The Coating Solution Forum presents:
The Importance of Corrosion Prevention —
REINFORCING OUR NATION’S
INFRASTRUCTURE.
Presented by:

02
TOPLINE FACTS
& FIGURES

How Stark is the Reality?
03
Stringent air quality
legislation and new
“effluent guidelines”
may result in
increased
concentration of
corrosive species in
water treatment
systems.1
Corrosion
responsible for 50%
of forced outages in
steam generating
plants.2
U.S. power grid
outages have risen
by 285% since 1984.3
Increasing demands
on our national
power grid, both due
to population growth
and tech demands,
growing at a rapid
pace: U.S. Population
Growth =
approximate 2.5
million per year.4
Electricity demand
rose approximately
10% between 2006
and 2016.5

How Great is the Cost?
04
Estimated cost of corrosion in
the electricity power industry
Over $23 billion
per year6
$698 million
fossil fuel8
Corrosion portion of annual
O&M cost estimated
$17.27 billion
per year9
Cost of corrosion to consumers
of electricity
$1.214 billion7
Fossil fuel facility cost
percentage as part of total
utility depreciation

How Attainable is a Qualified Solution?
Practical
economics
alongside
intervention
planning…
Qualified
contractors and
certified workers.
The solution is
within reach
through…
05

06
THE CORROSION
PROBLEM

What is Corrosion?
07
The physical properties of metal are
constantly in flux. This “disintegration
of metal” occurs through an
electrochemical process that starts on
the metal’s surface, as part of its natural
behavior.
As such, corrosion of steel rebar used
to reinforce concrete, causes cracking
as the byproduct of corrosion.

Causes of Corrosion
Water / moisture (humidity)
Acids
Bases
Salts
Oils
Within these power distribution
facilities and systems, the metallic
form will continually corrode due
to a variety of factors:
8

9
Assessment Selection and Engineering
While non-metallics and other
composite materials may mitigate
corrosion problems, costs can be
prohibitive and many are untested
for structural applications.
If metals are selected they must be
protected.

Corrosion Prevention
Some of the common coatings used are: Ultra-High Solids
(Plural Component) Coatings, Poly Urea, High Performance
Acrylics, High Performance Alkyds, Alkyd Esters and
Acrylics, Epoxy Esters, Pre-Catalyzed Epoxies, Moisture
Cured Urethanes, VOC Compliant Coatings, Powder
Coatings, Metalizing, Vinyls, Radiation Cured Coatings,
Sacrificial Coatings, and Vulcanized Rubbers.
Technological advancements in the formulation of coatings,
the expertise necessary to choose the appropriate coating
solution for each infrastructure asset, the proper
inspection by certified coatings inspectors and the proper
surface preparation and application by certified coatings
applicators, has increased the professionalism of the
industry and elongated expected performance life-cycles,
all of which fosters asset protection.
10

11
ECONOMIC
REALITIES

It is a paradoxical problem… the resources needed to provide service
to the grid siphon away efforts to prolong the life of the system, which
protects against costly outages.
However, if we only focus on the short-term economics, we may lose
sight of the ”long-view” savings.
The Cost of Service
Outages
12

A Deeper Look at the Numbers
13
World – Total Energy and Real GDP
14000
12000
10000
8000
6000
4000
0
1980 1986 1992 1996 2002 2006 2010
2000
60.0
50.0
40.0
40.0
30.0
20.0
0.0
10.0
TrillionUS2005$
MillionTonnesofOilEquiv.
Total Energy
Real GDP
Energy and
economic output
have a symbiotic
relationship…
energy drives
business, which
drives progress.10

14
QUALIFICATIONS

Stringent Industry Standard
enacted in 2004.
Standard shows proficiency in:
Environmental Safety and Health;
Process Control; Materials; Surface
Preparation; and Coating Application.
Certification Test: Is administered by a
3rd Party and tests knowledge, skill and
overall proficiency.
What is the “NACE 13/SSPC ACS-1 Standard?”
15

Inspector and Specification Writer Programs
The Protective Coatings Specialist Program (PCS) –
introduction to coatings and linings used to control
corrosion… defines and examines common coatings,
addressing when, how and why they should be used.
NACE Coating Inspector Program (CIP) – for over 30 years,
the “gold standard” for inspections in the protective
coatings industry.
16
The SSPC Protective Coatings Inspector Program (PCI) –
training in proper methods of inspection for surface
preparation and installation of industrial and marine
protective coatings and lining systems.

Independent Cost-Benefit Analysis
17
Location
Contractor
Certification
Contract Award
Final Contract Cost
Material
$/Sq Foot
NFESC Support
Total
Time
Qualified
Personnel
San Diego, CA
YES
$ 320 K
$ 320 K
$ 30 K
$ 17.50
$ 40 K
$ 390 K
2 months
Non-qualified
Personnel
Pensacola, FL
None
$ 320 K
$ 600 K
$ 30 K
$ 31.50
$ 240 K
$ 870 K
5 months
US Navy’s Naval Facilities
department (NAVFAC) did a cost-
benefit analysis regarding the use
of certified or non-certified
contractors on coatings projects.
The results showed that utilizing
certified contractors and trained
personnel has proven an
overwhelming “cost-benefit” success
in particular as it pertains to time.

The NACE 13/SSPC ACS-1
Standard was firmly in place
to execute the massive Capitol
Dome Restoration Project.
Case Study
18

LOCAL PLACEHOLDER FOR CASE STUDIES
19

American workforce, well versed
in the up-to-date techniques
and equipment to truly make
a difference in fighting corrosion.
The Coating Application Specialist
20

21
TAKEAWAYS

Preservation Through Mitigation
We can expand the
useable life of these assets,
allowing a long-term
cost benefit.
22

Responsible Economics
30%
Through proper
mitigation, costs
can be reduced
by as much as.11
23

Harnessing the expertise
of those trained to handle
these types of projects brings
about the culmination of
The Coating Solution.
Certified Personnel
24

25
Proper Assessment & Selection
+Qualified Applicators & Contractors
+ Certified Inspectors
The Coating Solution = Quality Job

The Coating Solution Forum presents:
The Importance of Corrosion Prevention —
Presented by:
REINFORCING OUR NATION’S
INFRASTRUCTURE.

THANK YOU
27

APPENDIX
28

29
1 Electric Power Research Institute
2 Corrosion Management Ltd.
3 U.S. Department of Energy
4 U.S. Census Bureau
5 Power-Technology.com
6 Polygon Group
7 Federal Energy Regulatory Commission
8 Federal Energy Regulatory Commission
9 Electric Power Research Institute
10 George C. Marshall Institute
11 NACE International
Appendix