Product Watch

Two weeks prevention, 50 years cure

Sika’s new galvanic anode system delivers up to 50 years concrete corrosion protection without monitoring or maintenance. Owners of large, corrosion prone concrete assets such as wharves, bridges, sea walls and the like can now significantly reduce the maintenance costs of those reinforced concrete assets.

Sika, New Zealand’s leading supplier of concrete protection and maintenance products, recently launched two new systems that take concrete repair and protection to a whole new level. The Sika Ferrogard Patch system increases the durability of traditional concrete patch repairs by providing protection against incipient anode corrosion. 

The Sika Ferrogard Duo system provides up to 50 years of reinforcement corrosion protection in chloride or carbonation contaminated concrete – without the need for regular monitoring and maintenance – and it is fully compatible with prestressed concrete structures. 
The launch of these two new systems is very timely. A large proportion of New Zealand’s infrastructure is now over 50 years old and much of it is located in aggressive coastal environments. It is not surprising therefore that there is an increasing demand from asset owners for extended service lives and reduced maintenance costs of reinforced concrete. 

Both Sika Ferrogard Patch and Sika Ferrogard Duo use galvanic protection to prevent reinforcement corrosion, which in turn extends asset life and reduces maintenance costs. 

Although using galvanic anodes in concrete patch repair is not new, the Sika Ferrogard Patch anodes deliver improved performance and reliability over previous systems. This is partly due to their installation just outside the patch repair. 

Mike Edwards, Sika New Zealand’s General Manager explains, “By placing the Sika Ferrogard Patch anodes outside the repair, they are closer to the area where corrosion is most likely to occur and are therefore more effective at preventing corrosion initiation. This external placement means we can also use a higher specification repair mortar for the patch repair, further improving repair durability. The repair mortar can also be spray applied without risking damage to the anodes.” 

The improved reliability over previous systems is reinforced by the Sika Ferrogard Patch system being active without the traditional requirement to pre-soak the anodes in water, therefore eliminating one critical installation step that is frequently overlooked in anode installation. This also means the anodes are immediately active when installed, irrespective of whether the contractor has completed the patch repair. 

The Sika Ferrogard Duo system, used for targeting concrete at risk of reinforcement corrosion, is a long-term solution for protecting reinforced concrete against reinforcement corrosion. 

Sika Ferrogard Duo greatly extends asset life and reduces ongoing maintenance costs to almost nothing. It is a hybrid system using discrete zinc anodes that are operated initially in a temporary impressed current corrosion protection phase before switching to galvanic protection phase. 

The impressed current phase, which typically uses a 12V power supply for just two weeks, halts reinforcement corrosion and ensures the steel reinforcement is fully passivated and in a non-corrosive environment. 

Once this phase is completed the power supplies are removed from the site and the anodes are connected directly to the steel reinforcement where they provide up to 50 years of galvanic protection against initiation of reinforcement corrosion – even in aggressive marine environments. 

“The greatest benefit to the asset owner is that after two weeks, when the power supplies are removed from site, no further monitoring, maintenance or adjustment of the system is required, so there are no ongoing costs,” says Mr Edwards. “The whole-of-life costs of the system are therefore much lower than traditional cathodic protection systems.” 

The Sika Ferrogard Duo system is also compatible with prestressed concrete structures which are generally difficult to repair. Engineers are often concerned about breaking out areas of contaminated concrete that may cause the tension to be lost and are wary of hydrogen embrittlement problems if cathodic protection is employed. The Sika Ferrogard Duo systems overcome both of these concerns and reduce the amount of concrete break out required to just that which is needed to make electrical connections to the steel reinforcement. 

For more information contact Sika NZ or email info@nz.sika.com

 

 

The protection of structural steel against atmospheric corrosion

An introduction to AS/NZS 2312.2:2014, Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings – Part 2: Hot dip galvanizing

The Galvanizing Association of New Zealand welcomes the release of the revision to AS/NZS 2312 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings.

Part 1 of the Standard covers paint systems and Part 2 covers hot dip galvanizing (HDG). Both use the same definitions of atmospheric corrosivity categories from NZS 3404.1:2009, but now clearly recognise that the design process and durability of the two products are very different.

Designers wishing to specify HDG need only use two Standards; one covering the design and durability of HDG steel (AS/NZS 2312.2), and the other dealing with the manufacturing process and tolerances (AS/NZS 4680).

Increased durability 
The latest international corrosivity and design standards for HDG means that the design durability (‘life to first maintenance’) of HDG is now aligned with long-term performance results in New Zealand and world recognised Standards.
As a result, the estimated life for HDG coatings on structural steel has increased as shown in the table below.

New duplex coatings section 
An all new and detailed section on the design of duplex coatings (paint over HDG) is included, with two performance options for durability (aesthetic and corrosion). A duplex system will increase the service life of the HDG article beyond that of the unpainted article. Further, the total life of a properly specified, applied and maintained duplex coating system is significantly greater than the sum of the lives of the HDG coating and the paint coating alone (by 1.5 – 2.3 times, depending on the environment).

Design details 
For engineers and fabricators, the design details are extensive and pictorial advice on good design practice provides clear instruction to the detailer. The effect the fabricated article’s condition has on the HDG process, for example the size of the article, laser cutting and other thermal processes, and required tolerances, are also clearly described.
Appendices to the Standard also cover corrosion in different environments, including bimetallic corrosion and the interaction of HDG steel with soil, concrete, water, chemicals, and wood.

Summary 
The new AS/NZS 2312.2 allows designers to more accurately estimate the durability of HDG coatings. In addition, the new Standard provides detailed design advice for duplex coatings, the effect of the steel chemistry and illustrates good design practice. It will serve as an essential aid for engineers, architects, specifiers and consultants for many years to come.
More information on the use of AS/NZS 2312.2 and hot dip galvanizing in general is available from the Galvanizing Association of New Zealand.

www.galvanizing.org.nz 

CP6606 Built-in Panel PC with ARM Cortex A8 CPU for cost-sensitive applications

The CP6606 ‘Economy’ Panel PC is ideally suited to the requirements of machine builders and manufacturers in cost-sensitive market segments. The all-in-one compact controller combines a TFT touch display (800 x 480 WVGA) in seven inch format with a powerful 1 GHz ARM Cortex A8 CPU and 1 GB DDR3 RAM.

The fanless CP6606, designed for control cabinet installation, is ideally suited for use as a compact, inexpensive Control Panel. In combination with TwinCAT automation software, the Panel PC becomes a flexible automation controller for small and medium-size machines, production plants or buildings. With TwinCAT OPC UA support the Panel PC can also be used as an OPC UA Client or Server, thus offering extensive connectivity and remote access functions.

“Beyond the high-quality colour touch screen, the CP6606 Panel PC impresses with its robust housing with aluminium front and sheet-steel rear cover, surpassing the quality and durability of the plastic panels typically found in the low-cost marketplace,” explains Frank Teepe, Industrial PC Product Manager at Beckhoff. The slightly curved front panel of the CP6606 further enhances the attractive appearance of the device.

With an operating temperature range from 0 to 55°C (storage temperature range -25 to +65°C) plus the panel front with IP 54 protection and the rear side with IP 20 protection, the CP6606 can also withstand demanding plant environments. Moreover, the fanless ‘Economy’ Panel PC offers increased reliability, since it does without rotating parts. A microSD card with a high-quality SLC Flash is used as storage medium. Equipment includes an RS232 interface, two USB 2.0 ports, an Ethernet connection, an EtherCAT connection and a 24-V power supply.

Ph 09 281 2736 or email support@beckhoff.co.nz

 

 

 

 

 

Isotech’s new range of portable calibrators

Isothermal Technology Ltd (Isotech) has been providing temperature calibration solutions since 1980, clients vary from National Metrology Institutes to calibration engineers working on-site.

Many nations rely on Isotech for their Primary Standards. For example metrology furnaces are used to melt and freeze pure metals providing a fixed temperature (ITS-90 Fixed Points) in order to calibrate standard thermometers. In industry, portable heat sources such as ‘Dry Block Calibrators’ can be used for calibration and Isotech produce Dry Blocks covering -100°C to 1200°C. Accredited laboratories use Isotech Stirred Liquid Baths in which thermometers under test are compared to standard thermometers.

Isotech has updated nine of its most popular calibrators to bring new styling and updated features.

The new “4000 Range” spans -45 to 1200°C with models that can be used as Dry Blocks or Stirred Liquid Baths with options for Infrared Thermometers, Surface Sensors and even to operate ITS-90 Fixed Point Cells.

Each model is available in three different versions from a cost effective heat source to fully featured devices which include a three channel temperature indicator, temperature logging and Ethernet interface. The ADVANCED versions have three input channels so that both the Standard and the Test Probes can be connected to the temperature read out. Investment in custom tooling has benefited in making the models both lighter and stronger than before.

Contact: Phone 09 526 0096 or email sales@instrumatics.co.nz 

 

 

 

 

Low maintenance, easy install seed vibrator

The E.MC Pneumatic Turbine Vibrators are available in a large range to suit a variety of applications from fluidising aggregate to seed sorting machines.

The E.MC Pneumatic Turbine Vibrator design is oil free, low maintenance and easy to install. Ideal for heavy demand applications due to the robust and simple design but just as suited for food industry clean environments because of the oil free air supply.

Control options can be a simple mechanical on/off lever valve or automatic control with a solenoid valve and process controller.
Assistance available for sizing and selection.

Contact; Ph 022 323 1297 or email sales@compairtech.co.nz

Working in the area of maintenance, horizontal infrastructure and engineering?

The 2nd New Zealand Coatings & Corrosion Conference & Expo will be held at the Ellerslie Events Centre in Auckland 29-30 July.
The keynote address starts off with the economics of corrosion by Wayne Thomson of Anode Engineering (Australia). 

There will be various case studies such as the story behind the repair of Victoria Wharf, the preparations underway for the Makatote Viaduct and the protective coatings history for Australia’s Phillip Island San Remo Bridge. 

There is also an interactive session to do with the differing opinions within industry for how to prepare and coat aged galvanizing. Glean from hearing ICS Inspection & Consultancy Services on methodologies for coating performance, how far applications should go when it comes to surface preparation and retaining warranties for work completed. 

The conference is packed with practical content, including a session on planning for durability – essential when it comes to the maintenance or implementation of horizontal infrastructure and engineering. Sean Ryder of Phoenix Solutions says that the most effective way of ensuring the durability of new and existing assets is to put a formal documented durability plan in place for implementation. Ryder will explain the entire process from beginning to end including how to specify durability requirements during Tendering and the differences between the requirements for existing and new assets. 

Both International Paint and Dulux are leading sponsors at this event. The conference has an exhibition area joined to it facilitating exhibitor’s products and services. See www.conferenz.co.nz/corrosion for the agenda and to register.

 

 

 

Kemppi unveils welding quality management system

New Zealand welding is in a state of growth with more certificated operators in this country than Australia and so the launch of Kemppi’s Arc System 3 welding quality management system at the Heavy Engineering Research Association (HERA) in Auckland early last month was well-received.

Arc System 3 is a modular suite of software-based solutions which has been specifically developed by Kemppi to improve welding quality management, operational productivity, and reduce cost and risk. The System offers a choice of Arc modules that work seamlessly together to capture ‘big data’ welding information. This information allows users to more effectively monitor, control and manage the quality and efficiency of their welding operations. 

Users can implement the various modules according to their needs. Plus, the System can be applied to single and multi-machine, and multi-site operations both within a country and across borders, and managed from a single central welding co-ordination point. Kemppi is currently implementing its first, multi-site commissioning of the System across international borders. Peikko Group, a leading global manufacturer and supplier of concrete connections and structures, together with Kemppi, will deploy the Arc 3 at Peikko’s production units in Finland, Lithuania and Slovakia. 

The System traces every weld, records welder qualifications, welding procedure specifications (WPS), all materials and operational welding parameters. Once welding parameters are set, any deviations by the welder are identified in real time and can be altered to eliminate the need for rework.

Kemppi Australia’s Managing Director, David Green said Arc System 3 automatically collects and analyses big data information for you so that you know at a glance how the welding operation is proceeding and if any adjustments need to be made, saving time and money. Plus, it can collate welding documentation automatically to significantly reduce the time and cost associated with post-welding administration.

In essence, Arc System 3 is an invaluable toolbox of solutions that support welding operations to become significantly more efficient and productive, save time and money, and minimise risk.”

The modular nature of the System means it can be tailored to each organisation’s specific requirements. The System’s flexibility ensures features such as NDT, welder maintenance and power source calibration/validation scheduling can be built in as required.
It also fully supports the operation of a formal welding quality management system, stated as a requirement under local welding standard AS/NZS1554.1:2014, and specifically the quality management requirements set out in AS/NZS ISO 3834-2, as recommended particularly for structural fabricators requiring third party approval under the AS/NZS1554.1 standard.

“Up to now, welding processes in critical operations have relied upon the integrity of the welder plus retrospective welding inspection to guarantee welding quality. The Arc System 3 revolutionises all this. It factually confirms that all welds are as they should be, and delivers complete peace of mind,” said Green. “Given the rebuilding and structural welding activity that is currently being undertaken in New Zealand, the Arc System 3 would prove invaluable in providing capability, documentation and reassurance,” he concluded.

The New Zealand market is currently looked after by Emil Dela Cruz sales manager for NSW and New Zealand but Green said that a rep on the ground on this side of the Tasman is becoming increasingly necessary for Kemppi.

For more information on the Kemppi Arc System 3 call Kemppi Australia on +61 (02) 8785 2000, email david.green@kemppi.com or visit www.kemppi.com 

 

 

Up skill your maintenance team to reduce downtime

Do you know how much your plant costs you to maintain?

Do you know the costs of downtime at your plant? 

Have you considered economical solutions for maintenance repair and operations? 

While past trends in preventative maintenance practices have seen significant reliability and cost down improvements, the latest research tells us that many companies are not investing in upskilling due to their reduced maintenance labour force and tight production schedules. Therefore, the best time to ensure and maximise the skill set and capability of the existing maintenance work force. 

Cost effective training is best done on-site and in-house. maintenance repair and operations (MRO) solutions have the potential to save costs, improve efficiencies, improve worker skill levels, safety and productivity and deliver reliability to plants – benefits companies simply cannot afford to overlook. 

Using the right products to properly maintain equipment is vital to the overall profitability and success of businesses. Providing workers who are in contact with this equipment with the necessary knowledge, skills, products and training for maintenance can help deliver the best equipment performance and reliability. 

Equipment that is maintained poorly can cost companies tens of thousands of dollars. For example, a hydraulic leak at one drop/second at $12/litre equates to $18,396 lost per year. Similarly, an air leak of one mm at 600kPa at 15c/Kwh can cost $360 lost per year. And in the competitive economic landscape of today, every dollar counts. 
At the end of the day, high quality products can only be as good as the people who use them. 

Up skilling via on-site and hands on maintenance and repair workshops
You only get out what you put in. And this notion of training is being taken to the next level by Henkel, offering a variety of Loctite training opportunities in an ongoing commitment to education using engineering adhesives, sealants and composite repair technologies. Loctite Maintenance and Reliability Workshops (MRW) offer a unique customer training service that has been successfully running for more than a decade in Australia and New Zealand. It can be tailored to meet the needs of any plant/workshop and is conducted on-site; providing hands-on training to maximise the efficiency and effectiveness of their maintenance operations, with reviews of common failure causes and prevention methods. 

Attendees of Loctite MRW have the opportunity to learn the best practices in MRO as well as the latest technology in engineering adhesives, sealants and composites. 

The Loctite MRW syllabus includes threadlocking, thread sealing, lubrication, gasketing, retaining and bonding. Attendees gain insight into such things as how a threaded fastener works, why gaskets fail, causes of leaks, potential fit problems and possible solutions of retaining, why assemblies seize, bonding basics and much more. 

The Loctite MRW runs across industries including manufacturing, mining, energy and food processes, and is suitable for all levels of personnel. Two hours of hands-on training and an in-plant follow-up will give your workforce the knowledge and tools to save time, improve reliability and equipment safety. 

When it comes to enhancing the skills of your team in MRO, maintenance engineers need look no further for a training solution that can also deliver cost savings and provide reliability to their plant. 

For more information on Loctite Maintenance and Repair Workshops or to register your interest, call 0800 109 030 or email loctite.enquiries@henkel.com  

 

Taking fumes seriously

Workshop managers and their employees are taking safe removal of airborne contaminants more seriously says, Geoff Ebdon, sales manager from New Zealand Duct & Flex. “So often our staff are approached or we get phone calls from workshop managers who have just had an ‘inspection’ and been advised that their poor or even non-existent extraction is not compliant. With budget restrictions, they are often primarily concerned about cost first and consideration for effectiveness sometimes comes second.” Good extraction is always inexpensive compared to the short and long term effects for workers directly exposed to (and co-workers indirectly) breathing contaminated air. But there are many options available that are very cost-effective.

Vapours, gases, dust and fumes all behave differently and the manner in which they move around mixed or suspended in the air is complex. Fume clouds from welding tend to be dense but are only partially visible – “It’s not what you can see that is causing the problem,” says Ebdon, “It’s what you can’t see”. Inhalable particles, i.e., those small enough to be ‘breathed in’ are anything from 0.01 µm up to 100 µm but the dangerous particles that can penetrate deeply into lungs and cannot be expelled are less than 10µm – these are invisible to the naked eye.

The smaller particles also remain suspended in air longer and move with the local current streams in the workshop/room – often carrying them a long way from the source to affect other staff who are not welding at all. Neal England, NZ Duct & Flex Engineering Manager, confirms he has often been asked, on a pre-install site visit, why it isn’t just possible to open more windows to solve the problem, but the further away from the source the contaminants travel, their dispersion only makes it harder to safely capture or control.

Welding fumes are best captured close to the source and removed in a smooth flow – for example, fume arms with external hinging and articulation not only last longer because the moving parts are on the outside, they also contribute to a beneficial smoother airflow, minimising eddies occurring in the capture hood that could push contaminated air back out. The hood needs to be as close to the process or source as possible, therefore it should be metal to withstand working temperatures, ideally with easy-to-grasp handles for constant changes, as the hood needs to be positioned so the fumes are extracted away from the welder, i.e., not so they pass in front.
Ebdon recommends purchasing managers check the manufacturers stated airflow at the hood before making a decision and it is not an option to connect any old fan with a length of flex available to solve the matter. If fumes are not to be filtered, then it is important to check who is in the vicinity – they might also be affected.

An example of good practice is a recent install requested by Steve Palmer, Site Engineer for University of Canterbury, who needed extraction for the welding bay in the site workshop.

The existing work area was fitted out to a very high standard and one of the stipulations was that the new extraction installed would be completed in a similar way. The maintenance staff carry out a lot of galvanised welding and these fumes are particularly toxic and irritating for staff with effects felt for many days, so an effective solution was critical. The area is not large, however, Palmer was impressed with the ease of the three metre reach achieved from the European-made fume arms distributed by NZ Duct & Flex.

NZ Duct & Flex employs its own install team and they ran modular Liplock ducting from two 160mm dia fume arms to a single exit. Each arm is linked to its own 0.7kW fume arm fan and the exhaust was the most efficient route – out through the ceiling. The Dektite was mounted onto a neat galvanised flashing plate as profiled roofs must be sealed off correctly. The gooseneck rain cover for the exhaust was created in minutes using a series of Liplock bends and the wide rubber seals on the lever lock connectors are ideal for sealing outside.

Fume arms are a very effective way of removing fumes away from the welder, capturing them and ensuring they leave the work area, not causing a nuisance to other workers further away. The robust metal powder-coated tubes use exterior hinging, i.e., all the articulation is outside of the tube, ensuring airflow is not interrupted, and the hinging does not become inoperative due to build-up of particles. An easy all round grab handle allows the operator to position the hood exactly where it will be most effective. This simple system is good value as all the components can easily be reconfigured if the workshop changes in the future.

For more information call 0508 69 38 28 or visit www.nzduct.co.nz 

Tame the energy hog of process heat

Industrial ovens and furnaces used for high temperature heating in variety of industries and applications, from aluminium smelting and oil refineries to manufacturing and food processing, are the energy hogs of your business. Now it’s time to tame this wild animal to save on fuel and to reduce emissions, and the prescription is simple: reduce, recycle and recover. Here are some examples how:
Reduce excess air. Make sure your burners are operating at their minimum excess air level. Lowering excess air levels lowers the furnaces energy requirements. Reducing excess air by 15 percent on a furnace running at 10,000˚C will reduce the energy usage by more than eight percent. That’s eight percent less emissions, and eight percent lower fuel costs. 

Recycle the energy being lost to atmosphere by preheating your incoming load. Preheating a load by 2,000˚C on a heating furnace running at 10,000˚C will reduce the energy usage by more than 15 percent. That’s 15 percent less emissions, and 15 percent lower fuel costs. 

Recover the energy by preheating the combustion air. Using the exhaust gasses to raise the combustion air temperature by 3,000˚C on a furnace running at 10,000˚C will reduce the energy usage by more than 20 percent. That’s 20 percent less emissions, and 20 percent lower fuel costs. 

Not sure where to start? Contact us to carry out a survey of your furnace and to get recommendations for the fuel saving option that suits your application the best. 

We can upgrade your current system or design and supply a new system to optimise the performance of your furnace. Among the equipment we supply there are burners, controls, safety systems, gas trains and combustion air blowers from the leading European and American manufacturers. 

Contact Ph: 09 274 51211 or email sales@nuwayenergy.co.nz