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Splash and immersion zones on offshore installations are areas that are exposed to extremely aggressive environments due to the effects of sea water, tides, wind, waves, and/or ultraviolet radiation. Various certifications such as NORSOK(1) exist to help guide customers select a coating based on its corrosion resistance performance. Despite the necessity of these standards, it is helpful to understand that other properties such as substrate surface and cure conditions can greatly effect performance of the coatings. In this paper, we will compare adhesion of two coatings to different substrate surface conditions while both coatings will be cured in two different environments. Our goal is to investigate the effect of curing environment of coatings on adhesion to the substrate.
Various polymeric coatings have been exposed to natural saltwater environments in Buzzard' s Bay, MA and at La Costa Island, FL for the last 18 years and 21 years respectively. The coating systems were applied to 8 inch (20.32 cm) by 8 inch (20.32 cm) by 40 feet (12.19 m) A36 steel "H" pilings. The depth of the water ranged from 4 feet (1.22 m) to 8 feet (2.44 m). Periodic visual inspections have been conducted to evaluate the performance of the coating/ primer systems in the splash zone and in the immersed zone. The coatings had windows to evaluate the under film corrosion attack by saltwater present near the Cape Cod canal. The coatings were evaluated according to ASTM visual standards at low tide. Results of the coating inspections and an evaluation of their effectiveness in preventing the corrosion of steel pilings in seawater will be presented.
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Destructive physical inspection for corrosion under protective coatings post-exposure suggests that significant metal loss may be occurring in the absence of a visual indication and that actual corrosion/material loss does not correlate with the visual inspection data.