.

Corrosion
 .
.
What is Corrosion?

It is basically defined as a natural process that causes the

transformation of pure metals into undesirable substances when
they react with substances like water or air.

This reaction causes damage and disintegration of the metal,

starting from the portion of the metal exposed to the
environment and spreading to the entire bulk of the metal.
 .
.
What is Corrosion?

Corrosion is usually an undesirable phenomenon since it negatively

affects the desirable properties of the metal.

It is a process through which refined metals are converted into

more stable compounds such as metal oxides, metal sulfides,
or metal hydroxides
 COST OF CORROSION:

The global cost of corrosion is estimated to be US$2.5 trillion

per annum which is equivalent to 3 to 4% of the global GDP
(2016)

India loses upto $70 billion annually towards Corrosion

 EFFECT OF EFFECTIVE CORROSION CONTROL:
❑ Maintenance Cost decreases

❑ Monitoring or inspection cost decreases

❑ Fewer failures saves Production loss

❑ Property damage decreases

❑ ‘Asset life extension’ will impact directly on the Capex

Typical Corrosion categories (ISO 12944-2):
 .
Corrosion impact on life of metals
 TERMINOLOGY USED IN COATING SYSTEM

HOT DIP GALVANIZING

POWDER COATING Sa2.5 / SSPC

WET PAINTING / CED

SINGLE COAT / DUAL COAT SWEEP BLASTING

TPC RAL 6005 / RAL 9005

MICRONS
GSM PPC
SS 304 / SS 316
METHODS OF CONTROLLING THE CORROSION RATE:

Corrosion control methods:

• Designing the appropriate system

• Material Selection

• Protective Coatings Selection

• Regular Inspection after installation

Designing - Coating System:
Suitable specification for the project shall be written before starting the design finalization.
Following are the criteria to be considered:

❖ Analyze the ‘Corrosive category’ of area of installation – ISO 12944 -2

❖ Establish any special condition / requirements which may affect the coating system – ISO
12944 – 5

❖ Examine the design of the structure to avoid corrosion traps & avoid Galvanic corrosion -
ISO 12944 – 3

❖ Select an ‘Optimum Coating system’ with suitable pretreatment ISO 12944 – 4

❖ Establish a program of inspections to be carried out at the time of Installation &

maintaining of the entire system for full service life
Types of Coating Systems offered @ A1 Fence:
❖ Hot Dip Galvanized (HDG)

❖ Duplex systems
❖ HDG + Powder coating
❖ HDG + Dual Powder coating
❖ HDG + Thermoplastic coating

❖ Multi coat – Wet painting system

❖ CED Primer + Powder coating
What is Galvanizing:

Galvanizing means applying a protective zinc layer to iron

or steel by dipping it into a molten zinc bath to prevent
corrosion and rust.
HOT DIP GALVANIZED COATING (EN ISO 1461):
GALVANIZING PROTECTION:

Zinc corrodes in preference to steel and sacrifices itself to protect

the steel, hence hot dip galvanizing will provide this sacrificial

protection. The corrosion products from the zinc are deposited on

the steel resealing it from the atmosphere and therefore stopping

corrosion
CATHODIC PROTECTION:

❖
HOT DIP GALVANIZED COATING – 3 WAY PROTECTION:

❖PHYSICAL BARRIER
❖SACRIFICIAL PROTECTION
HDG PROCESS:

❖
CORROSION DURABILITY:
.
Atmospheric Corrosivity Category - EN ISO 12944 - Part 2
FACTORS THAT AFFECT RATE OF CORROSION:

❖ Climatic & Atmospheric conditions:

Corrosion protection of steel structures by Protective paint systems

- EN ISO 12944:

❖ PART - 1 - General Introduction

❖ PART - 2 - Classification of Environment
❖ PART - 3 - Design Considerations
❖ PART - 4 - Type of Surface & Surface Preparations
❖ PART - 5 - Protective Paint system
❖ PART - 6 - Lab Performance Test methods
❖ PART - 7 - Execution & Supervision of Painting work
❖ PART - 8 - Development of Specification for New work
Atmospheric Corrosivity Category - EN ISO 12944 - Part 2
POWDER COATING SYSTEMS:
❖ POLYESTER POWDER COATING (PPC)
❖ Single coat PPC system
❖ Dual Coat PPC system
❖ THERMOPLASTIC POWDER COATING SYSTEM (TPC)
❖ 250 Microns coating
❖ 1000 Microns coating
❖ TPC + PPC DUAL POWDER COATING SYSTEM (TPC)

❖ 250 Microns coating

❖ 1000 Microns coating
RUST GRADES AS PER ISO 8501-01:
RUST GRADES AS PER ISO 8501-01:
TYPICAL PRETREATMENT SYSTEMS:

❖ 6.1 Water, solvent and chemical cleaning

❖ 6.2 Mechanical cleaning including blast-cleaning
TYPICAL Water, solvent and chemical system:

❖ 6.1 Water, solvent and chemical cleaning

❖ 6.1.1 Water cleaning
❖ 6.1.2 Steam cleaning
❖ 6.1.3 Emulsion cleaning
❖ 6.1.4 Alkaline cleaning
❖ 6.1.5 Organic-solvent cleaning
❖ 6.1.6 Cleaning by means of chemical conversion
❖ 6.1.7 Stripping
❖ 6.1.8 Acid pickling
TYPICAL PRETREATMENT SYSTEMS (Mechanical):
❖ 6.2.3 Blast-cleaning
❖ 6.2.3.1 Dry abrasive blast-cleaning
• 6.2.3.1.1 Centrifugal abrasive blast-cleaning
• 6.2.3.1.2 Compressed-air abrasive blast-cleaning
• 6.2.3.1.3 Vacuum or suction-head abrasive blast-cleaning

❖ 6.2.3.3 Wet abrasive blast-cleaning

• 6.2.3.3.1 Compressed-air wet abrasive blast-cleaning
• 6.2.3.3.2 Slurry blast-cleaning
• 6.2.3.3.3 Pressurized-liquid blast-cleaning
TYPICAL PRETREATMENT SYSTEMS (Mechanical):

❖ 6.2 Mechanical cleaning including blast-cleaning

❖ 6.2.1 Hand-tool cleaning

❖ 6.2.2 Power-tool cleaning
❖ 6.2.3 Blast-cleaning
Surface preparation grades:

❖ Sa 1 - Light blast-cleaning

❖ Sa 2 - Thorough blast-cleaning
❖ Sa 21/2 - Very thorough blast-cleaning

❖ Sa 3 - Blast-cleaning to visually clean steel

❖ ST 2 & ST 3 - Hand & Powder Tool cleaning

❖ Fl - Flame cleaning
❖ Be - Acid Pickling
METAL PRETREATMENT SYSTEM ISO 8501-01:
❖ Sa 1 Light blast-cleaning
When viewed without magnification, the surface shall be free
from visible oil, grease and dirt, and from poorly adhering mill
scale, rust, paint coatings and foreign matter.

❖ Sa 2 Thorough blast-cleaning
When viewed without magnification, the surface shall be free
from visible oil, grease and dirt, and from most of the mill
scale, rust, paint coatings and foreign matter. Any residual
contamination shall be firmly adhering
METAL PRETREATMENT SYSTEM ISO 8501-01:

❖ Sa 21/2 Very thorough blast-cleaning

When viewed without magnification, the surface shall be free from
visible oil, grease and dirt, and from mill scale, rust, paint
coatings and foreign matter. Any remaining traces of
contamination shall show only as slight stains in the form of spots
or stripes.

❖ Sa 3 Blast-cleaning to visually clean steel

When viewed without magnification, the surface shall be free from
visible oil, grease and dirt, and shall be free from mill scale, rust,
paint coatings and foreign matter. It shall have a uniform metallic
colour.
Surface preparation grades NACE/SSPC:

❖ SSPC-Surface Preparation

❖ (SP)-1: Solvent Cleaning

❖ SSPC-SP-2: Hand Tool Cleaning

❖ SSPC-SP-3: Power Tool Cleaning

❖ SSPC-SP-5: White Metal Blast Cleaning

❖ SSPC-SP-6: Commercial Blast Cleaning

Surface preparation grades NACE/SSPC:
❖ SSPC-SP-7: Brush-Off Blast Cleaning

❖ SSPC-SP-10: Near-White Metal Blast Cleaning

❖ SSPC-SP-11: Power Tool Cleaning to Bare Metal

❖ SSPC-SP-14: Industrial Blast Cleaning

❖ SSPC-SP-15: Commercial Grade Power Tool Cleaning

❖ SSPC-SP-16: Brush-Off Blast Cleaning of Non-Ferrous Metals

METAL PRETREATMENT SYSTEM ISO 8501-01:

❖ Sa 1 Light blast-cleaning

❖ Sa 2 Thorough blast-cleaning

❖ Sa 21/2 Very thorough blast-cleaning

❖ Sa 3 Blast-cleaning to visually clean steel

Standard Preparation of substrates - Primary:
Standard Preparation of substrates - Primary:
METAL PRETREATMENT SYSTEM ISO 8501-01:

SHOT Blasting GRIT Blasting

Surface Roughness measurement:
SWEEP BLASTING @ (A1 FENCE)
Sweep Blasting - Process Sequence

Measure the require roughness of

blasted surface ( For GI/HDG Rz
value- 25 to 40 and for MS- >40) or
as per specific requirement of the
customer

Check the salt content of blasted

material ( <50 mg/m2
Sweep Blasting -
Solving the Adhesion issue

One of the biggest reasons for failure is adhesion

issue and the solution lies with the applicator not
the powder manufacturer.

As the border fence is made of GI, we need to

prepare the GI substrate by pre-treating it with
SWEEP BLASTING before it goes for powder
coating with following advantages:

● Removes Oxides
● Improves anchorage which increases the
surface area available for the powder to grip
Surface Roughness measurement Ra & Rz:
Surface Roughness measurement:
Surface profile (roughness) and surface profile grading:
The surface profile of the substrates influences the adhesion of the coating. For
protective paint systems, a surface profile “medium (G)” or “medium (S)”, as
defined in ISO 8503-1, is particularly suitable.
Why to assess soluble salts & other invisible contaminants?:

?
METAL PRETREATMENT SYSTEM ISO 8501-01:
Assessment of prepared surfaces:
After the surface preparation procedure (cleaning as specified), the
prepared surfaces shall be assessed as described in ISO 8501-1 or ISO
8501-2, i.e. the cleanliness is assessed by evaluating the appearance of the
surface only.
In many instances, this is sufficient for the purpose, but for coatings likely
to be exposed to severe environments, such as water immersion and
continuous-condensation conditions, consideration shall be given to
testing for soluble salts and other invisible contaminants on the visually
clean surface by the physical and chemical methods which form the
subjects of the various parts of ISO 8502.
Pretreatment Process Sequence:

❑ Oxsilan Nano chemical by Chemetall Germany

❑ 10 tank system with multiple RO & DI water tank rinses
PC Plant (A1 FENCE – Sanjan & Khopoli)
PREREQUISITE FOR GOOD COATING SYSTEMS (BS EN13438):

❖ EXCELLENT METAL TREATMENT

❖ EXCELLENT CONVERSION COATING

❖ SELECTION OF CORRECT CATEGORY OF POWDER PAINT

❖ RIGHT WAY OF APPLICATION OF POWDER COATING

❖ PERIODIC QUALITY CHECKS

METAL TREATMENT FOR PPC & TPC COATING:

❖ Longevity of PPC & TPC coating is enhanced with proper surface preparation of the
substrate.

❖ A1 Fence carries out following pretreatment activities on all the parts :

• Sweep blasting of substrate – To ensure all oxides are removed & a correct profile
created for better anchorage of coating

• Which is followed by 10 stages spray ‘Nano Technology’ metal treatment process

• This conversion coating creates a NANO film on the surface of the metal- which
adheres Thermoplastic coating with substrate greatly.
NANO CHEMICAL PRETREATMENT & ADVANTAGES (A1 FENCE)

Nano
Chemical
PROCESS TESTS IN PRETREATMENT:

❖ Temperature of baths
❖ Titration of degreasing & Oxsilan bath
❖ Oil level percentage in bath
❖ Conductivity of all rinse waters
❖ Conductivity & pH level of Oxsilan bath
❖ Final Drip water conductivity level
INTERNATIONAL STANDARDS TO BE REMEMBERED:

ISO 12944 – CORROSION PROTECTION OF STEEL STRUCTURES WITH COATING

EN ISO 1461 – HOT DIP GALVANIZATION

BS EN 13438 – POWDER COATING ON HOT DIP GALVANIZED SUBSTRATE

TYPICAL POWDER APPLICATION METHODS
PPC – POLYESTER POWDER COATING

FOLLOWED
BY
A1 FENCE
TYPICAL PPC & TPC COATING APPLIED FIELDS:
Advantages of Thermoplastic Coating
Advantages of Thermoplastic Coating
Advantages of Thermoplastic Coating
Advantages of Thermoplastic Coating
Tests Conducted
 THERMOPLASTIC COATING:

Thermoplastic Powder: TDS & Test results

● TECHNICAL DATA SHEET

. ● LONGEVITY REPORT
● SALT SPRAY TEST
● ACCELERATED WEATHER TEST
● PAINT INFORMATION
● MASTER SPEC REPORT

AXALTA - PLASCOAT PPA 571 ES

TECHNICAL DATA SHEET-

Technical Data Sheet Plascoat * PPA 571ES

Technical Data Sheet-

Technical Data Sheet Plascoat * PPA 571ES

LONGEVITY REPORT-

Coating Longevity of PPA 571 Series

SALT SPRAY TEST

Salt Spray Test report

ACCELERATED WEATHER TEST

Accelerated Wheathering Test report * Plascoat PPA571

POWDER INFORMATION

Powder Information * Plascoat PPA 571ES

POWDER INFORMATION

Powder Information * Plascoat PPA 571ES

MASTER SPECIFICATION REPORT

Master Specification report * Plascoat PPA 571

Coating Test Awareness Training
Content

1. HDG
1.1 Test required for Hot Dip Galvanized products (HDG).
Tests required for HDG material as per BS EN ISO 1461 & ASTM A123

Appearance
1. Appearance
2. Coating Thickness.
3. Adhesion.
2. Coating Thickness

● Testing Standard for DFT as per BS EN ISO 1461

Gravimetric/Stripping method.
Magnetic Method

1.
2. Coating Thickness

● Reference Areas for testing as per BS EN ISO 1461

● Coating Thickness Required as per BS EN ISO 1461
● Coating Thickness Required as per ASTM A123
3. Adhesion

● As Per BS EN ISO 1461 ● As Per ASTM A123

4. Renovation

Test Required on Sweep

Blasted Surface
Sweep Blasting - Solving the
Adhesion issue

One of the biggest reasons for failure is

adhesion issue and the solution lies with the
applicator not the powder manufacturer.

As the border fence is made of GI, we need to

prepare the GI substrate by pre-treating it with
SWEEP BLASTING before it goes for powder
coating with following advantages:

● Removes Oxides
● Improves anchorage which increases the
surface area available for the powder to
grip
Test Required for Sweep Blasted Materials

1. Salt Content
2. Rz/Ra Value
3. Visual Inspection

1. Salt Content

Testing Standard as per ISO 8502-6 and ISO 8502-9

 Sweep Blasting Test

2. Rz/Ra Value
Testing Standard - ASTM D7127
Sweep Blasting

Dew Point & Substrate Temperature (before coating)

Testing Standard- EN ISO 8502-4

(Instrument- Hygrometer)
 Sweep Blasting

3. Visual Inspection

1. General cleanliness after blasting

2. Colour after blasting

3. Zinc layer condition - Firm, Loose or Lifting

Test Required on Powder Coated & Wet
painted
POWDER PROPERTY TESTS
POWDER COATING TESTS
POWDER COATING TESTS
Test required for Coated Products

● Wet Film Thickness - WFT (only on Wet painted product).

● Dry Film Thickness - DFT.
● Adhesion - Cross cut, cross Hatch & Pull-off
● Gloss.
● Colour - RAL Code
● Curing Test.
● Salt Spray Test
● UV Test.
● Surface Appearance
● Cyclic Corrosion Test
● Permeability
1. Wet Film Thickness - WFT (Wet Painting
System)
Testing Standard- EN ISO 2808

Method of WFT measurement.

1. Mechanical Method. (Comb Gauge, Wheel Gauge & Dial Gauge)
2. Gravimetric method.
3. Photo thermal method
2. Dry Film Thickness - DFT Testing as per ISO 19840
Other Standard- EN ISO 2808
Acceptance and rejection Criteria as per ISO 19840
Adhesion Test As per ISO 2409

Condition of Test panels- Temperature- (23+/-2)oC & Relative humidity (50+/-5)%

● Number of Cuts in each direction of lattice pattern- 6 cuts

Adhesion Test As per ISO 2409
Gloss Test as per EN ISO 2813

● Instrument- Gloss Tester.

Colour - RAL Shade

● RAL Shade Card

Curing Test

MEK Test
20 Double rubs on a Mek soaked cotton swabs
Salt Spray Test as per ISO 9227

Type of Salt Spray test as per ISO 9227.

1. Neutral Salt Spray (NSS),

2. Acetic Acid Salt Spray (AASS)
3. Copper-Accelerated salt spray (CASS).-
UV Test as per ASTM G154-23
Surface Appearance
Atmospheric Corrosion Tests
CYCLIC Corrosion Test
Immersion Test Requirements
Permeability Test

The permeability of coatings is an

important property to measure, as it
can impact the overall performance
and durability of the coating.

Coatings that are permeable to water

or other substances can allow them
to penetrate the coating and reach
the underlying substrate, potentially
causing corrosion, discoloration, or
other forms of damage.