to a painting chamber, where movable arms fi tted with conventional or airless nozzles and a pump apply shop primer. Moving the coated steel through a drying tunnel with heating and forced ventilation ensures a quick, ready-to-handle condition. In order to assure optimal results, shipyard person-nel must check all parameters and perfectly adjust the shop-priming machinery. This automated process leaves no room for errors for two primary reasons: 1) The area treated per day by even a

medium-sized machine is large. 2) Shop-primed steel is a substrate that will

receive, with more or less preparation, a fi nal anticorrosive system. Therefore, it must exhibit well-defi ned mechanical and chemical characteristics.

continued on page 8 “Primers”

continued from page 7 “Primers”

In regard to checking various elements, the coating inspector must do the following: ■ Analyze the condition of the steel in

stock (for cleanness and the presence of pitting, laminations, and other steel defects).

■ Check the impeller system parameters to achieve the specifi ed grade of blasting.

■ Select the correct abrasive.■ Check the abrasive for cleanness and

water-soluble salts content.■ Determine the correct line speed.■ Determine the necessary elements for

achieving the required roughness.■ Check the grade of abrasive blast clean-

ing and the related roughness.■ Set the correct paint application by

regulating the pressure and the longi-tudinal/transversal speed; selecting the proper nozzle, angle, and distance; and measuring DFT.

■ Check the mixing site.■ Ensure correct drying to minimize

handling damages.■ Control DFT by different methods (steel

plates, glass plates).■ Control fi lm porosity by glass plates.

The most important points that have to be checked are the following:1) Steel cleanness: a) Verify that the steel has been abrasive-

blasted to Sa 2, 5 according to ISO 8501-1 (NACE No. 2/SSPC-SP 10).

b) Perform the “Dust Test” in accor-dance with ISO Standard 8502-3. The cleanness rating of the surface should not exceed the quantity rating 2 or dust size 2 of this standard.

2) Check the surface roughness of the steel using comparators such as Rugotest No. 3, Kean-Tator ISO 8503-1, or by rep-lica tape according to NACE Standard RP0287. The blasting profi le should be in the range of Rz 40 to 70 µm.

3) Check of the spray pattern by measuring the following parameters:

a) The effective fan width of the sprayed primer (meters) b) The transverse speed of the 8

spray gun (passes/min) c) The speed of the plate (m/min).

Taking into consideration the a.m. pa-rameters, one can calculate the overlap using the following equation:

(Effective Fan Width [m]) x (Traverse Speed [strokes/min])

Speed of the plate (m/min)During production the spraying pattern

must be regularly checked. In case any parameter of the unit is changed, perform the check again and adjust the spraying parameter.4) Check the uniformity of the applied

fi lm. The uniformity of the applied shop primer can be checked using ~8 x 25-cm glass panels taped on the abrasive-blasted steel surface and than sprayed. After the glass panel has dried, examine it against a light source to check spraying pattern uniformity, applied fi lm density, and whether any porosity is present.

5) Check the DFT. Because the roughness of the steel surface is often higher than the thickness of the shop primer, one cannot measure the DFT of the shop primer directly on the steel plate or profi le surface. Furthermore, the shop primer’s very fast drying time makes it impossible to measure the wet-fi lm thickness. Hence a special measuring method exists for this purpose.

Take DFT measurements on smooth test panels, whose length should be 25 to 30% greater than the spraying angle of the nozzles. The added length allows one to also measure the overlapping area. The steel panels should be 500 x 100 x 1 mm. Do not use panels less than 1 mm thick because they will yield incorrect measurements. Measure the DFT with an electromagnetic instrument, and calibrate the tool on an unpainted steel panel. Take at least 10 readings equally spaced over the length of each test panel. At least 85% of the values should be within ±3 µm of the specifi ed fi lm thickness. Tape the smooth test panels onto both sides of the

steel plates.In addition to the above steps, be sure

to inform the plant manager, personnel, and owner surveyor on a daily basis of inspections performed before, during, and after application. Any automatic plant must be checked constantly by personnel or suitable devices, but recognize that only regular human surveys can assure good results.

ReportThe coating inspector must record and

report the following points:

1) Plates and profiles: what is being painted and which rust grade appears on the steel?

2) Abrasive material: type and size of blasting media used

3) Profi le: what is the surface profi le after blasting and the method used to measure it?

4) Speed of the conveyor

5) Dust test result

6) Steel temperature immediately before painting

7) Name and type of the shop primer

8) Batch number of the paint (both base and curing agent)

9) Which type and how much thinner has been added?

10) Viscosity (e.g., DIN Cup 4/second)

11) Paint temperature

12) Pump ratio

13) Input pressure of the pump

14) Size and width of the nozzles

15) Number of nozzles

16) Overlap type, namely, one- or two-directional spraying

17) Distance between the nozzle and the steel plates or profi les

18) DFT measurement

19) Storage of the steel plates and pro-fi les

20) Comments and remarks. ■

9

Coatings—A $108 Billion Opportunity

The Houston Coating Society held its fi rst meeting of 2005 on Thursday, January

6, 2005, featuring NACE International Coatings Market Manager Larry Christie as the guest speaker. His presentation was titled “Coatings—$108 Billion Opportunity.” Larry gave an overview of the perception of coat-ings for corrosion control versus the reality. Based on his 30-plus years in the coatings industry, he reviewed the numerous positive changes that have taken place regarding coating formulations and new and rede-signed application and surface preparation equipment. He discussed the improvements made in specifi cations and project quality that have occurred since the inception of the NACE Coating Inspector Program more than 20 years ago. His presentation discussed the ongoing development of the NACE Applicator Training Program and his vision of even

better-quality coatings-related projects once this new program is offered to the industry. There have always been many career opportunities in the fi eld of coat-ings. Larry pointed out that given the large sum of $108 billion spent annually in the United States coatings industry, there will virtually be no end to future business opportunities.

Door prize winners at the meeting were Tom Vahle and Anthony Leidelmeyer of Sherwin Williams Paints, who each re-ceived a NACE golf shirt and golf balls.

Meeting attendees were sorry to hear of the passing away of valued NACE member Gary Cox. Gary was remembered with a story by his good friend Bill Osburn and a minute of silence. Our condolences go to all of Gary’s family, his many friends, and from his friends at NACE International. ■

Monica Chauviere (ExxonMobil), President of the Houston Coating Society (HCS), introduced Guest Speaker Larry Christie, NACE International Coatings Market Manager, at the January Houston Coating Society meeting.

Thermal Spray Metallizing Inspection—Shifting Gearsby Bill Goulette, Certifi ed Coating Inspector

Ok a y , M r . Inspector. You

have a new assign-ment. The Boss needs you to be the inspec-tor on a project in which various metal parts are being ther-mal spray metallized.

Where do you start? The beginning is as good a place as any. First you will need to obtain a copy of the specifi cation. Also, you need to be familiar with the standards referenced in the specifi cation.

One problem may be that your experience has been primarily with organic coatings. You have inspected numerous applications involving epoxies, polyurethanes, vinyl esters, etc., but this is your fi rst metallizing inspection assignment.

At this point you realize that you don’t know all you need to know about metallizing. After some initial preparation (homework)

and a few deep breaths, you will realize that you have some answers but you also have some questions. A good course of action at this point is to seek guidance from a trust-worthy, reliable person who has worked with this process before.

You also realize that you need to shift gears a little bit. You have witnessed inorganic zinc (IOZ) coating applications so you predict there are some similarities. You are partly correct in that the nature of the IOZ fi lm is different from most organic coatings. It is conductive, it is less temperature-sensitive, it is solvent-resistant, and it is porous. The big difference is that the anodic metal (zinc) in the IOZ coating is bound to itself and to the substrate by a binder that is the result of a chemical reaction.

Metallizing has no binder and is not dependent on chemistry in the same way as other inorganic coatings. Basically, it is a metal that usually has been drawn into wire form, which is then melted and splat-

tered onto the substrate. This not an elegant description and does not take into account the technology and skill required to do this, but it captures the essential character of the process.

Therefore, you will be inspecting a metal rather than a resin. This takes you slightly out of your comfort zone. Never fear, it is a coating fi lm and you are a coating inspector. Do your thing.

For industrial corrosion protection there are two methods of metallizing application—flame spray and electric arc. The fi rst (and oldest) is fl ame spray. This method uses a handheld gun to push a wire (aluminum, zinc, or whatever) through a fl ame (commonly oxygen/acety-lene). The fl ame melts the metal wire and compressed air propels the metal to the substrate. This method usually employs smaller-diameter wire or less wire volume

continued on page 10 “Thermal”

continued from page 9 “Thermal”

per unit time compared to the arc spray method. The result is lower production and higher associated labor cost. Often the completed fi lm is slightly “smoother” than the results of arc spray. On the other hand, arc spraying uses electric voltage/amperage to cause two wires (one positive and one negative) to arc. The resulting melted metal is propelled to the substrate by compressed air. This brings us to the next gear shift.

VisualThe completed fi lm will not be smooth

or slick like an organic coating fi lm. It is, after all, melted metal that has been splat-tered onto the substrate. Some experience or judgment will be required to determine whether the applicators are applying an overly rough fi lm. The metallizing should be generally uniform and free of large irregular lumps. (You can recognize that there is a problem if the fi lm is visually lumpy and signifi cantly thicker than what was specifi ed.) This is usually a result of an application fault that causes the gun to spit out large chunks of wire.

Film QualityAnother good thing to know is that in

both processes (fl ame and arc) there are some adjustments that the applicator can make to adjust the application quality. Flame adjustments, wire feed speeds, air pressure, voltage, and amperage are all elements that affect application quality. For instance, increasing atomization air pressure can result in a smoother more uniform fi lm, but too much air will tend to quench the melted particles before impact with the substrate and may affect the tensile strength of the completed fi lm.

Surface PreparationNow we are back on more familiar ground.

The surface prep is virtually the same as for other coatings. Organic and inorganic

contaminant should be removed from the substrate to be coated. Pressure washing, steam clean-

ing, or solvent cleaning is very important. Abrasive blasting to NACE No. 1/SSPC-SP 5 (White Metal) is normally preferred, but NACE No. 2/SSPC-SP 10 (Near-White Metal) is sometimes used for benign atmospheric exposures. Again, consult the specifi cation. The only thing of signifi cance here is that the anchor profi le is typically deeper and must be angular (sharp) to assure optimum adhesion. Aluminum oxide or steel grit are the commonly used abrasives and the anchor profi le is typically in the 3 to 5 mil (75 to 125 µm) range.

Metallizing ApplicationThe coating fi lm should be applied in

multiple passes. Typically three or four passes are needed to produce a specifi ed thermal sprayed aluminum (TSA) total dry fi lm thickness (DFT) of 7 to 14 mils (178 to 356 µm). The reason for this, besides thickness control, is to avoid abnormal internal fi lm stresses that can occur when one thick hot pass is used to achieve the total thickness. Also, spray angles should be as close to perpendicular as possible.

Being alert to pre-heat requirements is one way to show that you are a “clued-in” thermal spray inspector. Flame spray ap-plications usually require a preheating of the start area, although this criterion has no particular value when arc spraying. The reason is this: Strangely, moisture can result from the fl ame as a result of the combustion gasses mixing to form H

2O.

This moisture can cause fl ash rusting. Pre-heating burns off initial moisture resulting from the fl ame and increases the spread between the dew point and surface tem-peratures. The electric arc spray processes employ very high-deposition energies and obviously involve no fl ame.

Seal CoatRed alert. We, meaning us experienced

coating inspectors, are accustomed to policing single DFTs of 2 to 6 mils (50 to 150 µm). We want to ensure that the an-chor profi le is covered; therefore, we are tempted to want to see enough seal coat

to fully cover the surface roughness. This was one of the more diffi cult gear shifts I had to make when I began inspecting TSA. The seal coat is usually thinned down to a 20 to 40% volume solids material and applied to achieve a DFT of 0.5 to 1.5 mils (13 to 38 µm). However, this is not going to cover the rough TSA in the way you prefer. It will not provide a full strong color. It will look as if there is not enough of it, but there probably is. The seal coat is intended to fi ll microporosity in the metallizing to prolong the time before anode oxidation. It is not meant to be thick enough to be a barrier coating, nor is it intended to prevent cor-rosion current between the environment and the metallization. How else is the TSA going to be sacrifi cial? Although a seal coat may visually appear as though there is not enough of it and it is usually unattractive, you just have to live with it as long as it meets specifi cation criteria.

Thickness InspectionDFT tests per SSPC-PA 2 using magnetic

instruments, such as Type 1 gauges. Yeah, we can do that—piece of cake

HolidaysDon’t spoil the mystery of the moment by

asking about a holiday test. The metal fi lm is conductive...you can’t holiday test it. An interesting holiday test that is used by some end users is to let it sit out in the rain for a day (or wet it). The little orange spots will alert you where the coating is too thin or incorrectly sealed. Strange, huh?

Proof TestingIn addition to the visual and thickness

inspection, metallizing is typically proof tested by bend test, knife-cut, or adhesion testing (or combination of these). Bend testing involves spraying a thin sample panel with the same setup as produc-tion spraying and bending it 180 degrees

10 continued on page 11 “Thermal”

around a mandrel (typically 0.5 in.). There should be no signifi cant cracking and no spalling when scraped. Fine hairline cracks are acceptable. A knife cut involves cutting the fi lm with a blade and rating the bond. This test is somewhat subjective and is normally used when other methods are not available. For my money, the truest test is the quantitative adhesion test. It is typically performed in accordance with ASTM D 4541 or ASTM C 633. See the specifi cations for these requirements and pass/fail values.

A guide for these methods can be found in NACE No. 12/AWS C2.23M/SSPC-CS 23.00, Specifi cation for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel. A guide to operator qualifi cations can be found in ANSI/AWS C2.18-93, Guide for the Protection of Steel with Thermal Spray Coatings of Aluminum, Zinc, and Their Alloys & Composites—Annex C.

Familiarity with the above issues will get you off to a good start. Don’t shy away from metallizing inspection because the best training is experience. Make us proud Mr. Inspector. ■

GetThis!Congratulations to Henry Mowers from Mechanicsburg, Pennsylvania. He is the winner

of our latest drawing for a free CIP course (from the Winter issue of InspectThis!). Henry successfully completed the CIP Session I Course in Orlando, Florida, in February 2004. When told about winning the course Henry said, “THIS IS GREAT!” Good luck Henry!

Still don’t get it? Send an e-mail to InspectThis@nace.org or send a fax to 281/228-6368 letting us know that you saw this article and we will put your name into a drawing for a free course registration. To be eligible you must have passed either the CIP Level 1 Course or the CIP Exam Course 1, and your recognition/certifi cation must be active. You can use the free course for a Level 2 ( Session III) or Peer Review, the choice is yours. The free course must be taken before June 30, 2006. (The prize is transferable, but may not be resold. If the prize is transferred, the person receiving the prize must meet the same criterion and have completed Level 1 before March 1, 2005.) ■

11

continued from page 10 “Thermal” Chairman’s CornerIn past issues of “InspectThis!” I have

discussed the vast opportunities now afforded to the NACE Coating Inspector Program (CIP) in offering our program in many foreign countries. We all go through learning processes in our lives and the CIP is going through just that. As we have recently offered programs in such loca-tions as Asia, Australia, China, Europe, Africa, and South America, we are learn-ing the importance of including relevant standards that affect coating inspectors in their particular locations.

All of you receiving “InspectThis!” are at a minimum Level I Coating Inspectors and therefore realize that we don’t have the luxury of simply adding all of these stan-dards to a course that is already maxed out as to how much information can be offered in a one-week training course. Therefore, we are currently looking at other ways of providing this added information to those students directly affected.

To maintain the integrity of the CIP and of your recognition we must keep the same training and testing guidelines no matter where the course is being presented. A major goal of CIP has always been that

Ray Stone, CIP Chairman

CIP recognition means the same anywhere in the world.

We are cur-rently consulting with coating in-spection experts in areas of the world where our courses are be-ing presented to determine which standards should be included for the students in those areas. One method currently being considered by the committee is to include these as an ap-pendix to the manuals in the areas needed, therefore allowing the instructor to discuss pertinent issues where the (ISO, Australian, European, etc.) standards differ in scope and defi nition from the NACE and SSPC standards we use for testing purposes.

Just as we teach in the courses, it is of primary importance that the inspector acquires, maintains, and understands the standards specifi c to the specifi cation and the conditions of the location he/she is working in. ■

Welcome to the “Peer

Corner.” I’m Steve Ponc io, NACE I n t e r n a t ion a l Treasurer and one of the CIP Peers. You may have a chance to visit with me for a couple of hours

for a CIP Peer Review in the near future, or maybe you have already enjoyed that experience. “InspectThis!” Editor Laura Bartlett has asked me to kick off or re-establish the column we in the past have called the “Peer Corner.”

I sincerely hope each one of you have enjoyed the holidays and I wish all a suc-cessful New Year.

In years past we have used this space

Peer CornerSteve Poncio

to pass on helpful advice about taking an oral examination and also have shared some humorous items such as the time when one of the Peers dragged a “non-student” into a Peer Review, offered him coffee, and then found out he was just standing in the area and was not a peer candidate at all (not once but twice).

The goal of our articles will be to help ease some of the undue anxiety that exists out there regarding Peer Review. We want to help potential candidates understand and then be able to focus on what is important—job knowledge—and not fear the Peers or the exam.

I can tell you that a lot of misinformation exists in the coating inspector population. This column will attempt to answer any questions you may want answered and dispel the misinformation (by the way there is no “doctor death”).

At this time I would encourage you to send any questions or concerns you may have. For those who have had the pleasure of taking the Peer Exam, please pass on any humorous incidents or advice that you think would be helpful.

Until next time here are a few tips:■ Pay attention to the instructions given

to you by the Peer prior to the ques-tions being asked.

■ Do not be afraid to ask for clarifi ca-tion if you do not understand what is being asked of you.

■ Develop an outline, either mentally or by making physical notes, and think before you speak.

■ Leave time for the Peers to ask clarify-ing questions.

By the way, Peers do not own or wear black hoods. ■

12

COATINGS RESOURCES—TECHNICAL COMMITTEESGet in on the Ground LevelHelp Develop the Standards That Affect YouWhether you want to help shape change in the coatings industry or just gain a better under-standing of the standards that affect you, participating in NACE technical committee meetings is your best resource for the latest in cutting-edge coatings technology. If you are a member and would like to join a committee, go to the Members Only section of the NACE Web site to join online, contact ann.miller@nace.org, or call 281/228-6264.

The following is a list of NACE Technical Committees that deal specifi cally with the protective coatings and linings industry. If you are a member of NACE, you may participate in technical committee activities.■ Specifi c Technology Groups (STGs) are groups of technical committees organized

under a specifi c scope of activity. They either sponsor or administer a number of Task Groups (TGs) and Technology Exchange Groups (TEGs).

■ TGs are small committees formed by one or more STGs to produce specifi c documents as assigned. The work of each TG generally culminates in a technical committee publication.

■ TEGs are committees that are formed by STGs to conduct symposium and/or technical information exchanges (TIEs). TEGs do not generate technical committee publications.

STG 02Coatings and Linings, Protective: AtmosphericScope: Determine uses, application, and performance of coatings for atmospheric ser-vice. Atmospheric service denotes industrial and commercial equipment, architectural structures, and bridges.

TEG 145XVapor Corrosion Inhibitors and Rust Preventives for Interim (Temporary) Corrosion Protection: Advances and Novel ApplicationsAssignment: To conduct a symposium based on the recently revised NACE Standard RP0487.

TG 146Coatings, Thermal-SprayAssignment: To prepare state-of-the-art reports and recommended practices and develop train-ing, testing, and other programs to promote the awareness and proper use of thermally sprayed metals, plastics, ceramics, etc.

TG 148Threaded Fasteners: Coatings and Methods of Protection for Threaded Fasteners Used with New Structural Steel, Piping, and EquipmentAssignment: To develop a state-of-the-art report on effective coatings and methods for corrosion control of these connections.

TEG 192XCoating Industry Problems Confronting Owners and ContractorsAssignment: To provide a format for handling problems and issues that affect the owner and contractor utilizing coatings. Problems and issues may include hazardous waste, volatile organic compounds, applicator training, federal and state regulations, and others that may develop.

TEG 229XFretting Corrosion Between Piping and Pipe SupportsAssignment: Determining extent and miti-gation of corrosion damage associated with coating failures and/or pipe wall thickness reduction due to abrasion from relative move-ment between pipe and pipe supports.

TEG 255XCoatings, Thermal-Spray for Corrosion ProtectionAssignment : Exchange of information regarding thermal-spray coatings used for corrosion protection.

TG 258Coatings for Concrete in Atmospheric and Nonimmersion Service, SelectionAssignment: To write a standard recom-mended practice on the selection of coatings for concrete in atmospheric and nonimmer-sion service.

TG 260Offshore Platform Maintenance Coatings (Nonimmersion): Standard Test MethodsAssignment: To write test methods that utilize effective and economical hardware and test specimens. Test methods will include (1) prohe-sion/ultraviolet exposure, (2) salt contamination resistance, (3) edge retention, (4) thermal cy-cling resistance, (5) wet adhesion, (6) wormhole wettability, (7) impact resistance, and (8) abra-sion resistance. They cover the coating systems for offshore platform structural steel—splash zone, anti-skid, above-the-water areas.

TG 261Vapor Corrosion Inhibitors and Rust Preventives for Interim (Temporary) Corrosion ProtectionAssignment: To write a standard on rust preventives and vapor corrosion inhibitors for interim (temporary) corrosion protection.

TEG 311XThreaded Fasteners: Coatings and Methods of Protection for Threaded Fasteners Used With Structural Steel, Piping, and EquipmentAssignment: Share information concerning, and discuss effective methods for, corrosion control of fasteners used with structural, pip-ing, and equipment connections.

TG 312Offshore Platforms: Coatings for Atmospheric and Splash Zone New ConstructionAssignment: To develop standard test meth-ods for new construction coatings. The test methods are similar, but not identical to, those for maintenance coatings.

TG 313Offshore Platforms: Coatings for Corrosion Control of SteelAssignment: To write a standard addressing corrosion control of steel offshore platforms by protective coatings. Sections on protective coatings in NACE Standard RP0176 will then be removed.

STG 03Coatings and Linings, Protective: Immersion and Buried ServiceScope: Determine effectiveness, performance criteria, and quality needs of immersion coatings and lining materials used in immersion service. 13

TEG 033XPipeline Rehabilitation CoatingsAssignment: To discuss the technologies of underground pipeline coatings used for pipeline rehabilitation.

TG 034Pipeline Coatings, External: Gouge TestAssignment: To write a test method and criteria for evaluation of gouge resistance of a particular coating.

TG 139Linings, Polyurea Internal for Water Tanks: Application and InspectionAssignment: To develop a recommended practice for the application and inspection of polyurea internal linings for water tanks.

TEG 225XLiners, Thermoplastic for Oilfi eld PipelinesAssignment: To provide a forum for partici-pants to discuss liner operation experience and research activities.

TG 247Coatings, Liquid Epoxy for External Repair, Rehabilitations, and Weld Joints on Buried Steel PipelinesAssignment: To develop a recommended practice for minimum specifi cations for liquid coatings and their application, inspection, and testing for use in the fi eld.

TG 248Coatings, Heat-Shrink Sleeves for External Repair, Rehabilitations, and Weld Joints on PipelinesAssignment: To develop a recommended practice for minimum specifi cations for heat-shrink sleeve coatings and their application, inspection, and testing for use in the fi eld.

TG 251Coatings, Tape for External Repair, Rehabilitations, and Weld Joints on PipelinesAssignment: To develop a recommended practice for minimum specifi cations for tape coatings and their application, inspection, and testing for use in the fi eld.

TG 263Offshore Ballast Water Tank Coatings: Standard Test Method

Assignment: To develop a new test standard for offshore ballast water tank coatings. The new test standard will

utilize effective and economical hardware and test procedures. These include (1) free-fi lm wa-ter absorption/desorption, (2) wet adhesion, (3) edge retention, (4) fl exibility, (5) condensation resistance, (6) thick-fi lm cracking resistance, (7) cathodic disbondment, and (8) salt-fog re-sistance. The methods cover coating systems for offshore ballast water tank coatings for both new construction and maintenance purposes.

TG 264Offshore Exterior Submerged Coatings: Standard Test MethodAssignment: To develop a new test standard for offshore exterior submerged coatings. The new test standard will utilize effective and economi-cal hardware and test procedures. These include (1) free-fi lm water absorption/desorption, (2) wet adhesion, (3) edge retention, (4) fl exibility, (5) cathodic disbondment, (6) impact resis-tance, and (7) salt-fog resistance. The methods cover the coating systems for offshore platform submerged coatings in new construction only.

TG 265Coating, Polyolefi n Resin Systems: Review of NACE Standard RP0185-96Assignment: Review and revise as necessary NACE Standard RP0185-96, “Extruded Polyolefi n Resin Coating Systems with Soft Adhesives for Underground or Submerged Pipe.”

TG 281Coatings, Polyurethane for Field Repair, Rehabilitation, and Girth Weld Joints on PipelinesAssignment: To develop a recommended practice for a minimal specifi cation for the fi eld application, repair, and testing for a poly-urethane coating to be used on the exterior of buried pipelines.

TG 296Coating Systems, Wax, for Underground Piping Systems: Review of NACE Standard RP0375Assignment: Review and revise as necessary NACE Standard RP0375, “Wax Coating Systems for Underground Piping Systems.”

TEG 303XLinings, Thin-Film Organic for Process VesselsAssignment: Informal presentations con-cerning use, performance, durability, appli-cation, and inspection of thin-fi lm linings to prevent corrosion or protect product quality by linings applied to process vessels.

STG 04Coatings and Linings, Protective: Surface PreparationScope: Determine effectiveness, performance criteria, and quality needs of various methods of surface preparation for the application of coatings and linings.

TG 006Blasting: Review of Joint Standards NACE Nos. 1 To 4/SSPC-SP 5, 10, 6, 7—White Metal Blast Cleaning, Near-White Metal Blast Cleaning, Commercial Blast Cleaning, and Brush-Off Blast CleaningAssignment: To review, revise, or reaffi rm as necessary joint blasting standards NACE No. 1-4/SSPC-SP 5, 10, 6, 7.

TG 007PrecleaningAssignment: To revise and update SSPC-SP 1 (“Solvent Cleaning”) into a joint standard.

TEG 064XRailcar Surface PreparationAssignment: To keep abreast of industry changes and techniques and report fi ndings annually.

TG 142Surface Preparation of Contaminated Steel SurfacesAssignment: To review and update NACE Publication 6G186, “Surface Preparation of Contaminated Steel Surfaces.”

TG 259Salt Contaminants, Nonvisible, Soluble on Coated and Uncoated Metallic Surfaces Immediately Prior to Coating Application: EvaluationAssignment: Prepare a technical committee report on evaluating nonvisible soluble salts on steel and other nonporous surfaces prior to coating application.

TG 275Surface Preparation of Metals to WJ-1 (Clean to Bare Substrate) by High-Pressure WaterjettingAssignment: Develop a standard recom-mended practice for surface preparation of metals to WJ-1 by high-pressure waterjetting. This standard will be based on information provided in NACE No. 5/SSPC-SP 12, “Surface Preparation and Cleaning of Metals by Water-jetting Prior to Recoating.”14

COATINGS RESOURCES—TECHNICAL COMMITTEES

TG 276Surface Preparation of Metals to WJ-2 (Very Thorough or Substantial Cleaning) by High-Pressure WaterjettingAssignment: Develop a standard recom-mended practice for surface preparation of metals to WJ-2 by high-pressure waterjetting. This standard will be based on information provided in NACE No. 5/SSPC-SP 12, “Surface Preparation and Cleaning of Metals by Water-jetting Prior to Recoating.”

TG 277Surface Preparation of Metals to WJ-3 (Thorough Cleaning) by High-Pressure WaterjettingAssignment: Develop a standard recom-mended practice for surface preparation of metals to WJ-3 by high-pressure waterjetting. This standard will be based on information provided in NACE No. 5/SSPC-SP 12, “Surface Preparation and Cleaning of Metals by Water-jetting Prior to Recoating.”

TG 278Surface Preparation of Metals to WJ-4 (Light Cleaning) by High-Pressure WaterjettingAssignment: Develop a standard recom-mended practice for surface preparation of metals to WJ-4 by high-pressure waterjetting. This standard will be based on information provided in NACE No. 5/SSPC-SP 12, “Surface Preparation and Cleaning of Metals by Water-jetting Prior to Recoating.”

TG 288Nonvisible Contaminants, Identifying Specifi c LevelsAssignment: Develop a standard to correctly identify various levels of nonvisible contami-nants, primarily soluble salts, to assist speci-fi ers in designating desired levels.

TG 295Lining, Tanks and Vessels for Immersion Service: Fabrication Details, Surface Finish Requirements, and Proper Design Considerations—Review of NACE Standard RP0178-2003Assignment : Review of NACE Standard RP0178-2003, “Fabrication Details, Surface Finish Requirements, and Proper Design Considerations for Tanks and Vessels to Be Lined for Immersion Service.”

TG 320Coating and Lining Applicator Qualifi cationAssignment: To develop a joint NACE/SSPC standard for qualifi cation of industrial coating and lining applicators.

TG 323Wet Abrasive Blast CleaningAssignment: To prepare a technical com-mittee report on surface preparation by processes that involve abrasive, possible air, and pressurized water—wet abrasive blast cleaning.

STG 43Transportation, LandScope: To promote the development of tech-niques to extend the life of land transportation equipment.

TG 063Railcars: Corrosion Protection and Control ProgramAssignment: Develop guidelines for railcar lining requalifi cation.

TG 066Railcars: The Application of Solvent-Free Coating Using Plural-Component Spray EquipmentAssignment: To prepare a state-of-the-art re-port on the application of solvent-free coatings with plural-component spray equipment.

TG 067Railcars: Interior Protection of Railcars Hauling SulfurAssignment: To produce a report on state-of-the-art methods for protecting sulfur cars.

TG 068Tank Truck Trailer Interiors: Corrosion Protection with Coatings and LiningsAssignment: To prepare a state-of-the-art report on coatings and linings that are applied to the interior surfaces of tank truck trailers for the purpose of mitigating corrosion. This report will include a description of the ge-neric-type systems, commodities transported, and life expectancy of the systems.

TG 069Tank Truck Interiors: Coating and Lining InspectionAssignment: Prepare a state-of-the-art report relating to inspection requirements as pro-vided in HM183. This report will include the criteria required to prevent damage of the ap-plied coating and/or lining during the yearly inspection and provide the necessary steps to ensure a continual serviceable system.

TEG 180XAutomotive CorrosionAssignment: Discuss corrosion issues fac-ing the ground transportation (automotive) industry.

TEG 228XCoatings Corrosion Protection and Control ProgramAssignment: Exchange information on cor-rosion protection and control program for railcar coatings.

TG 271Railcar and Tank Trailer Interiors, Used: Surface Decontamination ProceduresAssignment: To prepare a technical commit-tee report describing surface decontamina-tion procedures for used railcars and tank trailers prior to coating application.

TEG 272XRailcars for Molten Sulfur: Technical Advances for Lining Application and ServiceabilityAssignment : Information exchange on technological advances in lining application and service standards for tank cars in molten sulfur transportation.

TEG 291XRail Industry: Information Exchange on Coatings-Related IssuesAssignment: Technical information exchange in conjunction with an STG meeting.

TG 322Truck and Trailer Rails and Equipment: Manufacture and CoatingAssignment: To prepare a standard recom-mended practice for manufacture and coating of truck and trailer rails and equipment. ■

15

COATINGS RESOURCES—TECHNICAL COMMITTEES

COATINGS RESOURCES—STANDARDS & REPORTS

16

NACE InternationalProtective Coatings and Linings

Documents

Atmospheric Service Standards

NACE Standard RP0281-2004Method for Conducting Coating (Paint) Panel Evaluation Testing in Atmospheric Exposures, Item #21026

NACE Standard RP0487-2000Considerations in the Selection and Evaluation of Rust Preventives and Vapor Corrosion Inhibitors for Interim (Temporary) Corrosion Protection, Item #21037

NACE Standard RP0297-2004Maintenance Painting of Electrical Substation Apparatus Including Flow Coating of Transformer Radiators, Item #21081

NACE No. 12/AWS C2.23M/SSPC-CS 23.00Specifi cation for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the Corrosion Protection of Steel (RP0203-2003), Item #21100

Atmospheric Service Reports

NACE Publication 6H188 (1996 Edition)Coatings over Nonabrasive Cleaned Steel Surfaces, Item #24129

NACE Publication 80200/SSPC-TR 4Preparation of Protective Coating Specifi cations for Atmospheric Service, Item #24209

NACE Publication 02103Liquid-Applied Coatings for High-

Temperature Atmospheric Service, Item #24219

NACE Publication 02203/ICRI Technical Guideline 03741/SSPC-TR 5Design, Installation, and Maintenance of Protective Polymer Flooring Systems for Concrete, Item #24220

Immersion/Buried Service Standards

NACE Standard RP0274-2004High-Voltage Electrical Inspection of Pipeline Coatings Prior to Installation, Item #21010

NACE Standard RP0375-99Wax Coating Systems for Underground Piping Systems, Item #21013

NACE Standard RP0185-96Extruded Polyolefi n Resin Coating Systems with Soft Adhesives for Underground or Submerged Pipe, Item #21029

NACE Standard RP0188-99Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates, Item #21038

NACE Standard RP0490-2001Holiday Detection of Fusion-Bonded Epoxy External Pipeline Coatings of 250 to 760 µm (10 to 30 mils), Item # 21045

NACE Standard RP0892-2001Linings Over Concrete for Immersion Service, Item #21060

NACE Standard RP0394-2002Application, Performance, and Quality Control of Plant-Applied, Fusion-Bonded Epoxy External Pipe Coating, Item #21064

NACE Standard RP0298-98Sheet Rubber Linings for Abrasion and Corrosion Service, Item #21085

NACE Standard RP0399-2004Plant-Applied, External Coal Tar Enamel Pipe Coating Systems: Application, Perfor-mance, and Quality Control, Item #21089

NACE No. 10/SSPC-PA 6Fiberglass-Reinforced Plastic (FRP) Linings Applied to Bottoms of Carbon Steel Aboveground Storage Tanks (RP0202-2002), Item #21093

NACE Standard RP0402-2002Field-Applied Fusion-Bonded Epoxy (FBE) Pipe Coating Systems for Girth Weld Joints: Application, Performance, and Quality Control, Item #21096

NACE Standard RP0602-2002Field-Applied Coal Tar Enamel Pipe Coating Systems: Application, Perfor-mance, and Quality Control, Item #21098

NACE No. 11/SSPC-PA 8Thin-Film Organic Linings Applied in New Carbon Steel Process Vessels (RP0103-2003), Item #21099

NACE Standard RP0303-2003Field-Applied Heat-Shrinkable Sleeves for Pipelines: Application, Performance, and Quality Control, Item #21101

NACE Standard RP0304-2004Design, Installation, and Operation of Thermoplastic Liners for Oilfi eld Pipelines, Item #21103

NACE Standard TM0174-2002Laboratory Methods for the Evaluation of Protective Coatings and Lining Materials in Immersion Service, Item #21206

NACE Standard TM0102-2002Measurement of Protective Coating Electrical Conductance on Underground Pipelines, Item #21241

Immersion/Buried Service Reports

NACE Publication 10D199Coatings for the Repair and Rehabilitation of the External Coatings of Buried Steel Pipelines, Item #24201

COATINGS RESOURCES—STANDARDS & REPORTS

17

NACE Publication 6A100Coatings Used in Conjunction with Cathodic Protection, Item #24207

NACE Publication 6A195Introduction to Thick-Film Polyurethanes, Item #24186

NACE Publication 6A198Introduction to Thick-Film Polyurethanes, Polyureas, and Blends, Item #24197

NACE Publication 6A287 (1997 Edition) Electroless Nickel Coatings, Item #24089

Surface Preparation Standards

NACE Standard RP0178-2003Fabrication Details, Surface Finish Requirements, and Proper Design Considerations for Tanks and Vessels to Be Lined for Immersion Service, Item #21022

NACE Standard RP0287-2002Field Measurement of Surface Profi le of Abrasive Blast Cleaned Steel Surfaces Using a Replica Tape, Item #21035

NACE No. 1/SSPC-SP 5White Metal Blast Cleaning (RP0494-2000), Item #21065

NACE No. 2/SSPC-SP 10Near-White Metal Blast Cleaning (RP0594-2000), Item #21066

NACE No. 3/SSPC-SP 6Commercial Blast Cleaning (RP0694-2000), Item #21067

NACE No. 4/SSPC-SP 7Brush-Off Blast Cleaning (RP0794-2000), Item #21068

NACE No. 5/SSPC-SP 12Surface Preparation and Cleaning of Metals by Waterjetting Prior to Recoating (RP0595-2002), Item #21076

NACE No. 6/SSPC-SP 13Surface Preparation of Concrete (RP0397-2003), Item #21082

NACE No. 8/SSPC-SP 14Industrial Blast Cleaning (RP0299-99), Item #21088

Surface Preparation Reports

NACE Publication 6A192/SSPC-TR 3 (2000 Edition)Dehumidifi cation and Temperature Control During Surface Preparation, Application, and Curing for Coatings/Linings of Steel Tanks, Vessels, and Other Enclosed Spaces, Item #24083

NACE Publication 6G197/SSPC-TU 2Design, Installation, and Maintenance of Coating Systems for Concrete Used in Secondary Containment, Item #24193

NACE Publication 6G198/SSPC-TR 2Wet Abrasive Blast Cleaning, Item #24199

Land Transportation Standards

NACE Standard RP0386-2003Application of a Coating System to Interior Surfaces of Covered Steel Hopper Rail Cars in Plastic, Food, and Chemical Service, Item #21033

NACE Standard RP0592-2001Application of a Coating System to Interior Surfaces of New and Used Rail Tank Cars in Concentrated (90 to 98%) Sulfuric Acid Service, Item #21057

NACE Standard RP0692-2003Application of a Coating System to Exterior Surfaces of Steel Rail Cars, Item #21058

NACE Standard RP0295-2003Application of a Coating System to Interior Surfaces of New and Used Rail Tank Cars, Item #21070

NACE Standard RP0495-2003Guidelines for Qualifying Personnel as Abrasive Blasters and Coating and Lining Applicators in the Rail Industries, Item #21072

NACE Standard RP0398-98Recommendations for Training and Qualifying Personnel as Coating Inspectors in the Railcar Industry, Item #21086

NACE Standard RP0302-2002Selection and Application of a Coating System to Interior Surfaces of New and Used Rail Tank Cars in Molten Sulfur Service, Item #21095

Land Transportation Reports

NACE Publication 14C196The Application of Solvent-Free Epoxy Coatings to Railcars Using Plural-Component Spray Equipment, Item #24188

NACE Publication 14C296Protective Coatings for Mitigating Corrosion Under Insulation on Rail Tank Cars, Item #24191 ■

CIP COURSE SCHEDULECIP Course Schedule through June 30, 2005.

Please check the NACE Web site www.nace.org/EDUSchedule for updates.

CIP Level 1 Mar 6-11, 2005 ................ Norfolk, VA, U.S. .............. 05I44185 Mar 20-25, 2005 ............. Marabella, Trinidad6 ........05I44191Apr 3-8, 2005 .................. Bandung, Indonesia1 ........ 05I44165Apr 10-15, 2005 ............... Houston, TX, U.S. ............. 05I44108Apr 10-15, 2005 ............... Orlando, FL, U.S. .............. 05I44184May 2-7, 2005 .................. Bogota, Colombia18 .......... 05I44107May 8-13, 2005 ............... Brisbane, Australia1 ..........05I44167May 15-20, 2005 .............. Houston, TX, U.S. ............. 05I44125May 16-21, 2005 .............. Cuernavaca, Mexico19 ....... 05I44135May 29-Jun 3, 2005 ......... Kuala Lumpur, Malaysia1 . 05I44122Jun 12-17, 2005 ............... Ventura, CA, U.S. ...............05I44117

CIP Level 2Mar 6-11, 2005 ................ Barcelona, Spain30 ........... 05I44703Mar 6-11, 2005 ................ Anchorage, AK, U.S. ......... 05I44790Mar 6-11, 2005 ................ Norfolk, VA, U.S. .............. 05I44785Mar 6-11, 2005 ................ Vallejo, CA, U.S. ............... 05I44793Apr 10-15, 2005 ............... Orlando, FL, U.S. .............. 05I44784Apr 17-22, 2005 ............... Houston, TX, U.S. ............. 05I44708May 8-13, 2005 ............... Antwerp, Belgium3 ........... 05I44702Jun 5-10, 2005 ................. Houston, TX, U.S. ..............05I44725Jun 12-17, 2005 ............... Ventura, CA, U.S. ...............05I44717

CIP Session IIIApr 10-14, 2005 ............... Orlando, FL, U.S. .............. 05I44384Jun 5-9, 2005 .................. Houston, TX, U.S. ............. 05I44325

CIP Exam Course 1Apr 6-8, 2005 .................. Orlando, FL, U.S. ...............05I44619Apr 12-14, 2005 ............... S. Etienne, France2 ...........05I44608

CIP Peer ReviewMar 11-13, 2005 .............. Norfolk, VA, U.S. .............. 05I44485Mar 11-13, 2005 .............. Vallejo, CA, U.S. ............... 05I44493Apr 15-17, 2005 ............... Orlando, FL, U.S. ..............05I44484Apr 22-24, 2005 .............. Houston, TX, U.S. .............05I44408Jun 10-12, 2005 ............... Houston, TX, U.S. ............. 05I44425Jun 17-19, 2005 ............... Ventura, CA, U.S. .............. 05I44417

CIP 1-Day Bridge Specialty CourseApr 2, 2005 ..................... Houston, TX, U.S. ............. 05I44506Jun 18, 2005 .................... Ventura, CA, U.S. .............. 05I44505

Marine Coating InspectionMar 31-Apr 2, 2005 ......... Houston, TX, U.S. ............. 05I43804

Footnotes1 This course is being hosted by the Australasian Corrosion Association Inc. (ACA),

Australia. Register for this course by contacting ACA by phone: 613 9874 0800, fax: 613 9874 4800, or e-mail: aca@corrprev.org.au. Please note fees for hosted courses may differ from the standard course fees in North America. Contact the ACA for information on course fees.

2 This course is being hosted by Quorum—United Technologies for Corrosion Prevention (EMTS, France). Register for this course by contacting EMTS by phone: +33 442 241222, fax: +33 442 241233, or e-mail: ma@emts-quorum.com. Please note fees for hosted courses may differ from standard course fees in North America. Contact EMTS for information on course fees.

3 This course is being hosted by Quorum—United Technologies for Corrosion Prevention—Corrosion Protection Consultants, Belgium (CPC). Register for this course by contacting CPC by phone: +32 3 6443456, fax: +32 3 6441989, or e-mail: kristel1@yucom.be. Please note fees for hosted courses may differ from the standard course fees in North America. Contact Corrosion Protection Consultants for information on course fees.

6 This course is being hosted by Trinidad Inspection Services (TISL). Register for this course by contacting Rameshwair Rampersad or Mr. R. Navarro at phone: 1 868 658 3817, fax: 1 868 658 3727, or e-mail: training@tistt.com. Please note fees for hosted courses may differ from the standard course fees in North America. Contact TISL for information on course fees.

18 This course is being hosted by the Asociacion Colombiana de Ingenieros de Corrosion. Register for this course by contacting Martha Rengifo by phone: 571/620-6801, fax: 571/620-2827, or e-mail: nacecolombia@andinet.com Please note fees for hosted courses may differ from the standard course fees in North America. Contact the Asociacion Colombiana de Ingenieros de Corrosion for information on the course.

19 This course is being hosted by Corrosion y Proteccion, S.A. de C.V. Register for this course by contacting Lorenzo Martinez Gomez by phone: 52-777-1000909, 52-777-1002165, 52-555-4358013, 52-555-4310623, or e-mail: lmg@corrosionyproteccion.com. Please note fees for hosted courses may differ from the standard course fees in North America. Contact Corrosion y Proteccion for information on course fees, or visit their Web site at www.corrosionyproteccion.com.

28 This course is being hosted by Quorum— United Technologies for Corrosion Prevention (Rotterdam Painting Consultants b.v.). Register for this course by contacting Ben van den Tol by phone: 31 180 440000, fax: 31 180 440010, or e-mail: info@rpcbv.nl. Please note fees for hosted courses may differ from the standard course fees in North America.Contact Rotterdam Painting Consultants bv. for information on course fees.

30 This course is being hosted by Quorum—United Technologies for Corrosion Prevention (Iberia Corrosion Engineering S.L.). Register for this course by contacting Jose M. Faura, phone: 34 93 2151039, fax: 34 93 4873608, or e-mail: jmfaura@ice-quorum.com. Please note fees for hosted courses may differ from the standard course fees in North America. Contact Iberia Corrosion Ingineering S.L. for information on course fees.

18

Want to Learn More About High-Performance Coatings?

The same popular book off ered in the NACE CIP Level 2 course now has a workbook on CD-ROM!

NACE has taken one of its bestselling books and made it even better by putting it on CD-ROM! Corrosion Prevention

by Protective Coatings on CD-ROM is a must-have for anyone interested in all aspects of high-

performance coatings. Fully searchable and printable, this CD-ROM is a valuable tool

for those needing a quick refresher or wanting to understand or teach the basics of coatings work without hav-ing to interpret the chemistry and formulations involved.

This CD-ROM also includes more than 100 workbook pages with sample test questions!

$110 List Price, $83 NACE Member Item #38187

To order: 1 800/797-6223 (U.S. & Canada), 281/228-6223 (outside U.S. & Canada),

or go to www.nace.org/nacestore.

As I mentioned in my Fal l 2004 “InspectTh is ! ” ar t icle, Coach

Mike Ditka w i l l be speak ing a t CORROSION/2005 on Tuesday evening, April 5 from 5:30 to 6:15. To make this event even better, it is free to attend!

Ditka will be speaking about team-work. Teamwork is an essential element in the successful completion of any large industrial coating project. In addition to

having a complete knowledge of how a project works, all parties must work as a team, with the common goal of completing the project as specifi ed, on time, and within budget. To emphasize the importance of teamwork, sponsors for this event are representa-tive of a typical industrial coatings project team. NACE would like to thank the sponsors of this event.

Sponsors and the position they represent on the “team” are listed below:

■ Sherwin-Williams (material manufacturer)■ Graco (equipment supplier)■ CC Technologies (inspection company)■ Greater Houston CVB (owner) ■ Mobley (contractor)■ Betco Scaffolds (contractor supplier of scaffolding)■ Munters Corporation (contractor supplier of dehumidifi ca-

tion units)

(I would like to note that there could be many more players on an industrial coatings project team. This group is a hypothetical team—to be used strictly as an example of what an industrial coatings project team could look like.)

Coach Ditka knows what it takes to succeed as a team. During his 11 years with the Chicago Bears, Ditka’s teams dominated the NFC Central with 52 regular season victories (between 1985-1988). This victory record is the most ever by an NFL team in any four-year period. Ditka ranks second among all Bears coaches in both tenure and victories. In 1985, Mike Ditka’s team posted an 18-1 record. Ditka is the only Chicago Bear coach to lead his club to fi ve straight post-season appearances. In 1988, he won Coach of the Year honors during the same season in which he suffered a mid-season heart attack (11-22-88), and posted a 12-4 regular season record.

Prior to the 1982 season, Ditka signed on as head coach of the Chicago Bears, taking over a team that had had just two winning seasons in the previous 19 years. During his 10-year tenure as

head coach, Ditka led the Bears to six NFC Central titles, three additional appearances in the NFC title game (each time, their opponent went on to win the Super Bowl), and a Super Bowl victory (1986). He has been awarded Coach of the Year honors (1985 and 1988) by The Sporting News, the Associated Press, and pro football writers.

Ditka is one of only two men to have won a Super Bowl as a player, assistant coach, and head coach.

This is sure to be an event you won’t want to miss!

See you there!

Laura BartlettMarketing Specialist—CommunicationsNACE Internationallaura.bartlett@nace.orgwww.nace.org

I only have one thing to say, “Don’t miss Coach Mike Ditka!”