FEATURE WORKPLACE SAFETY


Keeping corrosion at bay M


uch of the utility industry’s carbon steel facility infrastructure is ageing.


Consequently, the cost of corrosion is on a path to dramatically escalate. Once corrosion starts, often through a


breach in traditional barrier-type coatings such as epoxies or polyurethanes, the coating can act like a greenhouse, trapping water, oxygen and other corrosion promoters. This allows the corrosion to spread quickly under the coating itself, which is difficult to inspect, and can lead to failure and costly premature replacement. For these reasons, such coatings are routinely reapplied at a sizeable cost in facility downtime, surface preparation, and coating application. Now a new generation of anti-corrosion


coatings, called chemically bonded phosphate ceramics (CBPCs), is poised to cost-effectively stop corrosion, improve safety and extend utility industry infrastructure and facility life while minimising maintenance and downtime. EonCoat is a spray applied inorganic


coating from the company of the same name. EonCoat represents a new category of CBPCs that can stop corrosion and reduce production downtime. In contrast to traditional polymer


coatings that sit on top of the substrate, the CBPC coating bonds through a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction. An alloy layer is formed. The company says this makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. Although traditional polymer coatings


bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge.


Del Williams discusses how a new category of CBPC coatings from Eoncoat can prevent corrision for a safer workplace


By contrast, the same damage to the ceramic-coated substrate will not spread corrosion in utility facility infrastructure because the carbon steel’s surface is turned into an alloy of stable oxides. Once the steel’s surface is stable it will no longer react with the environment. Visible in scanning electron microscope


photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel, which effectively stops corrosion in utility industry applications. The corrosion barrier is covered by a


ceramic shell that resists corrosion, fire, water, abrasion, impact, chemicals and high temperatures. Beyond this, the ceramic shell also helps to end the costly maintenance cycle of replacing typical coatings every seven to 10 years. “If the ceramic shell and alloy layer is


ever breached, the ceramic shell acts as a reservoir of phosphate to continually realloy the steel,” explains Merrick Alpert, president of EonCoat. “This ‘self heals’ the breach, depending on its size, and stops the corrosion if necessary. This capability, along with the coating’s other properties, enables effective corrosion protection for the life of in-service structures with a single application.” Because of the dual layer of corrosion


protection and unique self-healing capability of the alloy layer, the coating is expected to last a minimum of 30 years. Engineers looking to reduce costs are


also finding additional advantages to CBPC coatings beyond corrosion resistance. Such coatings consist of two non-


hazardous components that do not interact until applied by a standard


industrial plural spray system like those commonly used to apply polyurethane foam or polyurea coatings. Since CBPC coatings are inorganic and non-toxic, there are no VOCs, no HAPs and no odour. This means the coatings can be applied safely even in confined spaces. One of the greatest benefits, however, is


quick return to service that minimises facility downtime. The time saved on an anti-corrosion coating project with the ceramic coating comes both from simplified surface preparation and expedited curing time. With a typical industrial coating, near white metal blast cleaning (NACE 2 / SSPC-SP 10) is required to prepare the surface. But with the ceramic coating, only a NACE 3 / SSPC-SP 6 commercial blast cleaning is typically necessary. For corrosion protection projects using


typical polymer paints such as epoxies or polyurethanes, the cure time may be days or weeks before the next coat of traditional ‘three part systems’ can be applied, depending on the product. The cure time is necessary to allow each coat to achieve its full properties, even though it may feel dry to the touch. With traditional coatings, extensive


surface preparation is required and done a little at a time to avoid surface oxidation, commonly known as ‘flash rust’, which can require re-blasting. In contrast, a corrosion resistant coating for carbon steel utilising the ceramic coating in a single coat requires almost no curing time. Return to service can be achieved in as little as one hour. This kind of speed in getting an asset operational again can potentially save money in reduced utility facility downtime.


EonCoat eoncoat.com ESSENTIAL WORKPLACE SAFETY ADVICE FOR UK BUSINESSES


Arco is encouraging businesses to place first aid responsibilities at the top of their agendas with the help of its new version of the ‘First Aid and Training in the Workplace’ expert guide. Available to download online, the eguide now contains information regarding new motor vehicle kits, trauma first aid kits and electric shock rescue equipment to ensure businesses are fully equipped for any emergency situation that may arise on or off site. Employers can download the guide to get equipped with vital information regarding BS8599-1, Workplace First Aid Kits. The standard, which was


created in 2014 by The British Healthcare Trade Association and British Standards Institute (BSI), sets the minimum level that workplace first aid kits should conform to. In response to these standards, Arco’s updated guide contains information on its new range of first aid kits, which were created to ensure customers were complying to legislation, no matter the size or risk level of the workplace. The guide introduces Arco’s new Trauma First Aid supplies that are essential for a number of industries and workplaces such as any high risk


workplaces including glass and metal handling environments and workplaces where there is a high chance of someone receiving a serious injury. As well as including information on new and life-saving products available, Arco’s expert guide also covers current first aid legislation, while offering helpful guidelines for employers to follow to ensure they are fully compliant.


Arco 22 SUMMER 2017 | INDUSTRIAL COMPLIANCE www.arco.co.uk / INDUSTRIALCOMPLIANCE


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