2. Module T3-420 Asset Lifecycle and Durability 1

Module-3 OVERVIEW – ASSET LIFECYCLE AND DURABILITY Module-3 ; Overview – Asset Lifecycle And Durability © DocoPro Pty Ltd 2020

Contents 01. Course Objectives................................................................................1 02. Introduction..........................................................................................2 03. Whole Life of an Asset.........................................................................3 03.1 General.............................................................................................2 03.1.1 Asset Management....................................................................4 03.1.2 Circular Economy........................................................................4 03.2 New Assets.......................................................................................5 03.3 Maintenance of the Asset.................................................................6 03.4 Refurbishment of an Asset...............................................................7 03.5 Disposal of an Asset.........................................................................7 04. Durability...............................................................................................8 04.1 Asset Lifecycle..................................................................................8 04.1.1 Corrosion Surveys......................................................................8 04.2 Durability of Components................................................................10 04.3 Durability of Corrosion Protection Systems....................................12 04.3.1 Time to first maintenance.........................................................13 050.5O.1wCnoerrrsoSsipoencTieficchantiiocinasn..............................................................................................................................................1144 05.2 Coatings Inspector...........................................................................15 05.3 Construction Specification...............................................................15 05.4 Repair Specifications.......................................................................16 05.4.1 Condition Assessment..............................................................16 05.4.1.1 Corrosion Survey..............................................................17 05.4.1.2 Coating Surveys................................................................17 05.4.2 Specification Recommendatios................................................19 06. Supplier Specifications.....................................................................20 06.1 Product Specifications.....................................................................20 06.2 Application Methodologies..............................................................20 07. Summary of Owners Requirements.................................................22 08. Your Role in Asset Lifecycles...........................................................23 09. Project Outcomes..............................................................................24 09.1 Quality Control.................................................................................24 Module-2 ; Managing Expectations © DocoPro Pty Ltd 2020

1 Course Objectives This course module describes the disciplines of asset management and lifecy- cle. It then describes the durability of steel and concrete and why protection is important. Understanding the stages of an asset’s lifecycle enables the learner to understand the hierarchy of decision making and specification documentation related to protection of concrete and steel assets. With this learning, students can be better equipped to align their objectives with the project objectives and provide better outcomes for corrosion control. The following topics are covered; • Asset lifecycle • The circular economy • Durability of concrete and steel • Durability of protection systems including coating, surface treatments and membranes. • Construction Specification documents • Condition Assessment including corrosion survey and coatings survey • Repair Specification documents • Supplier Specifications and Applicator work methods • Quality Control for project success This module is aimed to provide all members of the supply chain an induction level of understanding of where different protection systems and maintenance programs fit within the Owners objectives. There may be many topics raised in this module that you have never had experi- ence with. Their purpose is simply to raise your awareness of the different stages of an assets lifecycle and how various protection systems can control corrosion. You will be required to demonstrate; • Basic understanding of the decision-making process relating to protection systems in asset lifecycles • Basic understanding of quality control processes This is done through completing; • Exercise M3-1 • Exercise M3-2 • Assessment questions Module-3 ; Overview – Asset Lifecycle And Durability ; Page-1 © DocoPro Pty Ltd 2020

2 Introduction Moving through the introductory modules of our courses you be developing an appreciation of how difficult it is to protect structures from degradation either through corrosion of metals or the degradation of concrete that leads to reinforcing steel corrosion. In a benign environment such as a dry rural environment inland from the coast, structures have greater resistance to degradation however move the same structures into coastal, marine or tropical environments and the degradation mechanisms can be significant. Additionally, where structures are exposed to chemical storage or manufacture the degradation mechanisms can be extremely aggressive. Ensuring structures of steel or concrete withstand degradation for significant portions of time requires a keen focus on; assessment, material selection, design and maintenance considerations and protection mechanisms. In this module we discuss the various controls used during the whole of life of managing an asset. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-2 © DocoPro Pty Ltd 2020

3 Whole Life of an Asset Asset management is a systematic process to guide the planning, acquisition, operation and maintenance, refurbishment and disposal of assets. Its objective is to maximize asset service delivery potential and manage related risks and costs over their entire lives and is an important element of a resource-efficient management process and a key concept within the circular economy. 3.1 General Taking effective responsibility for asset Asset Year 0 planning requires a strong and informed Creation Year 1 Asset Owner, Management team and Every 5 Years trained Contractors. The long-lived nature Operations Year 15 of many assets and the need for their Year 30 ongoing renewal means that planning Routine must be based on an understanding of Maintenance the full costs throughout to ensure long term value for money. Refurbishment 1 Refurbishment 2 The phases of an asset’s life cycle are: Run the Asset Year 45 down to end of life • Acquire - involving the specification of asset type and the timing, design, and End of life or Major Year 50 corrosion protection systems. refurbishment for extension of life • Operate and maintain - including operating and maintenance schedules FIGURE 1 - ASSET LIFECYCLE USING A 50 YEAR DESIGN LIFE to be specified FOR A CONCRETE SEWERAGE INLET CHANNEL • Refurbishment - schedules to be specified • Dispose - involving the specification of the intended method, costs and timing of disposal or retirement, including options such as alternative use, sale, or demolition. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-3 © DocoPro Pty Ltd 2020

3.1.1 Asset Management Asset Management is a specific discipline with separate career pathways and courses. Available Standards are ISO 31000 Risk Management and ISO 55000 Asset management Series. The life of an asset is usually from ten (15) years through to one hundred (100) years depending on its purpose and use. 3.1.2 Circular Economy Structures require consumption and use of natural resources often without regard to their end of useful life. This is described as a linear approach where materials are sourced, used and finally disposed of as waste. This produces secondary effects of rising carbon emissions, increased pressures on landfill, and unsus- tainable pollution. In modern times resources are becoming harder and more expensive to access, it is becoming ever more critical to find alternative means of sourcing and using materials. The industrial sector is a major consumer of natural resources. A modern approach to managing the way we use resources and materials is described as the Circular Economy where we evolve the processes, components and systems we use, to reduce waste and increase efficiency. Already consumer products are being designed to be reused or repurposed. Assets are designed and built to be more durable, and to be repaired, refurbished, reused and disas- sembled. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-4 © DocoPro Pty Ltd 2020

3.2 New Assets A new Asset has significant cost to its Owner and is unlikely to be built without significant consideration to construction cost, value or purpose of the asset, long term costs and end use. • Construction planning - Although many engineers and specifiers don’t spe- cifically quote corrosion or metals or degradation of concrete they often follow standards such as AS3735 (Liquid Retaining Structures Code) or Water Services Australia (WSA). Many Standards relating to construction of structures provide some description of protection mechanisms however do not do enough to specify which methods are available. At this early stage of an Assets lifecycle an Owner may; i) Need to save costs and get the asset running to provide revenue. Therefore, protection mechanisms are barely a consideration and will need to be re-assessed during asset utilization within the maintenance program, or; ii) Prefer to take a long-term view for protection of the asset. In this case their Owner should be seeking; - A design that provides access for future maintenance personnel. - A design that provides for corrosion resistance using either; resistant alloys, resistant concrete mixtures, and protective coating systems. To achieve long term protection Useful Standards may include; a) NACE SP0178 Design, Fabrication, and Surface Finish Practices for Tanks and Vessels to Be Lined for Immersion Service. b) ACI 357R-78 Guide for the Design and Construction of Fixed Offshore Concrete Structures. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-5 © DocoPro Pty Ltd 2020

3.3 Maintenance of the Asset Managing maintenance of an Asset ensures maximum output, reliability and less downtime. Even though maintenance costs may increase, over time this will stabilize as the Owner catches up to the degradation so more importantly, the output of product increases as equipment downtime decreases. By lowering the cost and increasing output the cost per item declines, and the Owners profit margin increases, returning excellent results on Owners investment. For example: Consider a refinery where between competitors, there is little differentiation in raw materials or product price, which are set by international markets. How then does one refinery become dramatically profitable, while the least viable barely break even? The difference is how well the assets are used, and the systems and people in- volved in the process. Maintenance of an asset can employ the following strategies, including; • Preventative maintenance – is where equipment condition assessments are being reported and recommendations for maintenance implemented before any breakdowns or loss of integrity. Often this occurs where an Owner is in control of their Asset Management program and will budget for maintenance costs in future years. Within each year there is sufficient funds to perform nominated tasks. Unfortunately, businesses often go through different trading cycles and when prices are falling an Owner will often reduce maintenance to save costs and hope to catch up during better trading conditions. • Reactive maintenance – also called corrective maintenance, is where maintenance activities wait until there is a breakdown or loss of integrity before implementing repairs. This often occurs where an Owner is running down their Asset because; i) it’s at the end of its lifecycle, or; ii) the facility needed to preserve profit by deferring preventative maintenance, or; iii) they have deferred preventative maintenance for a prolonged period and all maintenance budgets are being consumed in completing reactive maintenance. • Scheduled maintenance – is where an asset operates in a highly aggressive environment it may have limited shut down periods therefore the Owner builds the plant to meet the required operational timeframe and allocates all maintenance activities to one shutdown. This could be an annual shutdown with a five (5) yearly refurbishment. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-6 © DocoPro Pty Ltd 2020

3.4 Refurbishment of an Asset Refurbishment can be defined as bringing the Asset up to a certain, pre-determined, quality standard. It involves the replacement of worn and critical parts, and aesthetically making the structure look like new. Refurbishment of an asset may also be described as; • A major maintenance interval • Remediation • Capital improvement 3.5 Disposal of an Asset Traditional disposal of an asset involves demolition and most materials being sent to waste or landfill. However there are alternatives to the linear lifecycle which include the philosophy of circular economy and fortunately metals and concrete have opportunities for either recycling or reuse. Recycling opportunities include; • Concrete recycling involves crushing or pulverizing the concrete rubble near the demolition or building site. The recycled material is used as a base under new asphalt paving or aggregate for mixing new concrete. • Scrap metal can be processed and added into steel production. Over 50% of the world’s steel production uses recycled scrap metal, making it one of the world’s most recycled materials. Recycling scrap metal reduces the ecological impacts of mining raw materials from the ground and reduces up to 97% of mining wastes and provides a significant saving in greenhouse gas emissions. Making items from recycled aluminum uses just 5% of the energy as making the same item from raw materials. Reuse opportunities include; • Concrete has minimal use for reuse except for where larger pieces of con- crete can be carefully positioned to provide artificial reefs or placed along vulner- able stream banks or gullies to help control erosion. • Steel structures are inherently reusable and can be; i) Easily adapted through adding or removing sections to either increase or decrease the capacity of the structure to adapt for changing demand and usage. ii) Relocated for reuse where deconstruction of an existing steel structure is then transported and re-erected, generally in its original form, at a different location. iii) Components can be reused with careful deconstruction of an existing structure where the parts can be reclaimed and used on a new structure. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-7 © DocoPro Pty Ltd 2020

4 Durability Durability can be considered in multiple ways, where Asset durability is a function of; i) Durability of components - such as steel and concrete. In protection we often call these the substrate, and; ii) Durability of the protection systems - for the substrate such as coatings, treatments and cathodic protection. 4.1 Asset Lifecycle For the purpose of this module we will use the following life cycle expectations; TABLE 1 - LIFE CYCLE EXPECTATIONS Lifecycle of the Asset Duration in years Examples Very short term <15 Machinery or fire water tanks Short term 15 to 25 Medium term 25 – 50 Building facades High 50 – 75 Building structures, support structures such as pipe gantry Very high 75 + Electricity transmission towers, transmission pipelines. Bridges, wharfs and welded steel tanks 4.1.1 Corrosion Surveys Corrosion is often described as the deterioration of a material that results from a chemical or electrochemical reaction with its environment. A corrosion survey is a detailed analysis of the environment, materials of construction and operational conditions of the Asset. Its roots are based in electrochemistry where electrical principles and chemistry come together to understand the degradation process in steel and concrete. There are two main macro environments for corrosivity classifications where we describe; i) Atmospheric corrosion – Corrosion that occurs in normal environments above ground or above water. These are well understood such as the five corrosivity classifications described in various Standards including; - AS 4312-2008 Atmospheric corrosivity zones in Australia, and; - ISO 9223 Corrosion of metals and alloys. Corrosivity of atmospheres. Classification, determination, and estimation Module-3 ; Overview – Asset Lifecycle And Durability ; Page-8 © DocoPro Pty Ltd 2020

ii) Immersion service – Corrosion that occurs when structures are either; a) Buried in soil b) Immersed in seawater, fresh water, hot water or waste water c) Immersed in alkali or acid solutions d) Reinforcing steel corrosion – Corrosion that occurs within concrete structures including degradation mechanisms of the concrete layer. e) Insulation or fire proofing – Corrosion that occurs under fire proofing and thermal insulation or cryogenic insulation. Each one of these types of macro-environment can be subject to secondary influ- ences such as microbial induced corrosion, stress corrosion cracking, de-alloy- ing, electrolysis, and galvanic corrosion as described in Module 1 of this course. The corrosion survey will be documented and house a range of data presented as graphs, plots, diagrams, GIS maps and summarize; • The macroenvironmental factors • Different ranges of corrosivity potential • Propose either; i) Different substrate materials, or; ii) Different design to reduce the corrosion rate, or; iii) Suitable protection systems to reduce the corrosion rate A corrosion survey will include a combination of the following tests; TABLE 2 - ESSENTIAL TESTING FOR CORROSION SURVEYS A comprehensive understanding of corrosion surveys is beyond the limitations of this course however the above information is given to provide you an understanding of how much effort is involved from an Owners perspective in deciding on the necessary protection systems in designing for corrosion control. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-9 © DocoPro Pty Ltd 2020

4.2 Durability of Components All structures are designed to meet the expected structural loadings without using excess materials because of the obvious cost savings. Also concrete and steel are heavy construction materials and the more mass used increases the amount of materials needed to support increasing weights. Durability of steel and concrete are quite high where left untreated, and we can expect the following rates of corrosion and degradation; • Steel structures have corrosivity rates mentioned in many Standards we can reference with general corrosivity ranges like; TABLE 3 - GENERAL CORROSIVITY RATES ON STEEL Corrosivity Steel corrosion Typical environment Time to loss of 20% rate (µm/y) thickness on 22mm section Very low Dry indoors Low <1.3 Arid or urban inland 3,385 years Coastal or light industrial 176 years Medium 1.3–25 88 years High 25–50 Seashore (calm) 55 years 50–80 Moderate industrial 22 years Very High 80–200 Seashore (surf) Heavy industrial • In concrete, a loss of alkalinity is the prevailing factor for initiating corrosion of the reinforcing steel in high quality concrete. Carbonation to the depth of reinforcing steel is likely in the following intervals; TABLE 4 - GENERAL CARBONATION RATES IN CONCRETE VS INSITU HUMIDITY Relative humidity within Concrete carbonation rate Time to full carbonation at concrete (µm/y) 30mm cover Low <20% <500 60 years Medium 50 – 70% 1000 30 years High 90% <500 60 years Increased rates of carbonation occur in concrete where there are cracks, excessive porosity caused by air entrapment, or high water to cement ratio mixtures. The rate of carbonation in poor-quality concrete such as this is greater than in high-quality, properly cured pieces. Concrete carbonation also lessens the strength of the concrete and in many Standards relating to water retaining structures the minimum thickness of sound concrete over the reinforcing steel is in the order of fifty (50) millimeters concrete cover. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-10 © DocoPro Pty Ltd 2020

The corrosion and degradation mechanisms for steel and concrete rarely follow the linear scale of the predictions shown in the above tables because often there are other environmental factors that contribute to accelerate the degradation such as; contamination, pollution, chemical attack or chlorides in concrete. The general rates of corrosion of steel or carbonation of concrete are unlikely to be the main point of failure. The failure will occur in discreet locations where the degradation is greatest such as; the buried steel footing of a steel structure or the gas zone within a concrete sewer. Designing for longevity ensures the long-term durability, utilization and value of assets. Durable materials and robust construction standards can reduce mainte- nance costs and extend the economic viability of an Asset or Structure. Concrete and steel structures are extremely durable in comparison to timbers and light weight cladding however require protection from corrosion and degradation from their service environments. This is usually achieved through; • Concrete can be made more durable through the following protection systems; i. Special concrete admixtures ii. Thickness of concrete covering the reinforcing steel can be increased iii. Surface treatments to either penetrate or densify the surface iv. Protective coatings such as urethanes or epoxies v. Toppings such as render, geo-polymer membranes, tiling. • Steel can be made more durable through the following protection systems; i) Applying protective coatings to include removing mill-scale, construction primers and rust. ii) Metalizing the steel surface with an anodic metal such as zinc or aluminum through hot dip galvanizing or thermal metal spray. iii) Applying cathodic protection to the steel either through impressed current or galvanic anodes. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-11 © DocoPro Pty Ltd 2020

4.3 Durability of Corrosion Protection Systems A corrosion protection system is effective when the Owner has properly assessed the following; • The exposure conditions and the selection of an appropriate group of protection systems. • The microenvironment in combination with the protection system listed above. • The life requirement to first maintenance for any protection systems chosen, based on the requirements of the structure. • Other factors which influence selection of protection systems. Time to first Duration in Examples maintenance years Atmospheric in medium Immersion Very short term 2 – 5 years corrosivity Short term 5 to 10 Color coding for handrails or Membranes and linings in very road lines aggressive chemical environments Medium term 10 to 15 such as strong acid storage Long term 15 to 25 Extra-long term 25 + Light industrial treatments and Membranes and linings in coatings aggressive chemical environments such as mild acid storage Protective coatings and Membranes and linings in mild treatments environments such as wastewater and dilute acid storage Multiple layers of protective Membranes and linings in fresh coatings and treatments water or neutral soils Galvanizing or thermal metal Specialized treatments spray Module-3 ; Overview – Asset Lifecycle And Durability ; Page-12 © DocoPro Pty Ltd 2020

4.3.1 Time to first maintenance In describing the durability of protection systems, we consider the time to first maintenance. The term ‘time to first maintenance’ means different things such as; • Hot dip galvanizing (HDG) – The time for galvanizing to thin and minor corrosion to become visible. • Coatings – usually the most cost-effective maintenance over the asset life cycle is to repair scattered breakdown when up to 2% of the surface in any unit area is showing signs of deterioration or corrosion. This would include break down showing evidence of; i) Steel - breakdown from excessive weathering or exposure to chemicals presenting as; rusting at the peaks of a surface profile, or corrosion migrating under the coating film. Also, early onset of coating defects such as; blistering or flaking. ii) Concrete – blistering, flaking or breakdown from excessive weathering or exposure to chemicals. Asset 100 Years Lifecycle Durability 20 Years if unprotected of Materials Durability of corrosion 15 Years protection system Time to first 15 Years Maintanance FIGURE 2 - EXAMPLE USING COATINGS TO PROTECT THE INTERIOR OF A WELDED STEEL STORAGE TANK • Concrete can be considered a protection system for the embedded steel whether it be reinforcing steel, or when used as fireproofing on structural steel, or when used as a coating to weight subsea pipelines. In these situations, the concrete can undergo the same degradation as other concrete substrates. It may also be exposed to fire or high chloride environments. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-13 © DocoPro Pty Ltd 2020

5 Owners Specifications Informed Owners have Specifications that are either; • Developed within the Construction Specification – These dictate the original construction or manufacture of the Asset including its corrosion protection systems. They can remain relevant through the maintenance cycle depending on the modes of degradation observed on the steel or concrete structures. • Developed in response to the operational environment of the Asset – This document, being a repair specification is developed after further condition assessment and recommendations provided by corrosion technicians for the Owners. Understanding these documents are the guiding document for all suppliers to the maintenance and upgrade of the Asset ensures your service and/or product meets the needs of the Owner. 5.1 Corrosion Technician In understanding durability, a corrosion technician should be engaged within the design team, to investigate potential degradation mechanisms of the intended Structure or Asset, prior to the original construction taking place. Typical corrosion studies will include; • The corrosivity of the environment around the Structure • The degradation mechanisms caused by the operational conditions of the Asset • The potential corrosion rate of substrate materials such as steel and concrete • The specification of one or a combination of protection systems to include; liquid coatings, cathodic protection, or environmental conditioning. Recomended Corrosion technicians can Protection be sourced by searching for System accredited members within local corrosion associations Corrosion Coatings including; NACE International Study Survey or the Australasian Corrosion Association. Owners Specification FIGURE 3 - ELEMENTS OF AN OWNERS SPECIFICATION Module-3 ; Overview – Asset Lifecycle And Durability ; Page-14 © DocoPro Pty Ltd 2020

5.2 Coatings Inspector In specifying coating systems for protection of steel and concrete, a coatings inspector should be engaged within the design team, to design one or a combination of protection systems to include; cement admixtures, toppings, membranes, or liquid coatings. Coating Inspectors with Level 3 certification can be sourced by searching for accredited members within local corrosion associations including; FROSIO, BGAS, NACE International or the Australasian Corrosion Association. 5.3 Construction Specification The corrosion survey will provide information on the primary mechanisms of degradation and highlight any potential secondary mechanisms of degradation where protection systems can then be selected and specified to reduce the severity of corrosion. This will be documented in the Construction Specification where it details; TABLE 6 - TYPICAL SECTIONS WITHIN A CONSTRUCTION SPECIFICATION 01. Introduction 11. Requirements According to Substrate Material 02. Purpose and Scope 12. Coating Application 03. Referenced Documents 13. Passivation of Stainless Steel 04. Definitions 14. Bi-Metallic Corrosion 05. Quality Assurance 15. Cathodic Protection 06. Supplier’s Specification 16. Quality Control – Inspection and Testing 07. Work Health and Safety 17. Introduction 08. Statutory & Regulatory Requirements 18. Quality Control Records 09. Selection of Coatings 19. Inspection and Testing Methods 10. Design Service Life of Asset 20. Surface Preparation The construction specification will form part of the contract documents and should be followed through the whole construction cycle. Understanding and collaboration using Specification documents is discussed in another Module of these courses. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-15 © DocoPro Pty Ltd 2020

5.4 Repair Specifications During later maintenance cycles the corrosion technician should be further engaged to investigate if protection systems applied in accordance with the Construction Specification are providing adequate protection. Often a secondary Repair Specification needs to be developed as the Asset may be subject to different corrosion and degradation mechanisms than originally conceived for a number of reasons including’; i) Feasibility studies sought minimal construction cost so the Asset could start generating revenue with an expectation that future profit could provide plant upgrades in later years. ii) The original purpose of the Asset was expanded to process more corrosive materials. iii) Erection of the structures provided micro environmental conditions that led to increased corrosivity such as; shadowing causing greater time of wetness, housing birds which leave acidic droppings. iv) Quality inspection and verification of the corrosion protection systems was not performed, so they were not installed as per the Specification. v) Costs were saved during construction and corrosion protection systems providing less durability were accepted. 5.4.1 Condition Assessment To develop a repair specification may require assistance of two disciplines in including; • A corrosion technician – This needs to be experienced and accredited with a professional body as described below. • A Coatings Inspector – This needs to be a senior coatings inspector, often described as a Level 3 in many programs. Corrosion technicians and Coatings inspectors can be sourced by searching for accredited members within local corrosion associations including; FROSIO, BGAS, NACE International or the Australasian Corrosion Association. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-16 © DocoPro Pty Ltd 2020

5.4.1.1 Corrosion Survey • A review of the original corrosion survey through; i) Reviewing the corrosivity of the environment around the Structure ii) Review the corrosion rate of substrate materials such as steel and concrete • Investigation of the observed corrosion mechanisms to include; i) Identification of the degradation mechanisms caused by the operational conditions of the Asset ii) Review the performance of the protection systems such as performing a coating survey 5.4.1.2 Coating Surveys A Coating survey is a review of the applied coatings to concrete and steel surfac- es within the structure. The inspector will need; • The original construction specification to understand what requirements were expected of the coating suppliers and applicators. • The original quality control documents to understand what part of the works either; a) What quality control was performed by an Accredited coatings inspector b) Areas that did comply with the specification c) Areas that did not comply with the specification d) What changes were made during the works Module-3 ; Overview – Asset Lifecycle And Durability ; Page-17 © DocoPro Pty Ltd 2020

During the survey, the inspector will; • Define each area in segments. For example, rather than just referring to a concrete water storage tank, the inspector would separate the inspection into; interior wall, interior floor, exterior wall, exterior roof. In a welded steel tank, they can break down the element further and describe each steel plate as either a wall plate in strakes or a floor plate in rows. • Use a range of techniques to test the coatings ability to protect the sub- strate such as; i) Visual inspection for; a) Coating damage, blistering, or peeling paint. b) Surface corrosion Both can be reported in percentage of surface area using various Standards that include diagrams such as; ASTM D714 - Standard Test Method for Evaluating Degree of Blistering of Paints ASTM D610 Evaluating Degree of Rusting on Painted Steel Surfaces ii) Adhesion testing to confirm the coatings are free of under-film corrosion or poor adhesion to the substrate using various Standards such as; ISO 4624 - Paints and varnishes — Pull-off test for adhesion iii) Using cross sectional analysis to determine the stratification of coating layers and the thickness of each layer using various Standards such as; ASTM D4138 - Standard Practices for Measurement of Dry Film Thickness of Protective Coating Systems by Destructive, Cross-Sectioning Means AS/NZS 1580.108.2 - Methods of test for paints and related materials - Dry film thickness. Paint inspection gauge iv) Perform a dry film thickness audit to determine if the correct coating thickness was applied and determine the extent of any thinning of the coating through exposure to its environment. ISO 2808:2019 - Paints and varnishes — Determination of film thickness Performing a Coating Survey is discussed in another Module of these courses. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-18 © DocoPro Pty Ltd 2020

5.4.2 Specification Recommendations Using these techniques, the corrosion technician and coatings inspector can make an assessment of how well the protection systems are performing in the macroenvironment and the operating conditions it is exposed to. A detailed report will allocate; • Recommendations for changes within the existing Construction Specifica- tion to meet the Operational requirements or will recommend a new Repair Spec- ification be developed for maintaining the protection systems through to the next allocated refurbishment. • Describe durability of protection systems in terms of; i) Areas requiring immediate repair for safety or loss of integrity. ii) Areas that need repair within a short term iii) Areas with reasonable durability that will require maintenance in the medium term iv) Areas displaying little degradation and will likely meet the Owners long term expectation Lifecycl e Corrosion Survey Coatings Study Coatings Survey Durability of materials Revise Protectio n systems to match Protection system s operational conditions Construction Repair Specification Specification Applicator Supplier Specification Specification Applications provide Material suppliers methodologies fo r provide product systems of work and specification using methods of applicatio n materials approved by using pre-approved the Owner Specificatio n material s FIGURE 4 - HIERARCHY OF SPECIFICATION DOCUMENTS Following a review with the Owners representative a revised Specification will be developed to meet the durability objectives of the Owner. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-19 © DocoPro Pty Ltd 2020

6 Supplier Specifications Suppliers including Product Manufacturers and Applicators can also be consulted to contribute to the repair specification. 6.1 Product Specifications Product Manufacturers have a wealth of technical data related to their materials and are experienced in putting together Product Specifications and these are quite detailed. Generally, a Product Specification is written in response to an Owners Specification. Understanding the Owners Specification is the guiding document, a product manufacturer can; • Select which products and/or system of products meet the requirements of the Owners Specification • Use their Product Specification to detail the recommendations of their product to include; - Intended use and environmental exposure limits - Surface preparation required on the substrate prior to application - Curing cycles and application methods • Seek approval of their products from the Specification writer and then market those products directly to relevant Applicators. 6.2 Application Methodologies Applicator contractors are experienced in managing the ‘how to’ portion of the project. Given all the work that takes place in developing Specifications, the most important group are the Contractors whose job is to implement the requirements through their craftsmanship. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-20 © DocoPro Pty Ltd 2020

An Applicator generally has experience in; • Systems of work for; - Working at heights - Working in confined spaces - Building containment structures to prevent release to the environment - Waste disposal • Experience in the use of different products and how their properties interact with work methods, such as; - Methods of surface preparation - Curing cycles and recoating windows of mortars, linings, membranes, and liquid coatings - Methods and equipment to mix, pump, spray, trowel and finish different products Being involved in the Condition Assessment, an experienced Coating Inspector with Level 3 certification can be the focal point for the Specification writer in providing advise on product types and work methodologies since the Applicator contractors and Product Suppliers might not be engaged until after the Specification development. These groups likely do not have any commercial involvement until the Tendering phase. Within any product type, there are many manufacturers and product names, each with their own improvements. In difficult exposures or access, the improvements of one product may assist in application efficiencies and thus provide the Owner cost efficiencies. Understanding and collaboration using Specification documents is discussed in another Module of these courses Module-3 ; Overview – Asset Lifecycle And Durability ; Page-21 © DocoPro Pty Ltd 2020

7 Summary of Owners Requirements A well-informed Asset Owner has a thorough understanding of the purpose of their Asset. It likely includes, cost of construction, cost of maintenance, utilization or output of the Asset, cost of operating the asset and profitability of selling the benefits provided by the asset as well as the resale value and replacement cost of the Asset. They will have balanced all this information and developed design, durability, and maintenance options. Then sought guidance from professions who specialize in these fields. Their input will be captured in documents such as feasibility studies and construction specifications. Once the Asset is operational further assessment will be done to ensure the expectations of the original feasibility study have been met. Adjustments may need to be made to gain efficiencies such as improving equipment output or reliability. Complex structures or networks of Assets, need to process large amounts of information to ensure maintenance is properly programmed, budgeted, allocated and completed. Most Owners use a combination of the following systems; i) Computerized maintenance management system (CMMS). This is software that maintains a computer database of information about an organization’s maintenance operations. For example, determining which structures require maintenance and which vessels require inspection and to help management make informed decisions regarding calculating the cost of breakdown repair versus preventive maintenance for each asset. ii) Enterprise asset management (EAM) software applications. These include features such as asset life-cycle management, preventive maintenance scheduling and warranty management. These systems have developed to include wireless handheld applications and can be connected to smart sensors in the field. To meet the required corrosion protection further work will be done in preparation for maintenance cycles to include condition assessments, corrosion mapping, and/or coating surveys. This information will lead to the development of; • Procedures – Detailing how operators of the Asset can make assessment on what needs maintenance. • Repair Specifications – Being a function of the corrosivity of the environment and compatible materials with the original protection systems. These will also describe what Standards any repair work shall meet. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-22 © DocoPro Pty Ltd 2020

8 Your Role in Asset Lifecycles Understand that often many of us in our working lives are only engaged in a portion of an assets lifecycle. Maybe many times on many assets. Whether you are a Material supplier, Applicator, Engineer, Materials specifier, Equipment supplier, Quality inspector we all have an obligation to ensure our role is targeted towards meeting the Owners requirements. Owners representatives may have access a wealth of information but may not realize its relevant to your task. Be knowledgeable and ask the contact the following questions; • Have you had a condition assessment done? • Does the condition assessment include a corrosion survey and coatings survey? • Do you have a specification document prepared? • What products are currently used onsite? • What stage of the Asset Lifecycle are we currently in? For example: Repairing defects, first maintenance, general maintenance, extension of life, end of life, or refurbishment. • What level of durability do you require for the repairs? For example: 5 years, 10 years, 15 years, etc. You may be the first expert the Owner has had contact with. Ensuring you help them connect with experts from other disciplines makes you an effective focal point for the Owner but also other industry members. TABLE 7 - EXAMPLE OF HIGH PSM/SQFT COST FOR REPAIR OF DEFECTS Item New Construction Defects $400,000 Cost of works $1,000,000 Versus 500 Surface area 10,000 $800 800% Rate per unit of surface area $100 Increase in cost per unit of surface area Module-3 ; Overview – Asset Lifecycle And Durability ; Page-23 © DocoPro Pty Ltd 2020

9 Project Outcomes Protection systems for steel and concrete structures involve many variables that if not properly controlled present as defects. These usually develop; • Severe defects – develop over the first two years. • Minor defects - act to reduce the long-term durability of a protection system where a system designed for fifteen (15) year life needs refurbishment within ten (10) years. It is well recognized that the cost of performing the initial or refurbishment works is minimal compared to the cost of rectifying defective work. Consider the follow- ing project costs; • Mobilization – including height access, amenities, site management, training, and inductions. • Performing rectification – requires interruption to the Owners productivity and may require a shutdown of their facility to enable works to proceed. • Demobilization – includes removal of temporary structures, rectifying disturbed ground conditions, restarting production equipment. Considering the rectification work is likely a fraction of the total surface area, the cost per square meter (psm) or square foot (sqft) amounts to an incredible in- crease compared to the original works per unit of surface area. 9.1 Quality Control Quality Control in the Corrosion Industry is achieved simply by following a few key principles. As follows; • Be aware of the wide variety of studies, survey and design required in delivering excellent durability by using the information in this module and other modules within this course structure. • Understand that the designed durability of protection systems to directly related to the quality control of materials and application. • Collaborate with your peers and relevant associations to gain the best outcomes for your needs. • Recommend skilled operators based on accreditations and experience and do not compromise just to use the cheapest offer. Module-3 ; Overview – Asset Lifecycle And Durability ; Page-24 © DocoPro Pty Ltd 2020

• During project implementation use; i) Pre-job Conferences – to conceptualize the path forward with project teams. This helps collaboration and allows the team to develop the best delivery strategies. ii) Specialists – engage with those that assisted in developing the Specifi- cation should be included to communicate desired outcomes to the project teams. iii) Quality Control Processes– these documents need to be prepared and reviewed by the project specialists so they can be approved for use. These must align directly to the Specification and include; a) Inspection and Test Plan – being a checklist of critical stages of work where inspection is required. b) Product Inspection Forms (PIF) – also known as daily report forms, these are the data provided by Applicators during there daily inspections and are the verifying document referenced in the ITP. • Engage qualified inspectors to observe, inspect, test, measure and report the conformance requirements described in the Specification and listed in the ITP. • Engage competent Contractors however ensure you have visibility over their sub-contractor being the Applicators. • Ensure each level of the project team are providing written reports on progress, inspection, completion, and acceptance of each work stage. Understanding Quality Control is discussed in another Module of these courses Document Collaborate inspection, tests With Industry and progress Use skilled Engage operators Competent Inspectors Pre-Job Conference Quality Process Documents Module-3 ; Overview – Asset Lifecycle And Durability ; Page-25 © DocoPro Pty Ltd 2020