Corrosion, coatings, electrical transmission towers, poles, substations.

1. Weathered galvanized, previously painted
transmission poles, towers and substation
structures.

2.  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

7.  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.

9.  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.

10.  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.

11.  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.

12.  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. Re-
evaluate in 3-5 years.
 Both R-1 and R-2 will normally be done in ONE
climb= Major cost savings to paint within this
window of opportunity!

14.  R-3; Deteriorated.
 2 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.

16.  R-4; Severely Deteriorated.
 3 Climbs
 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.

18.  R-5; Totally deteriorated. 3 Plus Climbs
 Over 50% rust. Needs immediate attention.

20.  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.

21.  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.

22.  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.

23.  Three + Climbs
 Extensive cleaning; may include abrasive
blasting, power tools, etc.
 May require full prime and extra mils DFT
from tower finish coat.
 Costs may be affected by corrosive
atmospheres or climates.

24. 0
1000
2000
3000
4000
5000
6000
7000
8000
30 Years 40 Years 45 Years 50 Years
Paint
Labor

25.  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.

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

27.  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!

28. Description Picture # Corrosion
Rating
Repaint
Priority
Surface
Prep
Coating
System
Existing
D.F.T.
Notes

29.  Function over Form: Aesthetics don’t count as much
as performance + compatibility with substrates.
 High Solids/High-Build (up to 14 mils) Exceptional
edge retention.
 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.

30.  Founded in 1947 by William E. Hood
 1960’s – Expanded into industrial primers and
finishes
 1981 – introduced Protecto 401 Ceramic Epoxy Linings
 Today – Protecto 401 Ceramic Epoxy is most used
protective lining for sewage ductile iron pipe with
thousands of miles of pipe in use today
 3rd
generation of leadership, technical integrety and
product innovation continues to drive the company.

31.  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

32.  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.

34.  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!

35.  Reduces Undercutting and improves resistance
to cathodic disbonding
 Enhances Film-Build and especially edge
retention on towers.
 Lowers Permeability of the paint film.
 Can create non-ablative surface

37. 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

38.  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.