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Inorganic Zinc Coatings

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Inorganic Zinc Coatings INORGANIC ZINC COATINGS History, Chemistry, Properties, Applications and Alternatives A Compilation of Papers published in Australia and New Zealand 2nd Edition Copyright 2013 The Australasian Corrosion Association Inc PO Box 112 Kerrimuir Victoria 3129 Australia www.corrosion.com.au Publication Number – ACA 1 ACA 1 - Second Edition Published 2013 “Inorganic Zinc Coatings – History, Chemistry, Properties, Applications and Alternatives” ACA 1 - First Edition Published 1997 – titled “Sixty Years of Inorganic Zinc Coatings” ISBN 978-0-9875309-0-5 Copyright 2013 by the Australasian Corrosion Association Inc. All rights reserved The Australasian Corrosion Association Incorporated (ACA) is an Australia and New Zealand focussed membership-based not-for-profit organisation formed to provide a forum for exchange of information between its members and others with an interest in corrosion prevention. The information contained in its publications is intended for general guidance only and in no way replaces the services of professional consultants on particular projects. No legal liability for negligence or otherwise can be accepted by the Association for the information contained in this publication. No part of this publication may be reproduced in whole or in part, or stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without written permission of the publisher. This publication is sold subject to the condition that it shall not be lent, resold, hired out, or otherwise circulated without the publisher’s prior consent in any form of binding or cover other than that in which it is published. This condition being imposed on any subsequent purchasers. For information regarding permission, write to: The Chief Executive Officer The Australasian Corrosion Association Incorporated PO Box 112 Kerrimuir Victoria 3129 Australia Email: [email protected] The Australasian Corrosion Association Incorporated Australasian Office Suites 1 and 3 458 Middleborough Road Blackburn Victoria 3130 Australia PHONE: +61 3 9890 4833 FACSIMILE: +61 3 9890 7866 EMAIL: [email protected] WEBSITE: www.corrosion.com.au For contact information on ACA’s Branches and networks in Queensland, New South Wales, Newcastle, Victoria, Tasmania, South Australia, Northern Territory, Western Australia, and New Zealand see the ACA’s website www.corrosion.com.au. ii CONTENTS Introduction to 1997 Book ....................................................................................................................................... 1 Technical Papers ...................................................................................................................................................... 2 Note on Inorganic Zinc Silicates in Australian Standards........................................................................................ 6 Inorganic Zinc Silicates – The Early Days, Part I: Invention and Early Applications R A Francis ................................................................................................................................................... 7 Inorganic Zinc Silicates – The Early Days, Part II: The Morgan Whyalla Pipeline R A Francis ................................................................................................................................................. 18 Manufacture and Chemistry of Inorganic Zinc Silicates G Wiggins ................................................................................................................................................... 24 Industrial Applications of Inorganic Zinc Silicate Primers K W Dalzell ................................................................................................................................................. 31 Inorganic Zinc Silicates vs Metal Spray in Industrial Applications W L Mandeno and T A Sutherland .............................................................................................................. 38 Inorganic Zinc Silicate Coatings - Chemistry and Protective Properties E Riding ...................................................................................................................................................... 49 Effect of Atmospheric Conditions on the Long Term Properties of Solvent-borne Zinc Silicate Coatings G Eccleston ................................................................................................................................................. 55 Zinc Primers - The Way Forward E Hemmings and M J Mitchell.................................................................................................................... 66 Inorganic Zinc Silicates as Single-Coat Protective Systems for Steel A Szokolik.................................................................................................................................................... 76 Australia Patent No. 104,231 - Improvements in and Connected with Silicated Compositions V C J Nightingall ........................................................................................................................................ 86 Zinc Silicate Type Coatings C L O’Neill ................................................................................................................................................. 94 Test on the Corrosion Protection of Steelwork T H Russell .................................................................................................................................................. 96 The Role of Metallic Zinc in Zinc-Rich Paints D G Thomas, R T Cox and B A Richardson ................................................................................................ 98 Zinc Dust Pigmented Paints F Marson .................................................................................................................................................. 105 Abrasion Resistance of Inorganic Zinc Silicate Coatings D W Donald and F E Worsnop ................................................................................................................. 111 The Structure of Inorganic Zn-Rich Coatings examined with Optical and Electron Microscopy H Jaeger and R G Sherwood .................................................................................................................... 117 An Electron Microscope Study of the Structure of Inorganic Zn-Rich Coatings after Accelerated Testing H Jaeger, R G Sherwood, D W Donald and W J Kennedy ....................................................................... 129 Testing of Inorganic Zinc-Rich Anticorrosion Coatings in Different Atmospheres H Jaeger, D W Donald and F Yuan .......................................................................................................... 140 Improvements to the Curing Properties of Water Borne Inorganic Zinc Silicate Coatings D W Donald .............................................................................................................................................. 148 Inorganic Zinc Coatings I Baxter ..................................................................................................................................................... 153 Inorganic Zinc Silicate Coatings G J Biddle ................................................................................................................................................. 154 Inorganic Zinc or Galvanizing: Choosing the ideal Corrosion Protection for Structural Steel R A Francis ............................................................................................................................................... 163 A Comparison of the Corrosion Behaviour of Inorganic Zinc and Conventionally-coated Bridges R A Francis and A Szokolik ...................................................................................................................... 172 Water-based Inorganic Zincs – Performance vs Practicability E Hemmings and N Demirdjian ................................................................................................................ 181 iii Climatic Conditions for Successful Application of Zinc-rich Coatings F Salome ................................................................................................................................................... 192 Zinc Coating – As a Base for High Performance Systems A Szokolik.................................................................................................................................................. 201 Metallic Zinc Based Coating Systems – Evaluation of Performance K Lofhelm, E Hemmings, A Szokolik ........................................................................................................ 210 Repair of Single Coat Inorganic Zinc Silicate Coatings R A Francis, D Ellis and A L Walker ........................................................................................................ 219 Water-borne Silicates in Coatings and Construction Chemicals Adrian Thomas .......................................................................................................................................... 227 Potential Re-coating Treatment for Inorganic Zinc Silicate Coatings June Zhang and Andrew Walker ............................................................................................................... 259 Field Test for Water Insolubility of Water Borne Inorganic Zinc Coatings Ted Riding ...............................................................................................................................................
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