1. Asset Management Preservation
Presented By: Aaron Dacey, Coatings and Corrosion Engineer; North Carolina Department of Transportation

2. Introduction
This webinar will discuss protective coating of complex steel structures can be complicated, making the maintenance of these assets and their components a challenge. Each asset may have its own maintenance schedule, performance metrics and life-cycle expectations. This webinar will explain how to develop an effective asset management preservation program, based on these considerations, to achieve the optimal life of the coating system.

3. The Importance of Protective Coatings
Coatings play a critical role in protecting equipment and infrastructure from corrosion and failure in both the public and private sectors

4. The Importance of Protective Coatings
Protective coatings help to keep:
Processing plants operational
Maintain the integrity of pipelines and storage tanks
Protect bridges, towers, and platforms
Assure readiness of military ships, aircraft, and vehicles

5. Coatings Asset Management Program
Coating materials have a limited life expectancy; therefore, maintenance is important for achieving the design life of a properly installed coating system as well as preserving the integrity of equipment and infrastructure that the coating is being applied to

6. Why Have a Coatings Asset Management Program?
Ensures regular checks on the existing coating system and timely in-service repairs
Provides asset integrity and operational safety of facility
A corrosive environment can impact the integrity of a structure

7. Why Have a Coatings Asset Management Program?
Achieve longer service life of coatings
Improved performance time
Maximizes coatings investment
Improved uptime
Reduce overall cost of project

8. Coatings Asset Management Program
The program consists of:
Routinely evaluating the protective coatings applied
When necessary, creating a design for rehabilitation of the assets

9. Basic Elements of a Good Coatings Asset Management Program
Qualified coatings
Trained Coating Applicators
Qualified Contractors
Good Specifications
Qualified Inspection
Conducting Routine Surveys Post Application

10. Qualified Coatings
Coatings being applied within a facility should be verified for:
Achieving performance properties for environment being placed in
Where does this need to live? Is it near the coast? Is it in a hot and humid climate? Is it coating to experience extreme cold temperatures?

11. Qualified Coatings
Being compatible with previous coating applied (if conducting repair and maintenance work)
Meeting requirements of coating specification
Service life
Is the expected service life 5 years? 15 years? 20 years?

12. Qualified Coatings
It is good practice to require a certificate of conformance from coating manufacturer verifying the performance properties expected and specified are being met

13. Trained Coating Applicators
Applicators applying material should be properly trained to avoid costly mistakes.
Examples of acceptable training is:
SSPC CAS Level 1 and Level 2
SSPC C7 (Abrasive Blasting)
SSPC C12 (Airless Spray)

14. Qualified Contractors
Specifying qualified contractors provides the owner “piece of mind” that the work is being completed by trained contractors per the coating manufacturer’s product data sheet and job specification
SSPC QP 1
SSPC QP 2
SSPC QP 3

15. Good Specifications
In order to prevent premature corrosion, specifications must be written in a clear and concise manner- calling out specifics.
Words such as must and shall are used in lieu of could and should.
Proper Coatings must be specified

16. Qualified Inspection
All projects should have a qualified inspector performing inspection at major hold points throughout the project
Pre Surface Preparation
Surface Preparation
Coating Application
Post Coating Application

17. Qualified Inspection Examples of qualified inspection programs are:
SSPC PCI: Protective Coatings Inspector
SSPC BCI: Bridge Coating Inspector
SSPC CCI: Concrete Coating Inspector
NACE CIP: Coating Inspector Program
FROSIO

18. Conducting Routine Surveys Post Application
Conducting routine surveys post application allows the owner to see how the coating is performing and address problems early on
It is good practice to perform a yearly survey

19. Survey Reports Survey reports should consist of the following basics:
Precise location of structure
Original date coating work was completed
The manufacturer and type of coating originally applied
Any notes regarding special considerations or conditions employed during coating application
Requirement for and record of inspections

20. Survey Reports
Condition ratings and definitions need to be decided prior to the start of any survey to ensure that each yearly survey can be compared to the previous years

21. The ABC Rating System A- They don’t have to do anything within 3 years
Good
B- They have to do something within 3 years
Generally OK, but plan for some maintenance
C- They have to do something within 1 year
PROBLEM- MUST BE DEALT WITH!!

22. Survey Reports
A plan should be developed on what areas will be inspected and how to access those hard- to- reach access areas that can often become corrosion issues
An asset deemed unsafe should get priority
Pitted steel, leaking pipe, unsafe walkways, etc.

23. Survey Reports The survey evaluation should include: Adhesion
Appearance (gloss, chalk, primer, mill scale, rust, etc.)
Percent of failure
Dry film thickness (DFT)

24. Adhesion- Steel
ASTM D3359: Standard Test Methods for Measuring Adhesion by Tape Test
These test methods cover procedures for assessing the adhesion of coating films to metallic substrates by applying and removing pressure-sensitive tape over cuts made in the film

25. Adhesion- Steel
ASTM D4541: Standard Test Method for Pull-Off Strength of Coatings Using Portable Adhesion Testers
This test method covers a procedure for evaluating the pull-off strength (commonly referred to as adhesion) of a coating system from metal substrates. The test determines either the greatest perpendicular force (in tension) that a surface area can bear before a plug of material is detached, or whether the surface remains intact at a prescribed force (pass/fail)

26. Adhesion- Concrete
ASTM D7234: Standard Test Method for Pull-Off Adhesion Strength of Coatings on Concrete Using Pull-Off Adhesion Testers
This test method covers procedures for evaluating the pull-off adhesion strength of a coating on concrete. The test determines the greatest perpendicular force (in tension) that a surface area can bear before a plug of material is detached

27. Rust Evaluation SSPC VIS 2
Standard Method of Evaluating Degree of Rusting on Painted Steel Surfaces

28. Dry Film Thickness- Steel
ASTM D7091: Standard Practice for Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals

29. Dry Film Thickness- Steel
SSPC PA 2: Procedure for Determining Conformance to Dry Coating Thickness Requirements

30. Dry Film Thickness- Concrete
ASTM D6132: Standard Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings Using an Ultrasonic Coating Thickness Gage

31. Dry Film Thickness- Concrete
SSPC PA 9
This standard describes procedures to measure the thickness of dry, homogeneous coatings applied on cementitious surfaces using commercially available ultrasonic coating thickness gages. These procedures are intended to supplement manufacturers’ operating instructions for the manual operation of the gages and are not intended to replace them

32. Coatings Database
Some facilities will gather asset coating information in a computer database
The database contains:
Photos
Condition assessment reports
Survey tests such as:
Adhesion
Appearance (gloss, chalk, primer, mill scale, rust, etc.)
Percent of failure
Dry film thickness (DFT)
Using this information can allow facilities to show the progression of corrosion in a certain area over a period of time

33. Problems Within 1 Year Warranty
Typically you will find most coating application problems within the 1st year of service
If coating was installed properly after the 1st maintenance, very little repair will need to occur over the next several years
Known as the “Bathtub Curve”

34. Summary
By creating an asset management coatings program you can assure that recoat and overcoat is preformed before damaging corrosion sets in, allowing downtime of the asset to be minimized and decreasing cost of the overall project