Steelwork corrosion Control Second edition D.A. Bayliss and d. H. Deacon C D.A. Bavliss and D. H. Deacon
Steelwork Corrosion Control Second edition D. A. Bayliss and D. H. Deacon © 2002 D. A. Bayliss and D. H. Deacon
First published 2002 by Spon Press II New Fetter Lane London ec4p 4eE Simultaneously published in the USA and Canada by Spon Press 29 West 35th Street. New York. NY 1000 1 This edition published in the Tayl Spon Press is an imprint of the Taylor Francis Group e 2002 D. A Bayliss and D. H. Deacon All rights reserve part of this book may be reprinted or reproduce mechanical, or other means, now known or hereafter invented including photocopying and recording, or in any information storage or retrieval system, without permission in writing from the publishers British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library rary of Congress Cataloging in Publication Data A catalog record for this book has been requested ISBN 0-203-30114-.5 Master e-book ISBN ISBN 0-203-34048-5(Adobe eReader Format) ISBN 0-415-26101-5 (Print Edition) C 2002 D. 4. Bavliss and D. H. Deacon
First published 2002 by Spon Press 11 New Fetter Lane, London EC4P 4EE Simultaneously published in the USA and Canada by Spon Press 29 West 35th Street, New York, NY 10001 Spon Press is an imprint of the Taylor & Francis Group © 2002 D. A. Bayliss and D. H. Deacon All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying and recording, or in any information storage or retrieval system, without permission in writing from the publishers. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging in Publication Data A catalog record for this book has been requested ISBN 0-415-26101-5 This edition published in the Taylor & Francis e-Library, 2004. ISBN 0-203-30114-5 Master e-book ISBN ISBN 0-203-34048-5 (Adobe eReader Format) (Print Edition) © 2002 D. A. Bayliss and D. H. Deacon
Contents 1 Introduction 1.1 Health and safety considerations 2 The corrosion of steel 2. 1 Corrosion: the basic process 2.2 The electrochemical nature of corrosion 2.3 Corrosion terminology 2.3.1 Potential 2.3.2 Polarisation 2.4 Corrosion in air 2.4.1 Steel composition 2. 4. 2 Rust 2.5 Corrosion in water 2.5.1 Composition of water 2.5.2 Operating conditions 2.5.3 Steel composition 2.5.4 Corrosion rates of steel in water 2.6 Corrosion in soil 2. 7 Bacterial corrosion 2.8 Health and safety considerations ences Further reading 3 Surface preparation 3.1 Steel surface contaminants and condition 3.1.1 Oil and grease C D.A. Bavliss and D. H. Deacon
Contents Acknowledgements 1 Introduction 1.1 Health and safety considerations 2 The corrosion of steel 2.1 Corrosion: the basic process 2.2 The electrochemical nature of corrosion 2.3 Corrosion terminology 2.3.1 Potential 2.3.2 Polarisation 2.3.3 Passivity 2.4 Corrosion in air 2.4.1 Steel composition 2.4.2 Rust 2.5 Corrosion in water 2.5.1 Composition of water 2.5.2 Operating conditions 2.5.3 Steel composition 2.5.4 Corrosion rates of steel in water 2.6 Corrosion in soil 2.7 Bacterial corrosion 2.8 Health and safety considerations References Further reading 3 Surface preparation 3.1 Steel surface contaminants and conditions 3.1.1 Oil and grease © 2002 D. A. Bayliss and D. H. Deacon
3.1.2 Millscale 3.1.3 Surface cleanliness 3.1.4 Roughness 3.1.5 Surface defects and welds 3.2 Surface preparation methods 3.2.2 Hand-and power-tool cleaning 3.2.3 Abrasive blast-cleaning 3.2.4 Innovative methods 3.2.5 Flame cleaning 3.2.6 Pickling 3.2.7 Iron and zinc phosphating 3.3 Health and safety matters 3.3.1 General 3.3.2 Open nozzle blast-cleaning 3.3.3 Pressure water jetting 3.3.4 Flame cleaning Paints and paint coatings 4.1 General requirements 4.2 The nature of paint 4.2.1 Paint systems 4.3 Protection by paint films 4.3.1 Zinc-rich pigments 4.3.2 Inhibitive pigments 4.3.3 Barrier coatings 4.4 Properties of paint films 4.4.1 Adhesion 4.4.2 Flexibility 4.4.3 Hardness 4.44 Abrasion resistance 4.4.5 Permeability 4.4.6 esistance to microorganisms 4.4.7 Ageing of paint films 4.5 Paint film formation 4.6 Binders 4.6.1 Oxidation type 4.6.2 Solvent evaporation type 4.6.3 Chemically reacting type C D.A. Bavliss and D. H. Deacon
3.1.2 Millscale 3.1.3 Surface cleanliness 3.1.4 Roughness 3.1.5 Surface defects and welds 3.2 Surface preparation methods 3.2.1 Degreasing 3.2.2 Hand- and power-tool cleaning 3.2.3 Abrasive blast-cleaning 3.2.4 Innovative methods 3.2.5 Flame cleaning 3.2.6 Pickling 3.2.7 Iron and zinc phosphating 3.3 Health and safety matters 3.3.1 General 3.3.2 Open nozzle blast-cleaning 3.3.3 Pressure water jetting 3.3.4 Flame cleaning References 4 Paints and paint coatings 4.1 General requirements 4.2 The nature of paint 4.2.1 Paint systems 4.3 Protection by paint films 4.3.1 Zinc-rich pigments 4.3.2 Inhibitive pigments 4.3.3 Barrier coatings 4.4 Properties of paint films 4.4.1 Adhesion 4.4.2 Flexibility 4.4.3 Hardness 4.4.4 Abrasion resistance 4.4.5 Permeability 4.4.6 Resistance to microorganisms 4.4.7 Ageing of paint films 4.5 Paint film formation 4.6 Binders 4.6.1 Oxidation type 4.6.2 Solvent evaporation type 4.6.3 Chemically reacting type vi Contents © 2002 D. A. Bayliss and D. H. Deacon
4.7 Pigments 4.7.1 Inhibitive pigments 4.7.2 Other pigments 4.7.3 Extenders 4. 8 Solvents 9 Paint classificatio 4.9.1 Oil-based and oleo-resinous paints (oxidation drying) 4.9.2 Solvent evaporation paints 4.9.3 Chemical reaction paints 4.94 Zinc-rich coatings 4.9.5 Waterborne coatings 4.9.6 Compatibility of different paints 4.9.7 Heat-resistant coatings 4.9.8 Other coating materials and fillers 4.10 Health and safety matters References Further reading 5 Paint application 5.1 Methods of application 5.1.1 Brush application 5.1.2 Roller application 5.1.3 Airspray application 5.1.4 Airless spraying 5.1.5 Application of plural-component paints by 5.1.6 Electrostatic spray 5.1.7 Other application method 5.1.8 Comparison of application method 5.2. Application conditions 5.2.1 Pre-or post-fabrication 5.2.2 The painting shop 5.2.3 Ambient conditions 5. 2. 4 Storage of paint 5.2.5 Preparation of paint before use 5.3 The painter 5.4 Paint manufacturers 'data sheets 5.5 Health and safety matters 5.5.1 Airless spray C D.A. Bavliss and D. H. Deacon
4.7 Pigments 4.7.1 Inhibitive pigments 4.7.2 Other pigments 4.7.3 Extenders 4.8 Solvents 4.9 Paint classification 4.9.1 Oil-based and oleo-resinous paints (oxidation drying) 4.9.2 Solvent evaporation paints 4.9.3 Chemical reaction paints 4.9.4 Zinc-rich coatings 4.9.5 Waterborne coatings 4.9.6 Compatibility of different paints 4.9.7 Heat-resistant coatings 4.9.8 Other coating materials and fillers 4.10 Health and safety matters References Further reading 5 Paint application 5.1 Methods of application 5.1.1 Brush application 5.1.2 Roller application 5.1.3 Airspray application 5.1.4 Airless spraying 5.1.5 Application of plural-component paints by spray 5.1.6 Electrostatic spray 5.1.7 Other application methods 5.1.8 Comparison of application methods 5.2. Application conditions 5.2.1 Pre- or post-fabrication 5.2.2 The painting shop 5.2.3 Ambient conditions 5.2.4 Storage of paint 5.2.5 Preparation of paint before use 5.3 The painter 5.4 Paint manufacturers’ data sheets 5.5 Health and safety matters 5.5.1 Airless spray Contents vii © 2002 D. A. Bayliss and D. H. Deacon