Weathered galvanized, previously painted transmission poles, towers and substation

structures.

Better understand the corrosion process as it relates to T&D structures and equipment.

Better understand how to evaluate and prioritize weathered steel and galvanized structures.

Better understand basic coatings technology. Be aware of best available coatings technology,

and why some coatings are better choices than others.

Better understand how to plan and create a long-term Corrosion Maintenance Program.

Get to know Induron Protective Coatings

Corrosion is the deterioration of a substance (usually a metal) or its properties due to a reaction with its environment.

For steel and galvanizing: An electrochemical reaction with the environment, that produces a deterioration of the metal.

Anode, cathode, electrolyte, and metallic pathway are the four essential ingredients of a corrosion cell; and oxygen plays a role also. If any one is missing; the corrosion cell (circuit) cannot be complete; and electrochemical corrosion may slow down or stop.

0 years to 30 years: no maintenance required. 30 to 40 years: slight rust developing on bolts

and edges. 40 to 45 years: rust on edges, nuts, bolts,

climbing bolts and tops of angle iron. Slight rust on remainder of the structure.

45 to 50 years: heavy rust on edges, nuts, bolts, climbing pegs and tops of angle iron. Rust on remaining remainder of the tower.

Severe exposures or climates may reduce these estimates.

C1:Atmospheres with low level of pollution. Mostly rural areas.

C2:Urban and industrial atmospheres; moderate sulfur dioxide pollution.

C3:Coastal areas with low salinity.C4Industrial areas and coastal areas with moderate salinity.

C4-Industrial areas with high humidity and aggressive atmospheres. Also coastal and offshore areas with high salinity.    

C5i and C5m- Include coastal marine and industrial marine; high humidity and aggressive atmospheres.

If a Transmission structure has moderate corrosion (less than 10%) and is located in a coastal marine environment; the specification must take that into account. For example; the same structure in the same condition in a desert location with minimal pollution may generate a different coatings specification. The marine structure may specify more film thickness, an added full primer coat, or more surface preparation to achieve optimal corrosion resistance for the longest time.

R-1. Non-Deteriorated. 0-0.1% Rust. Coating almost intact; red

rust covers less than 0.1% of all surfaces. Re-evaluate in 6-12 years.

R-2; Slightly to moderately deteriorated. 0.1 to 1% rust. Coating somewhat

weathered. Both R-1 and R-2 will normally be done in

ONE climb= Major cost savings to paint within this window of opportunity!

R-3; Deteriorated. 2 Climbs. 3 Climbs. 1-10% rust. Coating thoroughly weathered,

blistered, or stained, up to 10% of surface area is covered with rust, rust blisters, hard scale or loose paint film, very little pitting visible. Needs attention in 1-3 years.

R-4; Severely Deteriorated. 10-50% rust. Large portion of surface is

covered with rust, pits, nodules, and non-adherent paint. Pitting is visible. Needs attention within 1 year.

R-5; Totally deteriorated. Over 50% rust. Needs immediate attention.

One Climb

After service life of 40 years.

Average 100 foot 345KV structure labor and material costs = $2,600

Costs may be affected by corrosive atmospheres or climates.

Two Climbs

After service life of 45 years.

Average 100 foot 345KV structure labor and material costs = $5200

Costs may be affected by corrosive atmospheres or climates.

Three Climbs

After service life of 50 years

Average 100 foot 345KV structure labor and material costs =$7800

Costs may be affected by corrosive atmospheres or climates.

Three + Climbs

Extensive cleaning; may include abrasive blasting, powertools, etc.

May require full prime and extra mils DFT from tower finish coat.

Costs may be affected by corrosive atmospheres or climates.

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About 22% of corrosion costs ($3.8 billion) was considered avoidable using practical, cost effective measures.

Methods include: pro-active protective coatings maintenance programs, cathodic protection, alloys, corrosion inhibitors, better design.

The hidden real costs of corrosion could be even higher than published, given undetected and undocumented corrosion within infrastructure, and measurement of indirect costs.

Pro-active protective coatings Plan. A well-written Coatings Specification. Product Quality. Qualified Contractors.

Field Survey to classify tower line segments, typically 10% of line inspected.

Develop Coatings Plan from field survey results.

Create an effective coatings specification with the utility from the Coatings Plan.

Remember, focusing on the worst towers first is not always the best plan!

ACT!

Function over Form: Aesthetics don’t count as much as performance + compatibility with substrates.

High Solids/High-Build (up to 14 mils) Penetrate substrate and passivate corrosion

cells. Easy to apply by paint mitt or pound/oval brush. Designed for absolute minimum cleaning and

surface preparation. Absolute maximum wetting and surface

tolerance for rusty surfaces.

High solids, low VOC (92% SBV). High-build 8-12 (builds easily to 15 mils). Excellent wetting and surface tolerance. Compatibility with galvanized and rust Easy to apply with mitts or pound brushes. Single component; no pot-life. Increased edge retention with new

technology

Micaceous iron oxide provides a very inert and stable pigment. It has a unique flake-like nature; enhancing barrier properties, providing a labyrinth effect against moisture penetration, absorbing ultraviolet light, and increasing adhesion to weathered galvanized, as well as intercoat adhesion. Erosion rates over granular shaped pigments are also greatly reduced. Film properties, such as flexibility are retained with MIO pigmentation.

Other highly effective pigments included in a high quality tower paint may include metallic zinc dust, aluminum, and ceramic microspheres. The benefits include increased compatibility with the substrate, improved corrosion resistance, increased barrier properties, better adhesion, and resistance to hostile environments, improved edge retention, high build properties. Avoid tower paints that do not contain high quality functional pigments. You can’t get 25 years from one coat without them!

Employee Training and Certifications

•Adult CPR, AED, and Community First Aid•High Voltage Electrical Safety for Power Generation, Transmission, & Distribution (required OSHA rule 1910.269)•Fall Protection •Tower / Pole Rescue•OSHA 10-hour Safety Training•Lead Awareness and Hazard Communication•*OSHA 30-hour Supervisor Safety Training•Lead Removal and Safe Operating Procedures•Hazardous Waste Operations and Emergency Response•* Lift / Boom Operations and Safety•* CCS-lhf1 and Permit Required Confined Space certification•* SSPC C-3 Supervisor / Competent Person•* NACE Certified Coating Inspector

1)      SSPC - QP1 (Field Application Coatings) 2)      SSPC - QP2 (Industrial Hazardous Paint Removal) 3)      ISO 9001:2008 (Quality Management System) 4)      EMR Safety Ratings. 5)      OSHA Safety logs. 6)      Background checks on workers (Transmission

system is part of Homeland Defense) no undocumented workers.

7)      Certified climbers. 8)      Certified electrical safety. 9)      New equipment issued for every job. 10)   Years of experience. 11)   Qualifications of job foreman. 12)   Knowledge of coatings and corrosion.