ANTI-CORROSION COATINGS TECHNICAL SUPPORT

Statement of Exterior Anti-Corrosion Probable Durability of Polyester Powder Coatings

STATEMENT OF EXTERIOR ANTI-CORROSION PROBABLE DURABILITY OF POLYESTER POWDER COATINGS

Anti-Corrosion Coatings applied to the Customers free issue galvanised steel products meet the general requirements of BS EN 13438 : 2005 & BS 1722 – 16 : 2009. Powder coatings applied provide protection against corrosion determined in part by Environmental Aggressiveness. For a steel item, whether it is exposed inside or outside, the corrosion speed varies according to the aggressiveness of the environment. The more aggressive the environment, the more corrosion takes hold. In 2018/2019, the ISO 12944 standard was revised and clause 9 was introduced – Protective Paint Systems and Laboratory Performance Test Methods for Offshore and Related Structures. In addition, the corrosion categories, C1 – C5 (very low to very high) were also revised and a new category of CX was added relating specifically to offshore structures. In addition, a 25+ years durability classification was developed to correspond to a new immersion category, Im4.

ISO 12944 – 2 specifies atmospheric corrosion categories.

ISO 12944-2 Tab. 1 – Categories of Corrosion
Category of corrosion
C1 – Very Low	Very little or no pollution.Heated buildings, offices, shops, schools, hotels etc.
C2 – Low	Low levels of pollution. Mostly rural areas.
C3 – Medium	Urban and industrial areas, moderate sulphur dioxide pollution. Coastal areas with low salinity [not under direct influence of salty air/wind]
C4 – High	Industrial areas and coastal areas with moderate salinity. Sea front areas
C5 – I Very High	Industrial areas with high levels of humidity (Middle East)
C5 – M Very High	Coastal and offshore areas with high salinity. Sea front protection barriers, oil rigs.
CX – Very High	Marine and offshore environments.

The Importance Of Good Design

The corrosion speed varies according to the design of the item, as well as mechanical processes such as cutting, bonding, folding, jointing and welding. It is important to consider the following:

The presence of chinks such as air gaps constitute a confined environment favorable to accelerated local corrosion.
Jointing of two materials creates galvanic couples starting up an accelerated corrosion – nuts or rivets often surrounded by rust marks.
Welds, in particular when oxidised and irregular.

Some parts are subject to working stresses such as:

Mechanical stress
Rapid or cyclic temperature changes
Permanent or repeated contact with fluids

These stresses increase the corrosion speed.

Part Maintenance

Corrosion can also be accelerated, when parts are encrusted with salts and dirt. Therefore periodic cleaning, with a frequency determined by the environment slows down the speed of corrosion. Quick and effective repairs of the anti-corrosion coating is vital to ensure the long-term protection provided by the powder coating. Assuming good design and on-going appropriate care and maintenance, Northpoint suggests the following as an indication of the powder coating life expectancy:

C1 – in excess of 15 years.
C2 – in excess of 15 years.
C3 – 5 – 15 years.
C4 – Non-standard processes required to offer any level of protection for these areas.
C5 – Non-standard processes required to offer any level of protection for these areas.
CX – All offshore systems must continue to go through 4,200 hours of cycling testing, which equates to 25 weeks.

Northpoint has over 35 years’ experience in delivering anti-corrosion powder coating systems. Our expertise are matched by our customer service, and our professional coating solutions can be tailored to each client’s specific requirements. Contact our team today for more information or a quotation.