AWS C2.20/C2.20M:2016

An American National Standard

Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete

AWS C2.20/C2.20M:2016

An American National Standard

Approved by the American National Standards Institute

May 19, 2016

Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete

2nd Edition

Supersedes AWS C2.20/C2.20M:2002

Prepared by the American Welding Society (AWS) C2 Committee on Thermal Spraying

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This AWS standard is a specification for thermal spraying zinc anodes on steel reinforced concrete. This standard is for- matted as an industrial process instruction. The scope includes: job description, safety, pass/fail job reference standards, feedstock materials, equipment, a step-by-step process instruction for surface preparation, thermal spraying, and quality control. There are five annexes, including job control record and portable adhesion testing.

ISBN: 978-0-87171-888-4

© 2016 by American Welding Society

All rights reserved Printed in the United States of America

Photocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copy- right owner.

Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appro- priate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet: <www.copyright.com>.

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmen- tal bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the pro- cess and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information pub- lished herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.

This standard may be superseded by new editions. This standard may also be corrected through publication of amend- ments or errata, or supplemented by publication of addenda. Information on the latest editions of AWS standards includ- ing amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.

AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 8669 NW 36 St, # 130, Miami, FL 33166 (see Annex C). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS C2 Committee on Thermal Spraying. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS C2 Committee on Thermal Spray- ing and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS C2 Committee on Thermal Spraying to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36 St,

# 130, Miami, FL 33166.

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Personnel

AWS C2 Committee on Thermal Spraying

K. L. Sender, Chair Oerlikon Metco (US), Incorporated

W. J. Arata, Vice Chair Carpenter Powder Products

1. M. Rosario, Secretary American Welding Society

   D. M. Beneteau CenterLine (Windsor) Ltd.

   C. C. Berndt Swinburne University of Technology

   1. M. Blasingame Superior Shot Peening, Incorporated

      1. J. Connelly Green Belting Industries, Ltd.

         1. Duminie HC Starck North American Trading, LLC

1. Froning The Boeing Company

   D. T. Haegele Select Arc

   D. C. Hayden Hayden Corporation

   J. O. Hayden Hayden Corporation

2. M. Karinchak Platt Brothers

   1. R. Lasa Florida Department of Transportation

D. A. Lee Kennametal, Incorporated

1. M. Medford INSPEC, Incorporated

   1. R. Moody Plasma Powders and Systems

      1. Mosier Polymet Corporation

         1. Ryan Carpenter Powder Products

         2. Sampath Chart Industries

            C. Sauer NAVAIR

            1. P. Yanski Praxair TAFA

               
               

               Advisors to the AWS C2 Committee on Thermal Spraying

               R. Ahmed Patronas Carigali Sdn Bhd.

            2. T. Costello NAVSEA

            M. R. Dorfman Oerlikon Metco (US), Incorporated

         3. F. Grimenstein Nation Coating Systems, Incorporated

            1. J. Grubowski DDL OMNI

D. Guillen Idaho National Laboratory

1. A. Kapur Bay State Surface Technologies

   1. Roy Quality Calibration and Consulting

S. Szapra Naval Surface Warfare Center

C. Tudor International MetalFusion Corporation

T. H. Via Via Technologies

M. Weinstein Wall Colmonoy Corporation

AWS C2C Subcommittee on Thermal Sprayed Coatings for Reinforced Concrete

I. R. Lasa, Chair Florida Department of Transportation

J. M. Rosario, Secretary American Welding Society

M. L. Berndt Aurecon Australia

J. M. Brodar Salt River Project

J. Costa Structural Technologies

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AWS C2C Subcommittee on Thermal Sprayed Coatings for Reinforced Concrete (Continued)

N. M. Karinchak Platt Brothers

D. A. Lee Kennametal, Incorporated

D. G. Tepke SKA Consulting Engineers, Incorporated

Advisors to the AWS C2C Subcommittee on Thermal Sprayed Coatings for Reinforced Concrete

J. O. Hayden Hayden Corporation

F. S. Rogers Thermion, Incorporated

A. P. Yanski Praxair TAFA

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Foreword

This foreword is not part of this standard but is included for informational purposes only.

Cathodic protection (CP) is a proven technique for corrosion protection of chloride contaminated concrete structures. Zinc thermal sprayed coatings are used as distributed anodes in both sacrificial cathodic protection (SCP) and impressed current cathodic protection (ICCP) systems. The California Department of Transportation pioneered zinc thermal sprayed coatings as anodes for ICCP systems on reinforced concrete structures on the Richmond-San Rafael Bridge in 1983,(1, 2) and the Florida Department of Transportation (FDOT) pioneered its use as a SCP system in 1989.(3, 4) In 2012 it was estimated that the FDOT alone has used thermal sprayed zinc in over 30 bridges with a combined total of 700,000 square feet of metallized concrete. The Oregon Department of Transportation was the first to install the zinc thermal sprayed coatings as ICCP system anodes in the repairs of steel reinforced concrete on a bridge substructure in 1991. The use of thermal sprayed zinc anodes is recognized at this time as a standard practice for corrosion control on reinforced concrete members.

This AWS process standard covers the application of zinc thermal spray coatings to concrete, with a connection to the reinforcement, using arc and flame spray equipment. This standard is formatted as an industrial process instruction (see flow chart) and the scope includes: job description, safety, pass/fail job reference standards, feedstock materials, equip- ment, and a step-by-step process instruction for surface preparation, thermal spraying, and quality control.

Specifications and Requirements

Inspection and Acceptance Tests

Fail

Job Reference Standard

Equipment Setup and Operation

Surface Preparation

Zn TSC

Application

Accept

Specifications and Requirements

Accept

There are five annexes, including safety information for thermal spraying and job control record. Further information on guidelines for CP of reinforced concrete is available in NACE Standard RP0290.

A vertical line in the margin or underlined text in clauses, tables, or figures indicates an editorial or technical change from the 2002 edition.

Comments and suggestions for the improvement of this standard are welcomed. They should be sent to the Secretary, AWS C2 Committee on Thermal Spraying, American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33166.

1 Carello, R. A., D. M. Parks, and J. A. Apostolos, 1989, Development, Testing and Field Application of Metallized Cathodic Pro- tection Coatings on Reinforced Concrete Substructures, FHWA/CA/TL-89/04, Sacramento, CA: State of California Department of Transportation.

2 Apostolos, J. A., D. M. Parks, and R. A. Carello, Cathodic protection of reinforced concrete using metallized zinc, Materials Perfor- mance, V. 26, No. 12, pp. 22–28, December 1987. Available from NACE International, 1440 S. Creek Drive, Houston, TX 77084- 4906.

3 Sagues, A. A. and R. G. Powers, 1994, Sprayed Zinc Galvanic Anode for Corrosion Protection of Marine Substructure Reinforced Concrete, SHRP-S-405, Washington, DC: Strategic Highway Research Program.

4 Apostolos, J. A., D. M. Parks, and R. A. Carello, Cathodic protection of reinforced concrete using metallized zinc, Materials Perfor- mance, V. 26, No. 12, pp. 22–28, December 1987. Available from NACE International, 1440 S. Creek Drive, Houston, TX 77084- 4906.

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Table of Contents

Page No.

Personnel v

Foreword vii

List of Tables xi

List of Figures xi

1. General Requirements 1

   1. Scope 1

   2. Units of Measure 1

   3. Safety 1

2. Normative References 2

3. Terms and Definitions 3

4. Job and Contract Specification 3

   1. Requirements 3

   2. Job Reference Standard 6

   3. Thermal Spray Boundary 6

   4. Job Control Record 6

   5. Thermal Spray Coating Inspector 6

   6. Thermal Spray Operator Qualification 6

   7. Pre-Contract Award Validation 6

5. Materials 7

   1. Zinc Thermal Spray Wire 7

   2. Tensile Bond Strength Test Specimens 7

   3. Bend Test Requirements 7

   4. Gases 7

   5. Abrasive Blasting Media and Air 7

6. Equipment for Thermal Spraying 8

   1. Thermal Spray Equipment 8

   2. Air Compressors 8

7. Inspection and Quality Control Equipment 8

   1. Surface Preparation 8

   2. Zinc Thermal Spray coating on Concrete 9

8. Application-Process Methods 10

   1. Surface Preparation 10

   2. Thermal Spraying 11

9. Repair of Zinc Thermal Spray Coating on Reinforced Concrete 13

10. Records 13

11. Debris Containment and Control 13

12. Utility Services 14

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Page No.

Annex A (Normative)—Sample Job Control Record for Applying Zinc Thermal Spray Coating on Concrete 15

Annex B (Informative)—Safety Information for Thermal Spraying 19

Annex C (Informative)—Requesting an Official Interpretation on an AWS Standard 27

Annex D (Informative)—List of Informative References 29

Annex E (Informative)—Conversion Factors Used in this Publication 31

List of AWS Documents on Thermal Spraying 33

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List of Tables

Table Page No.

1. Inspection and Acceptance Tests 5

2. Thermal Spray Coating Inspection and Acceptance Tests—Laboratory 5

3. Bend-Test Cracking Threshold: Mandrel Diameter vs. TSC Thickness 7

4. Flame and Arc Spray Standoff Distances and Spray-Pass Widths (Nominal) 12

1. Graphic Symbols 19

2. Noise Levels Produced by Spray Guns 25

3. Recommended Shade Numbers for Helmets and Goggles 25

List of Figures

Figure Page No.

1. TSC Bend Test Pass and Fail Samples 8

2. Process Flow Chart for Repairing Zinc Thermal Spray Coatings (TSC) on Reinforced Concrete 13

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Specification for Thermal Spraying Zinc Anodes on Steel Reinforced Concrete

1. General Requirements

   1. Scope. This standard covers the application of zinc thermal spray coatings to steel reinforced concrete using arc and flame spray equipment. The application of the zinc on steel reinforced concrete requires an electrical connection to the steel reinforcement. Although other metals can also be applied with these methods and equipment, at this time the stan- dard only covers zinc and zinc alloys. This standard is formatted as an industrial process instruction: job description, safety, Pass/Fail Job Reference Standard, feedstock materials, equipment, a step-by-step process instruction for surface preparation, thermal spraying, quality control (QC), and a Job Control Record.

      This standard is based on the literature, equipment, process developments, and industrial practices known at the time of publication. This standard does not cover the design standards or recommended practices for cathodic protection (CP) systems. The design of a CP system for reinforced concrete structures, including the connection of the zinc coating to the steel reinforcement, should be undertaken by an experienced and qualified Corrosion Engineer. Table 1 summarizes inspection, test methods, and acceptance criteria that shall be employed.

   2. Units of Measure. This standard makes use of both U.S. Customary Units and the International System of Units (SI). The latter are shown within brackets ([ ]) or in appropriate columns in tables and figures. The measurements may not be exact equivalents; therefore, each system must be used independently. For the purposes of determining conform- ance with this specification, an observed or calculated value shall be rounded to the nearest unit in the last right-hand place of figures used in expressing the limiting values in accordance with the rounding-off method given in ASTM E29, Standard Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications.

   3. Safety. Safety and health issues and concerns are beyond the scope of this standard; some safety and health informa- tion is provided in Annex B, but such issues are not fully addressed herein.

      Safety and health information is available from the following sources: American Welding Society:

      1. ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes

      2. AWS Safety and Health Fact Sheets

      3. Other safety and health information on the AWS website Material or Equipment Manufacturers:

1. Safety Data Sheets supplied by materials manufacturers

2. Operating Manuals supplied by equipment manufacturers Applicable Regulatory Agencies

1. NFPA 51B, Standard for Fire Prevention During Welding, Cutting, and Other Hot Work.

2. U.S. Department of Labor Regulations, CFR-29, Part 1910.107, Spray finishing using flammable and combustible materials.

Work performed in accordance with this standard may involve the use of materials that have been deemed hazardous, and may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety and health risks that may be encountered. The user of this standard should establish an appropriate safety program to address such risks as well as to meet applicable regulatory requirements. ANSI Z49.1 should be considered when developing the safety program.

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