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Galvanized protective coatings have been used for structural steel to mitigate steel corrosion in atmospheric exposures and chloride-rich marine environments. The galvanizing process involves dipping steel elements free of surface mill scale in a molten zinc bath where the diffusion of zinc into the steel matrix allows for zinc-iron alloy layers of decreasing zinc concentrations by depth to form in the steel. Oher elements such as tin, antimony and aluminum may be added to the galvanizing bath to control reaction rates, surface appearance and corrosion behavior. Hot-dipped galvanizing provides corrosion protection by developing a barrier layer and in certain conditions provide beneficial galvanic coupling of the zinc-rich layers to the steel.
Protective coatings for structural steel bridges include galvanized steel. The zinc alloy layers of galvanized steel provide beneficial galvanic coupling with the steel substrate to mitigate corrosion activity. However, coating defects exposing the steel substrate to the chloride exposure environments can affect the zinc corrosion activity and thus the mitigation of steel corrosion. Electrochemical measurements including open-circuit potential, linear polarization resistance, and the electrochemical noise (EN) technique were conducted on coated steel plates with defects subjected to various chloride solutions to identify the zinc activity and steel corrosion. The EN testing was used to identify the local electrochemical activity of the zinc and the steel substrate and corrosion mitigation afforded by the coatings when subjected to a chloride solution.
Impressed current rectifiers are the backbone of a pipeline operator’s cathodic protection (CP) systems. A rectifier’s ability to protect a large length of electrically continuous pipeline considerably improves efficiencies and reduces material costs as compared to galvanic systems. However, like galvanic anodes, impressed current anodes are a consumable asset, and require replacement at the end of their service life to ensure that the rectifier can continue to adequately protect the pipeline.
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A building, partially clad in fluoropolymer coated aluminum panels, was observed to have an aesthetically unacceptable appearance while still under construction. Once installed on the building, many of the panels exhibited a vertical streaked appearance under certain conditions. When the panels were at ground level, or when the sun was bright, the streaky appearance was not noticeable. However, in conditions of low light, such as during early morning, dusk, or on cloudy days the streaky appearance was reported to become apparent. A visual mock-up, consisting of multiple coated panels that had been approved by the architect as a guide to the anticipated appearance were also present on-site as a reference. This visual mock-up was used as a reference for acceptable appearance of the coated panels.
An innovative thermoplastic type of coating material based on pure isobutene homopolymer was investigated to determine whether it would be fit for purpose in CUI services at low and moderate temperatures up to 120 °C. This polymer is commonly called Polyisobutene (PIB) and has a unique set of properties that are beneficial for protecting metallic structures from corrosion. Polyisobutene is a polyolefin with a chemical structure similar to Polyethylene (PE) and Polypropylene (PP). One of the major differences is that PE and PP are solid materials with a high degree of crystallinity, whereas PIB does not have a crystallization or melting temperature. PIB has a glass transition temperature (Tg) below – 60 °C which indicates that the polymer is a liquid above this temperature.