Asset Management Preservation

1
Asset Management Preservation

• Presented By Aaron Dacey, Coatings and
  Corrosion Engineer North Carolina Department of
  Transportation

2
Introduction

• This webinar will discuss protective coating of
  complex steel structures can be complicated,
  making the maintenance of these assets and their
  components a challenge. Each asset may have its
  own maintenance schedule, performance metrics and
  life-cycle expectations. This webinar will
  explain how to develop an effective asset
  management preservation program, based on these
  considerations, to achieve the optimal life of
  the coating system.

3
The Importance of Protective Coatings

• Coatings play a critical role in protecting
  equipment and infrastructure from corrosion and
  failure in both the public and private sectors

4
The Importance of Protective Coatings

• Protective coatings help to keep
• Processing plants operational
• Maintain the integrity of pipelines and storage
  tanks
• Protect bridges, towers, and platforms
• Assure readiness of military ships, aircraft, and
  vehicles

5
Coatings Asset Management Program

• Coating materials have a limited life expectancy
  therefore, maintenance is important for achieving
  the design life of a properly installed coating
  system as well as preserving the integrity of
  equipment and infrastructure that the coating is
  being applied to

6
Why Have a Coatings Asset Management Program?

• Ensures regular checks on the existing coating
  system and timely in-service repairs
• Provides asset integrity and operational safety
  of facility
• A corrosive environment can impact the integrity
  of a structure

7
Why Have a Coatings Asset Management Program?

• Achieve longer service life of coatings
• Improved performance time
• Maximizes coatings investment
• Improved uptime
• Reduce overall cost of project

8
Coatings Asset Management Program

• The program consists of
• Routinely evaluating the protective coatings
  applied
• When necessary, creating a design for
  rehabilitation of the assets

9
Basic Elements of a Good Coatings Asset
Management Program

• Qualified coatings
• Trained Coating Applicators
• Qualified Contractors
• Good Specifications
• Qualified Inspection
• Conducting Routine Surveys Post Application

10
Qualified Coatings

• Coatings being applied within a facility should
  be verified for
• Achieving performance properties for environment
  being placed in
• Where does this need to live? Is it near the
  coast? Is it in a hot and humid climate? Is it
  coating to experience extreme cold temperatures?

11
Qualified Coatings

• Being compatible with previous coating applied
  (if conducting repair and maintenance work)
• Meeting requirements of coating specification
• Service life
• Is the expected service life 5 years? 15 years?
  20 years?

12
Qualified Coatings

• It is good practice to require a certificate of
  conformance from coating manufacturer verifying
  the performance properties expected and specified
  are being met

13
Trained Coating Applicators

• Applicators applying material should be properly
  trained to avoid costly mistakes.
• Examples of acceptable training is
• SSPC CAS Level 1 and Level 2
• SSPC C7 (Abrasive Blasting)
• SSPC C12 (Airless Spray)

14
Qualified Contractors

• Specifying qualified contractors provides the
  owner piece of mind that the work is being
  completed by trained contractors per the coating
  manufacturers product data sheet and job
  specification
• SSPC QP 1
• SSPC QP 2
• SSPC QP 3

15
Good Specifications

• In order to prevent premature corrosion,
  specifications must be written in a clear and
  concise manner- calling out specifics.
• Words such as must and shall are used in lieu of
  could and should.
• Proper Coatings must be specified

16
Qualified Inspection

• All projects should have a qualified inspector
  performing inspection at major hold points
  throughout the project
• Pre Surface Preparation
• Surface Preparation
• Coating Application
• Post Coating Application

17
Qualified Inspection

• Examples of qualified inspection programs are
• SSPC PCI Protective Coatings Inspector
• SSPC BCI Bridge Coating Inspector
• SSPC CCI Concrete Coating Inspector
• NACE CIP Coating Inspector Program
• FROSIO

18
Conducting Routine Surveys Post Application

• Conducting routine surveys post application
  allows the owner to see how the coating is
  performing and address problems early on
• It is good practice to perform a yearly survey

19
Survey Reports

• Survey reports should consist of the following
  basics
• Precise location of structure
• Original date coating work was completed
• The manufacturer and type of coating originally
  applied
• Any notes regarding special considerations or
  conditions employed during coating application
• Requirement for and record of inspections

20
Survey Reports

• Condition ratings and definitions need to be
  decided prior to the start of any survey to
  ensure that each yearly survey can be compared to
  the previous years

21
The ABC Rating System

• A- They dont have to do anything within 3 years
• Good
• B- They have to do something within 3 years
• Generally OK, but plan for some maintenance
• C- They have to do something within 1 year
• PROBLEM- MUST BE DEALT WITH!!

22
Survey Reports

• A plan should be developed on what areas will be
  inspected and how to access those hard- to- reach
  access areas that can often become corrosion
  issues
• An asset deemed unsafe should get priority
• Pitted steel, leaking pipe, unsafe walkways, etc.

23
Survey Reports

• The survey evaluation should include
• Adhesion
• Appearance (gloss, chalk, primer, mill scale,
  rust, etc.)
• Percent of failure
• Dry film thickness (DFT)

24
Adhesion- Steel

• ASTM D3359 Standard Test Methods for Measuring
  Adhesion by Tape Test
• These test methods cover procedures for assessing
  the adhesion of coating films to metallic
  substrates by applying and removing
  pressure-sensitive tape over cuts made in the
  film

25
Adhesion- Steel

• ASTM D4541 Standard Test Method for Pull-Off
  Strength of Coatings Using Portable Adhesion
  Testers
• This test method covers a procedure for
  evaluating the pull-off strength (commonly
  referred to as adhesion) of a coating system from
  metal substrates. The test determines either the
  greatest perpendicular force (in tension) that a
  surface area can bear before a plug of material
  is detached, or whether the surface remains
  intact at a prescribed force (pass/fail)

26
Adhesion- Concrete

• ASTM D7234 Standard Test Method for Pull-Off
  Adhesion Strength of Coatings on Concrete Using
  Pull-Off Adhesion Testers
• This test method covers procedures for
  evaluating the pull-off adhesion strength of a
  coating on concrete. The test determines the
  greatest perpendicular force (in tension) that a
  surface area can bear before a plug of material
  is detached

27
Rust Evaluation

• SSPC VIS 2
• Standard Method of Evaluating Degree of Rusting
  on Painted Steel Surfaces

28
Dry Film Thickness- Steel

• ASTM D7091 Standard Practice for Nondestructive
  Measurement of Dry Film Thickness of Nonmagnetic
  Coatings Applied to Ferrous Metals and
  Nonmagnetic, Nonconductive Coatings Applied to
  Non-Ferrous Metals

29
Dry Film Thickness- Steel

• SSPC PA 2 Procedure for Determining Conformance
  to Dry Coating Thickness Requirements

30
Dry Film Thickness- Concrete

• ASTM D6132 Standard Test Method for
  Nondestructive Measurement of Dry Film Thickness
  of Applied Organic Coatings Using an Ultrasonic
  Coating Thickness Gage

31
Dry Film Thickness- Concrete

• SSPC PA 9
• This standard describes procedures to measure the
  thickness of dry, homogeneous coatings applied on
  cementitious surfaces using commercially
  available ultrasonic coating thickness gages.
  These procedures are intended to supplement
  manufacturers operating instructions for the
  manual operation of the gages and are not
  intended to replace them

32
Coatings Database

• Some facilities will gather asset coating
  information in a computer database
• The database contains
• Photos
• Condition assessment reports
• Survey tests such as
• Adhesion
• Appearance (gloss, chalk, primer, mill scale,
  rust, etc.)
• Percent of failure
• Dry film thickness (DFT)
• Using this information can allow facilities to
  show the progression of corrosion in a certain
  area over a period of time

33
Problems Within 1 Year Warranty

• Typically you will find most coating application
  problems within the 1st year of service
• If coating was installed properly after the 1st
  maintenance, very little repair will need to
  occur over the next several years
• Known as the Bathtub Curve

34
Summary

• By creating an asset management coatings program
  you can assure that recoat and overcoat is
  preformed before damaging corrosion sets in,
  allowing downtime of the asset to be minimized
  and decreasing cost of the overall project