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FeedsHome: February - March 2010 › Lead Story › Helping rail engineers to prevent corrosion
Helping rail engineers to prevent corrosion
01/03/2010 | Channel: Business Improvement
Much of the cost of refurbishing our railway network could have been avoided if correct corrosion-prevention strategies had been employed over the years. DAVID DEACON explains how the Institute of Corrosion can support all stakeholders in the
rail industry
The refurbishment of the railway network is costing billions of pounds to bring many of the sector’s structures up to a reasonable standard. A major part of the cost of this refurbishment is necessary because of the lack of maintenance against the ravages of corrosion on the network. Without a proper understanding of corrosion-control techniques, methods and materials, the costly ‘battle against corrosion’ will not be won.
The total cost of corrosion on an annual basis within the UK and many developed countries is generally not realised by rail engineers and architects – the very people who are responsible for designing, specifying, constructing and maintaining buildings, stations, bridges, tunnels and other structures in rural, industrial and marine environments, not forgetting the associated rolling stock.
The origins of the Institute of Corrosion
Over 30 years ago, the Government’s Minister for Technology, Mr Anthony Wedgwood-Benn, set up a Department of Trade and Industry Committee to work on establishing, more accurately, the cost of corrosion to the UK. This Committee, chaired by Dr T. P. Hoar produced the DTI Report on the cost of corrosion. The findings of the committee showed that, across a wide range of industries – including the railways – and covering diverse structures, equipment and plant, the cost of corrosion to the UK represented a staggering 3.6 per cent of the gross national product (GNP). These figures were reconfirmed by a second, brief DTI report published in 2001.
The first DTI report, published in 1971, was the first of a number of reports endeavouring to assess the cost of corrosion in various countries. The Japanese and the Americans followed the pattern of the UK Government’s report and established that the cost in both of those countries was almost identical.
The UK report assessed areas where potential savings could be made. It identified
a number of industries – for example, construction and general engineering,
including the railway network – as being possible major contributors to this saving. They estimated that 25 per cent could be saved immediately across ten sectors of industry.
The DTI reported that potential savings could be made immediately; these were
listed as far as general industry (the railways included) was concerned. It was stated that unnecessary, costly failures occurred for the following reason: “attention to corrosion is largely confined to the avoidance of bad mistakes made in the previous design. This method of learning by trial and error is expensive and wasteful.”
It was also stated in the report that engineers responsible for maintaining the
infrastructure could make significant savings by “more awareness in selection, specification and control of the application of protectives”. Regrettably, to the present time, engineers are still wasting money for the same reason and failing to make the savings, on both large and small projects, which could be achieved by using the expertise that is available from the membership of the Institute of Corrosion.
Since that 1971 report with all its detailed information, considerable changes have been implemented by many organisations concerned with maintaining structures and plant. However, I have been concerned, as an independent consultant, with the protection of structural steel since the report’s publication and I still find that, to this day, many engineers and architects are unaware of the requirements for basic long-term corrosion protection of structures.
One of the outcomes of the report was the merger of the various corrosion bodies into a single professional institute, now named the Institute of Corrosion, whose member companies and individuals can provide the products, services and expertise to ensure that any corrosion control programme can be the most cost-effective long-term option.
The chairman of the DTI Committee, Dr T. P. Hoar, was made the first Honorary Life Fellow of the Institute of Corrosion for his part in this exceptional work, and he was the first recipient of the U. R. Evans Award – the highest accolade given by our Institute. Professor Graham Wood at Manchester University, a past president of the Institute of Corrosion, was appointed the first ‘Professor of Rust’, as he was described in the media at that time, in order to implement the report’s findings.
All this experience from within the membership of the Institute of Corrosion is available to the railway industry, as it undergoes a period of major refurbishment of its infrastructure.
The activities of the Institute of Corrosion
The growth in membership of the Institute, both individual and sustaining company members, has increased significantly since the publication of the DTI report, and the
re-organisation of the Institute of Corrosion to meet its aims and objectives has resulted in a number of areas of improved corrosion-control measures.
These objectives have been progressively and steadily achieved over the past 25 years by various means. The major annual conference and exhibition, which was first held in 1981 in conjunction with the Corrosion Exhibition, CORREX, has attracted a wide range of delegates from different engineering and architectural backgrounds to hear about the latest practical techniques for design and corrosion-control methods. In addition, delegates are able to mix with the members of the Institute at these events and to establish long-term contacts for advice and guidance on practical corrosion matters.
Industrial Coating Applicator Training Scheme (ICATS)
The 2009 Conference heralded a major advance in corrosion control, with the launch of a new insurance initiative that will have major benefits for both those practising anti-corrosion activity and the owners of structures being protected. The ICATS Guarantee Scheme provides indemnity for the cost of repair and reinstatement of insured works to their original condition based on manufacturing defects, unsuitability of works and faulty or defective application of protective coatings. The scheme, which gives ‘no blame’ cover for structures for up to nine years, is available to all registered member companies and employees who have undertaken the ICATS training programme developed by Correx Limited. ICATS is now mandatory for both Network Rail and Highways Authority painting and repainting contracts.
It is clear that all the information is readily available to ensure that the correct specification, the correct methods of preparation and coating application, and the most cost-effective long-term coatings for any given application can be provided through companies and individuals who are members of the Institute of Corrosion.
In addition to the annual national conference, the regional branches, which are located throughout the UK and Ireland, hold half-day and evening ‘get-togethers’ on topical, practical subjects for both members and non-members in a relaxed environment.
Training courses
The Institute of Corrosion has also developed a series of training courses for individuals who wish to improve their understanding and knowledge of corrosion and, particularly, the methods used in its prevention. These courses are run both in-house, in conjunction with course providers, and also with external bodies. In particular, there is the 2-day practical ‘Fundamentals of Corrosion’ course, factorywhich can be held at any location throughout the UK, or indeed overseas.
In addition to these basic training courses, engineers and those with a ‘need to know’, can attend a series of certification schemes, which have been established to improve the quality of training and certification of inspectors. Topics include: painting, pipe coating, cathodic protection, and fire protection.
The introduction by the Institute of this widely recognised qualification and certification programme for coating and cathodic protection inspectors has resulted in over 1000 certificates being issued since the inauguration of the scheme. On a range of construction sites and structures there are many so-called inspectors carrying out quality control duties without formal training or qualifications, and who have not taken up Institute of Corrosion membership.
As an independent consultant involved in failure investigation and litigation on many recent corrosion failures, I have found instances where inspectors have been present and witnessed incorrect application or procedures, without understanding the implication of their errors.
Corrosion Management Magazine
The Institute of Corrosion also publishes a regular magazine, which is available to both members and non-members, entitled ‘Corrosion Management’. This bimonthly magazine includes – in addition to technical articles – news of events and Institute activities. It also contains a comprehensive source guide for engineers and specifiers, who are then able to contact organisations when specific help and guidance in solving corrosion problems, or with corrosion prevention, is needed.
There are over 80 organisations who have joined the Institute of Corrosion as sustaining corporate members and this covers a very wide spectrum of companies, including coating suppliers and coating applicators, and cathodic protection and monitoring companies, as well as consultants for advice, testing and inspection. In addition, a number of structure owners, specifiers and reciprocal organisations are also included.
Two examples
The Forth Rail Bridge has been recoated, after removal of all the existing coatings applied since the bridge was first opened in 1890. The new coating system and the methods of surface preparation, which have been carefully specified and tested, will give a ‘life to first maintenance’ of 25 years.
Reference panels of the coating system and the standard of surface preparation were monitored by an Institute of Corrosion Level III painting inspector, and the reference panels will be retained for 12 years to monitor the performance of the coating system by an Institute of Corrosion sustaining member company.
The High Level Rail Bridge across the river in Newcastle upon Tyne had all the paintwork examined and analysed by a sustaining member consultancy company from the Institute. The refurbishment project has subsequently won several awards for the team involved.
In conclusion
In summary, the four main aims of the Institute of Corrosion are:
David H Deacon FTSC FICorr is a past president of the Institute of Corrosion.
')";>
Full details of the Institute and all its activities can be obtained from The Institute of Corrosion, 7B High Street Mews, Leighton Buzzard, LU7 1EA, or by visiting the website.
Tel: 01525 851 771
Email: admin@icorr.org
Web: www.icorr.org
The total cost of corrosion on an annual basis within the UK and many developed countries is generally not realised by rail engineers and architects – the very people who are responsible for designing, specifying, constructing and maintaining buildings, stations, bridges, tunnels and other structures in rural, industrial and marine environments, not forgetting the associated rolling stock.
The origins of the Institute of Corrosion
Over 30 years ago, the Government’s Minister for Technology, Mr Anthony Wedgwood-Benn, set up a Department of Trade and Industry Committee to work on establishing, more accurately, the cost of corrosion to the UK. This Committee, chaired by Dr T. P. Hoar produced the DTI Report on the cost of corrosion. The findings of the committee showed that, across a wide range of industries – including the railways – and covering diverse structures, equipment and plant, the cost of corrosion to the UK represented a staggering 3.6 per cent of the gross national product (GNP). These figures were reconfirmed by a second, brief DTI report published in 2001.
The first DTI report, published in 1971, was the first of a number of reports endeavouring to assess the cost of corrosion in various countries. The Japanese and the Americans followed the pattern of the UK Government’s report and established that the cost in both of those countries was almost identical.
The UK report assessed areas where potential savings could be made. It identified
a number of industries – for example, construction and general engineering,
including the railway network – as being possible major contributors to this saving. They estimated that 25 per cent could be saved immediately across ten sectors of industry.
The DTI reported that potential savings could be made immediately; these were
listed as far as general industry (the railways included) was concerned. It was stated that unnecessary, costly failures occurred for the following reason: “attention to corrosion is largely confined to the avoidance of bad mistakes made in the previous design. This method of learning by trial and error is expensive and wasteful.”
It was also stated in the report that engineers responsible for maintaining the
infrastructure could make significant savings by “more awareness in selection, specification and control of the application of protectives”. Regrettably, to the present time, engineers are still wasting money for the same reason and failing to make the savings, on both large and small projects, which could be achieved by using the expertise that is available from the membership of the Institute of Corrosion.
Since that 1971 report with all its detailed information, considerable changes have been implemented by many organisations concerned with maintaining structures and plant. However, I have been concerned, as an independent consultant, with the protection of structural steel since the report’s publication and I still find that, to this day, many engineers and architects are unaware of the requirements for basic long-term corrosion protection of structures.
One of the outcomes of the report was the merger of the various corrosion bodies into a single professional institute, now named the Institute of Corrosion, whose member companies and individuals can provide the products, services and expertise to ensure that any corrosion control programme can be the most cost-effective long-term option.
The chairman of the DTI Committee, Dr T. P. Hoar, was made the first Honorary Life Fellow of the Institute of Corrosion for his part in this exceptional work, and he was the first recipient of the U. R. Evans Award – the highest accolade given by our Institute. Professor Graham Wood at Manchester University, a past president of the Institute of Corrosion, was appointed the first ‘Professor of Rust’, as he was described in the media at that time, in order to implement the report’s findings.
All this experience from within the membership of the Institute of Corrosion is available to the railway industry, as it undergoes a period of major refurbishment of its infrastructure.
The activities of the Institute of Corrosion
The growth in membership of the Institute, both individual and sustaining company members, has increased significantly since the publication of the DTI report, and the
re-organisation of the Institute of Corrosion to meet its aims and objectives has resulted in a number of areas of improved corrosion-control measures.
These objectives have been progressively and steadily achieved over the past 25 years by various means. The major annual conference and exhibition, which was first held in 1981 in conjunction with the Corrosion Exhibition, CORREX, has attracted a wide range of delegates from different engineering and architectural backgrounds to hear about the latest practical techniques for design and corrosion-control methods. In addition, delegates are able to mix with the members of the Institute at these events and to establish long-term contacts for advice and guidance on practical corrosion matters.
Industrial Coating Applicator Training Scheme (ICATS)
The 2009 Conference heralded a major advance in corrosion control, with the launch of a new insurance initiative that will have major benefits for both those practising anti-corrosion activity and the owners of structures being protected. The ICATS Guarantee Scheme provides indemnity for the cost of repair and reinstatement of insured works to their original condition based on manufacturing defects, unsuitability of works and faulty or defective application of protective coatings. The scheme, which gives ‘no blame’ cover for structures for up to nine years, is available to all registered member companies and employees who have undertaken the ICATS training programme developed by Correx Limited. ICATS is now mandatory for both Network Rail and Highways Authority painting and repainting contracts.
It is clear that all the information is readily available to ensure that the correct specification, the correct methods of preparation and coating application, and the most cost-effective long-term coatings for any given application can be provided through companies and individuals who are members of the Institute of Corrosion.
In addition to the annual national conference, the regional branches, which are located throughout the UK and Ireland, hold half-day and evening ‘get-togethers’ on topical, practical subjects for both members and non-members in a relaxed environment.
Training courses
The Institute of Corrosion has also developed a series of training courses for individuals who wish to improve their understanding and knowledge of corrosion and, particularly, the methods used in its prevention. These courses are run both in-house, in conjunction with course providers, and also with external bodies. In particular, there is the 2-day practical ‘Fundamentals of Corrosion’ course, factorywhich can be held at any location throughout the UK, or indeed overseas.
In addition to these basic training courses, engineers and those with a ‘need to know’, can attend a series of certification schemes, which have been established to improve the quality of training and certification of inspectors. Topics include: painting, pipe coating, cathodic protection, and fire protection.
The introduction by the Institute of this widely recognised qualification and certification programme for coating and cathodic protection inspectors has resulted in over 1000 certificates being issued since the inauguration of the scheme. On a range of construction sites and structures there are many so-called inspectors carrying out quality control duties without formal training or qualifications, and who have not taken up Institute of Corrosion membership.
As an independent consultant involved in failure investigation and litigation on many recent corrosion failures, I have found instances where inspectors have been present and witnessed incorrect application or procedures, without understanding the implication of their errors.
Corrosion Management Magazine
The Institute of Corrosion also publishes a regular magazine, which is available to both members and non-members, entitled ‘Corrosion Management’. This bimonthly magazine includes – in addition to technical articles – news of events and Institute activities. It also contains a comprehensive source guide for engineers and specifiers, who are then able to contact organisations when specific help and guidance in solving corrosion problems, or with corrosion prevention, is needed.
There are over 80 organisations who have joined the Institute of Corrosion as sustaining corporate members and this covers a very wide spectrum of companies, including coating suppliers and coating applicators, and cathodic protection and monitoring companies, as well as consultants for advice, testing and inspection. In addition, a number of structure owners, specifiers and reciprocal organisations are also included.
Two examples
The Forth Rail Bridge has been recoated, after removal of all the existing coatings applied since the bridge was first opened in 1890. The new coating system and the methods of surface preparation, which have been carefully specified and tested, will give a ‘life to first maintenance’ of 25 years.
Reference panels of the coating system and the standard of surface preparation were monitored by an Institute of Corrosion Level III painting inspector, and the reference panels will be retained for 12 years to monitor the performance of the coating system by an Institute of Corrosion sustaining member company.
The High Level Rail Bridge across the river in Newcastle upon Tyne had all the paintwork examined and analysed by a sustaining member consultancy company from the Institute. The refurbishment project has subsequently won several awards for the team involved.
In conclusion
In summary, the four main aims of the Institute of Corrosion are:
- To promote valued service to its members through fellowship backed by professional recognition and status for individual members.
- To advance the understanding of the technology and science in the practice of corrosion control and corrosion management.
- To encourage the exchange of information and ideas on the subjects for the public and engineering benefit.
- To develop access to a wide variety of corrosion-related events and co-operate on other activities with appropriate societies, organisations and Government bodies.
David H Deacon FTSC FICorr is a past president of the Institute of Corrosion.
')";>Full details of the Institute and all its activities can be obtained from The Institute of Corrosion, 7B High Street Mews, Leighton Buzzard, LU7 1EA, or by visiting the website.
Tel: 01525 851 771
Email: admin@icorr.org
Web: www.icorr.org
