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Corrosion is one of the leading maintenance costs across the United States Surface Navy, with approximately 25 cents of every dollar spent on maintenance going towards fighting or correcting corrosion. In addition to the huge financial burden, corrosion can limit the ability of our Navy’s ships to meet operational commitments and even prevent them from achieving their expected service life (ESL).
Corrosion is one of the leading maintenance costs across the United States Surface Navy, with approximately 25 cents of every dollar spent on maintenance going towards fighting or correcting corrosion. In addition to the huge financial burden, corrosion can limit the ability of our Navy’s ships to meet operational commitments and even prevent them from achieving their expected service life (ESL). In February of 2011, Surface Team One (ST1) stood up the Corrosion Control Knowledge Sharing Network (KSN) in order to streamline the efforts to fight and win the war against corrosion. The Corrosion KSN formed a strong and diverse team comprised of members from the operator, maintenance execution, maintenance planning, engineering, research and development and program management organizations. Together, the team set out to “single up” the efforts to evaluate and mitigate the corrosion issues facing the Fleet. In the short time since its creation, the Corrosion KSN has been fighting the war on corrosion from multiple fronts and has already made considerable progress. The Corrosion KSN is helping fit corrosion improvements into availability work packages in order to impact the Fleet’s corrosion problems now. The KSN has helped implement improved coatings like polysiloxane (MIL-PRF-24635 type V, class 2, grade B) into the Surface Fleet. The KSN is also initiating efforts now that will have long term impacts to help improve the Surface Navy’s corrosion control capabilities while interfacing with ship’s force to bring corrosion awareness back to the sailors. Additionally, the KSN is injecting corrosion avoidance early on in the life of Surface Ships to ensure today’s ships can reach their ESL and become a part of tomorrow’s Navy. The Corrosion KSN has created a Program Management Plan to help align the efforts of its various members and to ensure a common, systematic approach is being used. This plan will aid in maximizing the KSN’s efforts regarding the Navy’s corrosion problems by helping the members determine the strategic and tactical plans for the KSN. The primary elements of this program plan are as follows: policy, acquisition process improvements, strategic communications, technology transition to expedite corrosion mitigation materials and practices, corrosion control planning and execution for assessments and availabilities, and training. The Corrosion Control KSN is progressing on several fronts with the ultimate goal of helping the US Navy win the war on corrosion.
The use of duplex coating systems (hot dip galvanizing or thermal spray coating with one or more liquid-applied coatings) for long term protection of structural steel is becoming more mainstream in many industries. This paper describes the advantages of employing duplex coating systems as well as some important considerations for designers prior to specifying their use. It also highlights an ongoing initiative to help agencies more efficiently and effectively use duplex coatings on steel bridges by developing guidelines, standards, and other materials.
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Zinc rich coatings have long been used in the protective coatings industry as one of the primary means of steel substrate protection against corrosion. The primary protection mechanism has historically been galvanic sacrificial loss of zinc metal and the simultaneous formation of protective zinc oxides and salts. Various standards and customer specifications exist to ensure that the coating will provide the necessary corrosion protection for the life of the asset.
The role of a Coating Inspector has evolved considerably over the past few decades, and the responsibilities have increased over what used to be a rather straightforward job: to verify that surface preparation and coating application meet the project specification requirements. Today there are week-long or multi-week basic and advanced coating inspection courses, specialty courses that are industry-specific (e.g., bridge, nuclear), courses that are substrate-specific (e.g., concrete coatings inspection) and even coating-specific (e.g., inspection of thermal spray coatings).