Session 5-Thermal Spray Coatings For Corrosion Protection-What You Need To Know
Session 5-Thermal Spray Coatings For Corrosion Protection-What You Need To Know
Session 5-Thermal Spray Coatings For Corrosion Protection-What You Need To Know
• Corrosion Basics
• Thermal Spray Coating-What It Is & What It Does
• Advantages & Disadvantages
• Basics for Good Application
• Steel Bridge Metallizing Case Studies
• Metallizing of Concrete Substructures
THERMAL SPRAY
COATING FOR
CORROSION
PROTECTION
CORROSION BASICS
THERMAL SPRAY
Iron Ore
Exposure
Corrosion/Rust
Blast Furnace
• Anode
• Cathode
• Metallic Pathway
• Electrolyte
COATINGS DECISIONS BASED ON THERMAL SPRAY
COATING FOR
CORROSION
CORROSION CYCLE PROTECTION
>20%
Repair w/Overcoat
6-10%
Touch-up / Spot
3-5%
Time
THERMAL SPRAY
COATING FOR
CORROSION
PROTECTION
METHODS OF PROTECTION
THERMAL SPRAY
• PROTECTIVE COATINGS
• Conventional Liquid Coatings:
• Barrier
• Inhibitive
• Sacrificial
• CATHODIC PROTECTION
• Impressed Current
• Sacrificial Galvanic
• ALTERNATIVE MATERIALS
• Alloys (Stainless Steel, Brass)
• Composites
• Aluminum
HOW PROTECTIVE THERMAL SPRAY
COATING FOR
CORROSION
COATINGS WORK PROTECTION
• Barrier Coatings
• Most liquid coatings work this way. They provide a semi-permeable
barrier to air and moisture that provides a barrier to environmental
exposure.
• Inhibitive Coatings
• Some coatings passivate the steel to prevent corrosion.
• Conversion coatings (phosphoric acid and chromate washes) and
calcium sulfonates work this way.
• Galvanic (Sacrificial) Coatings
• Coatings give off electrons and sacrifice themselves for the substrate.
Zinc and lead based coatings work this way.
THERMAL SPRAY
Flame spray
Arc-spray system system Powder spray system
THERMAL SPRAY
ARC–SPRAY SYSTEM
THERMAL SPRAY
Typical Metallizing
Operation
THERMAL SPRAY
Cleaning and
metallizing of
the Rainbow
Bridge, Niagara
Falls, NY
THERMAL SPRAY
• Metallizing is performing as
well as anticipated after a 15
year evaluation.
• Problem areas were limited to
isolated areas of deck/joint
leakage.
• MCU overcoat may be
needed in visible areas.
THERMAL SPRAY
Rehabilitation
and Recoating
of the Stickney
Point Bridge,
Sarasota, FL
THERMAL SPRAY
• Metallizing:
• 50+ Years of corrosion protection
• Advances in portable metallizing equipment
• Decrease in future maintenance painting
projects
• Ability to blast, metallize and seal in one shift
• Less restrictive ambient condition requirements
THERMAL SPRAY
• Specifications Utilized:
• Florida DOT, Section 561, “Coating Existing Structural Steel”
• SSPC-CS 23.00/AWS C.2.23/NACE No. 12, “Application of Thermal Spray
Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and
Composites for the Corrosion Protection of Structural Steel.”
Note: TSP referenced CS-23 in it’s entirety, and only discussed those
items that changed from joint standard.
THERMAL SPRAY
METALLIZING OF CONCRETE
SUBSTRUCTURES
THERMAL SPRAY
• Direct Connection
• An electrical circuit is established such that current flows from the
external metallizing to the rebar.
SACRIFICIAL CATHODIC THERMAL SPRAY
COATING FOR
CORROSION
PROTECTION PROTECTION
• Arc-Sprayed Metallizing
o Requires an electrical connection to the steel reinforcement, but can be
used without concrete restoration by application directly to the steel
reinforcement.
THERMAL SPRAY
Questions?
[email protected]
(904) 652-1099