CORROSION NEWS - FEBRUARY 2001

Guggenheim Museum at Bilbao Not Corroded - Only Needs a Good Cleaning

Mystery in Cook Inlet. Spill from Corroded Pipeline Suspected

Excessive Rust Found on Walls of Radioactive Waste Tank

Senate Votes 98-0 for New Pipeline Safety Measures

New Fiber Optics Effort Take Aim at $44 Billion Corrosion Problem

Analysts Question Concord, N.C.-Based Speedway Motorsports' Additive Sales

A Space Age Solution for Corroded Auto Headers

Corrosion Big Hazard in Mideast

Microbes May be Corroding Casings at Paducah Kentucky Plant

WHI USA, Inc. Announces MIC Bacteria Test Kits

MITSUBISHI Recalls Autos Due to Corrosion

Corrosion a Factor in Another Auto Recall in the UK

Pipeline Through Snohomish County Washington Remains Closed

Repairs on Cracked Pipe Complete; Plant Set to Reopen

Online Auction Firm Fails to Sell Killing Machine Why: Corrosion

City's Gridlock Chaos Could Be Solved Today

Work Proceeds on Blueprint for National Nuclear Waste Repository

State's Bridges Improve, 15 Percent Still Deficient

Polyester Film Suitable for Coating Drinks Cans

Homeowners Put Blame On Treatment Process for Pin-Hole Corrosion in Pipes

The Chipping and Painting of Navy Vessels Costs 16 to 32 Million Dollars per Year

Two Miramar Jets Grounded; Corrosion and Cracks Found during Mandatory inspection

Water Safer to Drink at a Cost of $500,000 aimed to Reduce Corrosion

Indiana Counties Strained by Failing Bridges; Purdue Report says 30 Percent are Deficient - $616 Million to Fix versus $60 Million Annually to Maintain

Scientists to Grill Energy Officials on Yucca Mountain Waste Plan and Corrosion Effects

American Airlines Employee Program Saves $150 Million - Enough to Buy New Boeing 777

Growth Potential for Corrosion Resistant Metal Seen in Pollution Abatement

Nondestructive Testing Of Corrosion Undercoatings

Airworthiness Directive - Repair Costs $30,000 Not Including Lost Time

Computer-based Assets Monitoring System Hope to Reduce $400 Million in Losses Annually

UK Guidelines Avoids Winter Auto Problems and Corrosion Too

Restivo to Rejoin Corrpro as Director

Corrosion Program Weighs Prevention

Innovations Help Reduce Corrosion

Flat-Rolled Steel Losing Auto Parts to Plastic Composites Give Boost in Corrosion Resistance

Cleaning Caused N-plant Leak

Flight 261 Hearings Spotlight Jackscrew

Abandoned Ships may Pose Threat to Environment in Brazil

Lubrizol Looks Beyond Lubricants

Russian Ship Sets Out to Haul in Mir

GUGGENHEIM MUSEUM AT BILBAO NOT CORRODED - ONLY NEEDS A GOOD CLEANING  top

Denver's Titanium Metals Corp. says it's been absolved of an embarrassing and widely publicized fracas involving discolored titanium panels used to build the futuristic Guggenheim Museum in Bilbao, Spain. Apparently, there is no corrosion on the Guggenheim, and there is no leaching, all that is needed is a good cleaning.

Timet supplied the titanium sheets - some 43,000 fish-scale-like panels - that clad the shimmering, waterfront museum, completed in 1997.

Staining on the Guggenheim, however, has raised questions about its prospects for other architectural projects, including plans to use the metal on the exterior of a 146,000-square-foot addition to the Denver Art Museum. Last summer, beginning with a front-page article in the Philadelphia Inquirer, Timet has taken a drubbing in the international press for promising too much. In several places on Guggeheim Bilbao's exterior, the wafer-thin titanium panels have lost their original luster. Brownish streaks run down one side of the curvaceous building. On the museum's southern side, some patches have darkened, taking on a gray, soot-like coloration.

An analysis of the stains by Timet and the museum's technical adviser - a nonprofit metals research institute called Fundacion Inasmet in San Sebastian, Spain - concluded the discoloration was caused early on at a construction site that lacked "quality control." Airborne dirt and pollution, he said, became imbedded not in the titanium but in the protective oxide film that is naturally generated when titanium is first exposed to oxygen.

MYSTERY IN COOK INLET. SPILL FROM CORRODED PIPELINE SUSPECTED  top

A whitish substance boiled to Cook Inlet's surface, leaving a two-mile-long sheen and softball-sized blobs near Unocal's aging Dolly Varden oil and gas producing platform.

Environmental officials spent a blustery afternoon Tuesday aboard boats and planes trying to track down what the state Department of Environmental Conservation dubbed the ''mystery sheen,'' but without luck. It vanished as quickly as it appeared.

Whatever the substance was, and however small the spill, the DEC, as well as Cook Inlet Citizens Advisory Council and Cook Inlet Keeper, are curious about the source. If it was an undersea pipeline, it only heightens concern over the integrity of the roughly 100 miles of pipes that have carried more than a billion barrels of oil and a trillion barrels of natural gas under the Inlet since production began 35 years ago.

The material may have been associated with natural gas condensate -- the product of gas molecules binding with water molecules -- that could have leaked from an eight-inch wide pipeline that feeds gas from the Trading Bay production facility to the Dolly Varden platform where it is burned as fuel, according to the DEC.

In 1999, corrosion punched a hole in another subsea oil pipeline leading to the Dillon platform. These is a concern with the aging infrastructure of the Cook Inlet pipelines. Cook Inlet Keeper, an Inlet conservation group, has been complaining for weeks that there needs to be more oversight and replacement of aging equipment. ''When you've got 100 miles of pipelines under Cook Inlet which have been put there before 1970, it's hardly a mystery that they're leaking and breaking,'' said Bob Shavelson, director of the Keeper. Unocal said its lines are under constant scrutiny. It has programs to prevent external pipe corrosion, it treats the internal walls with chemicals to prevent bacteria and deposits from building up, and it constantly monitors internal line pressure, Sinz said. The company also routinely checks the condition of the sea bed, she said.

EXCESSIVE RUST FOUND ON WALLS OF RADIOACTIVE WASTE TANK  top

An excessive amount of rust has been found on the walls of a 34-year-old double-shell tank holding 165,000 gallons of highly radioactive waste at the Hanford nuclear reservation. The U.S. Department of Energy and contractor CH2M Hill Hanford Group, which manages the underground tank farms at Hanford's 200 Area, are trying to determine if the rust means Tank AY-101's half-inch-thick steel walls are weakening.

So far, no cracks or leaks have been detected. "What we are doing is trying to get more information on it," Dana Bryson, a division director in DOE's Office of River Protection, said Tuesday. Tank AY-101 is one of 28 newer double-wall tanks, along with 149 older single-shell tanks, that hold nearly 54 million gallons of highly radioactive waste at Hanford. Because 67 of the single-wall tanks have leaked over the years, crews have been pumping liquid waste out of them into the double-shell tanks, none of which have been reported as leaking.

The heavy rust patches were found near the top of the outside of the inner tank wall. Some rust was also found on the inner side of the outer wall. Crews will spend the next two months using robotic ultrasonic devices to measure the thickness of the tank's two walls to track potential thinning and possible corrosion.

SENATE VOTES 98-0 FOR NEW PIPELINE SAFETY MEASURES  top

The companies that operate the nation's aging pipeline network would face increased inspection requirements and higher fines for violations under legislation approved by the Senate. The bill, which passed 98-0 Thursday, included a last-minute amendment to require operators to inspect pipelines at least every five years. However, the Transportation Department's inspector general could provide exemptions.

The challenging part will be implementation. There are some questions that need to be asked and worked out. For instance, the inspections may make it difficult to get people all the fuel that they need. Environmentalists characterized the bill as a "very small step" in the right direction.

The bill expands state oversight of hazardous liquid and natural gas pipelines, increases outlays for safety efforts by $13 billion over several years and improves whistle-blower protections. Pipeline operators for the first time would have to submit to federal or state agencies detailed risk assessments and inspection plans. The Transportation Department, which oversees pipelines, would fund research into technologies to better detect pipeline flaws.

The Senate passed similar legislation last year, without the five-year inspection requirement. That bill failed in the House after critics complained it was too easy on pipeline operators in the wake of 15 deaths resulting from recent pipeline incidents. In June 1999 a pipeline rupture in Bellingham, Wash. dumped 229,000 gallons of gasoline into a creek, where the fuel caught fire, killing three people, and an explosion two months later near a campground at Carlsbad, N.M., in which a dozen people were killed.

Other provisions of the Senate bill would:

-Require operators to enhance the qualifications of pipeline personnel.
-Require owners and operators of pipelines to report any spill of more than five gallons.
-Increase civil penalties for regulatory violations.

NEW FIBER OPTICS EFFORT TAKE AIM AT $44 BILLION CORROSION PROBLEM  top

With backing from a leading Canadian venture capital company, Fiber Optic Systems Technology Inc. (FOX-TEK) today announced the closing of $3.2 million (US$2.1) million in outside financing and completion of agreements that mark the official launch of the company.

FOX-TEK, with laboratories and offices in Toronto, and offices in Philadelphia, builds intelligence into structures. The company modifies standard fiber optic cable to gauge the integrity of large structures. FOX-TEK is backed by Toronto-based strategic venture capital company, Pinetree Capital Corp.(CDNX: PNP.) Pinetree contributed $2.15 million (US$1.4 million) of the total investment, making it the lead investor in the deal. "This is the technology that integrates intelligence and communications capability into large-scale structures," said FOX-TEK scientific advisor and aerospace engineer Dr. Roderick Tennyson. "FOX-TEK is at the heart of the development, design, fabrication and introduction of intelligent sensing which will accurately monitor factors such as physical strain and temperature within existing or new-build structures such as bridges, pipelines, buildings and dams."

FOX-TEK is launching on the ground floor of a new construction technology called 'smart structures.' Lengths of glass fiber optic cable are specially- designed and treated, and then embedded in or bonded to concrete structures. FOX-TEK's sophisticated monitoring devices are connected to the embedded fiber optic cables. The data extracted from the fiber optic cables and analyzed by the monitoring devices provide precise information on strain and temperature within the structure. The data from these sensors will translate into extended life of infrastructure, as well as significant time and cost savings for the civil engineering community.

FOX-TEK enters an existing fiber optic sensor market expected to grow from $100 million (1998) to $350 million (2008). FOX-TEK technology is also designed to replace a portion of the existing semiconductor-based sensor market, expected to grow from $12.6 billion to $21.8 billion by 2008. The over- all sensor market is ramping up to deal with massive deterioration in national infrastructure; corrosion of steel in concrete in Canada alone is an estimated $44 billion problem.

ANALYSTS QUESTION CONCORD, N.C.-BASED SPEEDWAY MOTORSPORTS' ADDITIVE SALES  top

Now that federal regulators have claimed that Speedway Motorsports Inc. used false and misleading information to advertise its automobile additives, analysts are questioning why the company got involved in selling the product in the first place. The Federal Trade Commission last week filed a lawsuit contending Concord-based Speedway Motorsports did not have reasonable evidence to back up claims in infomercials, on a Web site and in brochures that three additives sold under the zMax brand increase gas mileage, reduce engine wear and corrosion and extend engine life. The products include an engine additive, a fuel line additive and a transmission additive.

A SPACE AGE SOLUTION FOR CORRODED AUTO HEADERS  top

For those who are really obsessive about our cars, cleanliness isn't restricted to the surface. We like to get inside, underneath, in the trunk and under the hood. The engine bay is typically the biggest challenge. But no matter how hard you work, one thing that can really let it down is the exhaust manifold. This is the big chunk of tubular metal that exhausts the engine's hot gasses. Stock manifolds are usually cast iron, and after even limited use they turn into corroded, brown lumps with surface features like the moon.

Powder coating is paint, and not suitable for high-heat applications. Nickel plating is great until you start the engine, then it discolours. What would be really nice is for the headers to shine up like chrome, have the scratch and chip resistance of powder coating, plus resist heat like the nose cone of the Space Shuttle. What you want is a space age, ceramic metallic coating with the trade name Cermakrome. This product provides extremely high levels of corrosion and chemical protection in very thin films. When applied to exhaust systems, it will withstand continuous temperatures of over 704C (1,300F).

Treating a single exhaust header for a four-cylinder car will cost around $125; double that for a pair from a small block V-8. A pair of valve covers will set you back $95 and straight pipe will run $10 to $15 per foot. Cermakrome is also used on mufflers, oil pans, intake manifolds and other components subject to extreme heat. The product will work on any metal except magnesium.

CORROSION BIG HAZARD IN MIDEAST  top

The serious environmental and economic problems posed by corrosion in the harsh Middle East climate has made it essential for experts to keep abreast of the latest technologies in combating this hazard, delegates at a key conference heard yesterday.

The conference, the 9th M.E. Corrosion Conference and Exhibition on the theme "Advancing Corrosion Technology" was opened yesterday by Minister of Housing, Municipalities and Environment Shaikh Khalid bin Abdulla Al Khalifa. The minister said it was in the interest of companies and the nation to safeguard against corrosion because it cost countries millions of dollars in wasted infrastructure, ruined natural resources and interrupted industrial progress.

He commended the organisers of the conference for their efforts in maintaining the scientific tempo of the event and said Bahrain, with its sights set on a bright new future was an ideal venue for such events.

The conference is being organised by the Bahrain Society of Engineers and NACE International, the Corrosion Society. More than 80 abstracts from 17 countries have been accepted for publication in the conference proceedings. Selected papers from this list will be presented in lecture sessions at the conference. "Corrosion remains a major concern for the industry whether it is the oil, gas, chemical, power, utilities, naval, auto and aircraft industries," said Dr Iba F. Al Adel, president-elect of NACE International in his opening remarks. "The typical cost of corrosion to most countries' economies has been estimated to be around 4 per cent of their Gross National Product, which may be equal to the medical care costs in some countries."

MICROBES MAY BE CORRODING CASINGS AT PADUCAH KENTUCKY PLANT  top

A new report suggests that ''microbial agents'' are responsible for severe corrosion that has eaten through stainless-steel casings on wells that monitor water quality around the Paducah Gaseous Diffusion Plant.

The corrosion on the 1/16th-inch casings at 19 groundwater-monitoring wells around landfills outside the plant's north fence was found near where radioactive ''black ooze'' was seen seeping up from the ground about 16 months ago. Energy Department officials dismissed the ooze as ''roofing materials.'' And officials say the corrosion is not related to groundwater contamination from decades of secret work with nuclear and other hazardous materials at the 1,800-acre nuclear fuel production complex. Instead, they say the bacteria create enzymes which, combined with a mild chemical reaction, eats away the metal.

At various times in its history, the Paducah plant has used powerful acids to recover and dissolve metals. But no studies have linked acids to the corrosion. In a report sent to the Kentucky Department for Environmental Protection this week, Bechtel Jacobs, the cleanup contractor at Paducah, said the wells should be abandoned and replaced.

The contractor also recommended that ''further use of metal casings'' in monitoring wells be discontinued in favor of plastic. Last fall, the Energy Department abandoned three of the wells due to the corrosion. Greg Cook, a spokesman for Bechtel Jacobs, said the corrosion ''could occur in anybody's well.'' He attributed the problem to ''soil conditions in Paducah.'' There does not appear to be a health concern involved with the corrosion. Since 1988, when solvents and radioactive isotopes were found during sampling, residents around the plant have been provided free municipal water service by the government. But the report said that corrosion seen in one well casing ''is probably a consequence of stagnant water being trapped alongside the well casing during installation'' and that a seal apparently was not intact.

Harold Smith, a Louisville metallurgist, said microbial corrosion and pitting, though unusual, can occur in certain environments, such as sewers or swampy areas. ''It is possible to have an environment that will attack'' steel, he said. ''It is not totally impervious.'' Cook said the government will have to pay to have replacement wells installed, with the total cost possibly reaching $ 1.5 million.

WHI USA, INC. ANNOUNCES MIC BACTERIA TEST KITS  top

WHI USA, Inc. today announced the availability of MIC bacteria test kits which are easy to use for the layman and accurate to determine the presence or absence of MIC causing bacteria. The kits use Biological Activity Reaction Test (BART) technology & were developed and manufactured by Droycon Bioconcepts Inc. of Regina, SK, Canada.

"We have had over 15 years experience with various testing systems to determine the presence or absence of MIC causing bacteria. The BART system is the only one we feel confident in for it's accuracy, ease of use & understanding of the results, for people in the field. You just fill the tubes with the sample and wait for the colorimetric results. We have compiled the individual BART test, into a kit, to give a good understanding of how the bacteria may be thriving in the individual system being tested. We have included 2 test for each bacteria in the kit, so you can leave one set for the customer in the field & take the other back to the office," said Doug Chartier, president of WHI USA, Inc.

Chartier states, "Bacteria with Sci-Fi names like Sulfate Reducing & Acid Producing like to consume the internal iron pipe of oil & gas wells and the pipelines which transport the needed energy to our consumer cities. They eventually "eat" their way through to create leaks and present a real danger to lives and property."

It's called MIC "Microbiologically Influenced Corrosion" and the DOE's Argonne National Laboratories, at the University of Chicago states, MIC accounts for 15 to 30% of the corrosion Failures in the Gas and Nuclear Industry alone.

WHI USA and it's sister company Wildhorse Industries have been testing for and treating MIC corrosion in the oilfield and pipeline industry for over 15 years. Recently, MIC has been identified as a major problem within the fire sprinkler industry. WHI USA and Wildhorse Industries are entering this market with their expertise derived from the energy sector. WHI USA, Inc. may be contacted Toll Free at 1-888-659-9222 or on the Internet at: www.MIC-Testing.com or www.Pipeline-Corrosion.com . They are located in Brighton, Colorado.

MITSUBISHI RECALLS AUTOS DUE TO CORROSION  top

The Mitsubishi motor company is recalling more than 5,000 UK-owned cars because of a possible corrosion problem, it was announced today. The models affected are Galant Saloons and 5-door coupes built between 1993 and 1996. The potential fault is water penetration of the lateral lower steering arm ball joints, which could cause corrosion and accelerate wear.UK customers will be contacted in April and asked to take cars to a dealership for a free check. The UK recall is part of a worldwide recall of 1.5 million Mitsubishi vehicles and involves cars mainly bought in the USA and Japan.

CORROSION A FACTOR IN ANOTHER AUTO RECALL IN THE UK  top

When should vehicle manufacturers withdraw cars and what are consumers entitled to expect in these circumstances? Statistics from the Society of Motor Manufacturers and Traders which they obtain from the DVLA show that there are approximately 27m cars in use in the UK. The Society's annual review of cars sold here showed that a staggering 2,197,615 vehicles were bought in 1999 across both the commercial and the private sector. The rate of car recalls is surprisingly high.

Last year there were problems with the Peugeot 206 model that has been selling like hot cakes. 59,000 were sold in 1999, of which Peugeot confirmed that a large number needed to be recalled. This decision would have been taken at the highest levels. Owners received letters from a customs relations manager asking them to take the cars to their dealer to enable 'necessary' modifications to be carried out to the fuel filter system in order to eliminate the 'risk of petrol seepage under the vehicle in front of the rear right hand wheel due to perforation of the fuel filter housing caused by external corrosion'.

According to the Department of Transport's vehicle safety section, there were 125 campaigns involving the recall of cars in the UK in 1999. This involved approximately one million vehicles, suggesting that the problem is relatively widespread. Voluntary codes of practice drafted by the Department of Transport set out guidelines on procedures for the recall of vehicles and components that have safety related defects.

The Code of Practice on vehicle safety defects defines a safety defect as 'a feature of design construction liable to cause significant risk of personal injury or death'. The decision to recall will have a significant impact on manufacturers. A decision to recall vehicles would be expected even if the risk of a defect causing injury was slight. In Peugeot's case its customer relations department said that there was a fire risk from petrol seepage due to a batch of filters which 'can be affected by corrosion'.

PIPELINE THROUGH SNOHOMISH COUNTY WASHINGTON REMAINS CLOSED  top

A 37-mile section of the Olympic pipeline through Bellingham resumed operation last week, but its operators are still working to fix potential problems in the Snohomish County portion of the line. BP Pipelines, which operates Olympic Pipe Line Co., detected 94 "anomalies" in the 77-mile stretch of pipe between Ferndale and Renton during a series of tests last summer. Thirty-five of those problem spots were in Snohomish County. Crews are digging up sections of the 16-inch line to conduct visual inspections on places with dents and corrosion. The section will remain closed until at least late spring.

A June 10, 1999, rupture in the segment of the line through Bellingham allowed 229,000 gallons of gasoline to gush into Whatcom Creek and erupt into a fireball. Three people were killed. Last week, the U.S. Transportation Department's Office of Pipeline Safety said the section of the line between Ferndale in Whatcom County and Allen in Skagit County could operate at reduced pressure and that the agency will continue to monitor it. Further testing will be conducted in the system before it is put back in full service.

REPAIRS ON CRACKED PIPE COMPLETE; PLANT SET TO REOPEN  top

Repairs are complete on a cracked pipe at the V.C. Summer Nuclear Station and the plant should resume production in two weeks, South Carolina Electric & Gas Co. says. The plant met all federal requirements when the crack was discovered in October, which has Nuclear Regulatory Commission investigators questioning the standards. Regulators say the 2.7-inch crack in the weld seam appears to be the first of its kind at a commercial nuclear plant in the United States. But NRC officials say this small crack has forced them to review current inspection methods designed to detect leaks or cracks. Summer plant workers completed the ultrasonic testing required under current code. No problems were detected.

NRC investigators agreed with plant officials that water stress, corrosion and a welding technique used more than 20 years ago led to the crack. But they question whether industry tests are strong enough to detect problems that are still small and correctable. The large crack, and several other smaller ones, were later discovered by an electric current test. A section of the cracked pipe was removed for testing. Workers replaced that section of pipe and welded the new piece in place. Regulators say the leak never posed a threat to the surrounding environment. But if the crack had become wider and allowed large amounts of water to spill, it could have been harder to keep highly radioactive fuel from melting, according to the Nuclear Control Institute, a watchdog group.

ONLINE AUCTION FIRM FAILS TO SELL KILLING MACHINE WHY: CORROSION  top

For sale: one lethal injection machine. Barely used. This graceful addition to the family home popped up on eBay, the Internet auction site, after being abandoned by its owner, the state of Delaware. Described as a "massively rare" item, the device was offered in full working order delivered to your door. Package and posting extra. The item, which automatically sends a poisonous cocktail to the bloodstream, had been sent back to its makers in Boston for repairs after corrosion problems.

These proved severe. Officials ordered a new machine, freeing up the old one for sale. "The control module is designed utilising state-of-the-art, solid-state, power, digital and timing circuitry and conventional electrical switches," ran the particulars, which added that the lot had been used twice. Despite these enticements, "Delaware Lethal Injection Execution Module" failed to reach its reserve price by yesterday, despite attracting 10 bids for its unusual mix of chrome, fine metal detailing, soft pastel colours and death. Delaware plans to try again later in the year - hoping to improve on the current best offer.

CITY'S GRIDLOCK CHAOS COULD BE SOLVED TODAY  top

A solution to Aberdeen's traffic congestion nightmare could be found today if a proposal to reopen Grandholm Bridge is passed - but it would still take three months and more than GBP 250,000 to carry out the vital repairs. But reopening the bridge will be only a temporary solution and council officers say a long-term answer to the traffic problems must be found before the bridge is closed for good.

Grandholm Bridge was closed before Christmas on safety grounds by Cala Homes, which is building an urban village on the old Grandholm Mill site, forcing motorists who used the bridge to find alternative routes. Traffic jams resulting from the closure sparked public outcry in the city and surrounding area as commuters found themselves caught in a no-win situation. Bridge of Don and Persley Bridge could not cope with the increased traffic.

Independent engineers have declared Grandholm Bridge unsafe for use. The council's director of environment and property advises that the speediest solution is to repair the bridge, which is suffering from heavy structural corrosion. However, this would be only a stop-gap measure allowing breathing space for longer-term remedies. A GBP (Pound - Great Britain) 250,000 loan would be made to Cala so the firm could carry out the work - and there would be additional expenditure of up to GBP 50,000 for maintenance. Consultation would also continue in Tillydrone on the introduction of traffic-calming measures at an estimated cost of up to GBP 30,000.

WORK PROCEEDS ON BLUEPRINT FOR NATIONAL NUCLEAR WASTE REPOSITORY  top

Scientists are designing a system of tunnels with the best possible chance of safely entombing high-level nuclear waste inside Yucca Mountain for 10,000 years. Yucca Mountain Project scientists are looking far into the future to anticipate how geological conditions could change, a process they call "design evolution," to develop their repository design, the Las Vegas Review-Journal reported Monday.

Located about 90 miles northwest of Las Vegas, Yucca Mountain is the only site being studied to entomb 77,000 tons of the nation's high-level nuclear waste, mostly metal rods containing spent fuel pellets from commercial power reactors. Of key importance will be taking into account surface water that could trickle down through cracks in the volcanic-rock ridge, potentially corroding waste canisters. Scientists must also calculate how far apart packages of the decaying, radioactive waste must be spaced so the repository can operate at a cool enough temperature to avoid triggering unpredictable water movement in the rock.

The scientists are trying to convince an independent, presidentially appointed panel of experts that the highly radioactive waste can be safely contained in the mountain by keeping it cool enough and dry enough for at least 10 millenniums. To prevent a disastrous situation, the federal team must forecast what mix of metals surrounding the ceramic nuclear fuel pellets will withstand corrosion the longest, even though rainfall and climate conditions or earthquakes and volcanic activity can't be predicted.

STATE'S BRIDGES IMPROVE, 15 PERCENT STILL DEFICIENT  top

Thanks to an infusion of cash, Minnesota's bridges are in better shape than they were four years ago. But there is still reason to be concerned about the future, the state's chief bridge engineer says. An analysis of the situation found that the condition of Minnesota's bridges in 2000 was among the very best in the country - second only to Arizona's. Minnesota was also second to Arizona in an AP analysis of data from 1996.

The latest data from the Federal Highway Administration show some improvement in the condition of bridges in Minnesota and the nation as a whole. Nationally, 28 percent of bridges were deemed deficient, compared to 31 percent in 1996.

Minnesota counties had been spending about $30 million a year on bridge repairs and replacement, but that figure has increased to around $50 million in the last few years. Similarly, he said, state spending had been running around $25 million a year but will be around $50 million annually for the next couple of years. Minnesota is counting on technology to help make its replacements last longer than the original bridges. For instance, he said, epoxy coatings on steel reinforcement bars help prevent corrosion, while denser concrete overlays on bridge decks make the surface more durable.

POLYESTER FILM SUITABLE FOR COATING DRINKS CANS  top

Teijin Ltd has developed a polyester film containing a lubricant which is said to be ideal for laminating onto the metal's surface. The film consists of particles with an average diameter of 0.001-2.5 [micro]m, and its heat resistance and viscosity makes it ideal for making easy-open ring-pull cans, as well as being fairly corrosion-resistant at higher temperatures.

The cap of an easy-open can is produced by using aluminium, tin plate and tin-free steel; the inner surface of the can cap that comes into contact with the contents is coated with a corrosion proofing membrane, and the metal sheet is scored at a position where an opening is to be formed to define an openable sector. Inner coatings are often damaged or ruptured by the scoring process, and therefore a repair coating film is placed on the coating film.

These corrosion proofing coating films are formed by dissolving or dispersing a coating agent containing a corrosion inhibitor in an organic solvent to prepare a coating liquid, applying it to a metal sheet and then removing the solvent by drying. However, some solvent that remains may flow into the can, contaminating the contents; in addition, repair coatings are often required, slowing the process even more. Previous attempts have been made to devise a coating that will not pollute the can contents, but the can caps thus produced are still apt to corrode along the score lines, especially when the can is kept hot (higher than 60[degrees]C). Teijin's solution to the problem is the film, which has been patented.

The polyester used is a linear polyester comprising dicarboxylic acid and glycol components, preferably with a melting point of 270[degrees]C or less as film can then easily be produced from it industrially. The lubricant is either organic or inorganic, for example inorganic fine particles like silica and alumina, or fine resin particles such as a cross-linked silicone resin. The film must have a peak temperature of at least 60-120[degrees]C, though 80-120[degrees]C would be better; lower than 60[degrees]C and corrosion may be a problem, any higher and processing the laminate becomes difficult.

For further information, contact: Teijin Ltd, 2-1-1 Uchisaiwai-cho, Chiyoda-ku, Tokyo, 100-8585, Japan; tel: +81-3-4506-4890; fax: +81-3-3506-4491

HOMEOWNERS PUT BLAME ON TREATMENT PROCESS FOR PIN-HOLE CORROSION IN PIPES  top

Some south Carroll County homeowners think they know what's causing a wave of pinhole leaks, but they've yet to convince the county that its water treatment process is to blame and that reimbursements for damages and repairs are due.

Homeowners in the Carroll Square, Carrolltowne, Oklahoma, Hilltop and Clipper Hill community associations have been pressing county officials for months to explain why interior pipes and supply lines running through yards started springing leaks a year ago. Because the groups are in discussions with officials over the problem, key players are reluctant to comment. But a letter being circulated to Carroll Square homeowners contends the treatment process is to blame.

According to a consultant hired by the groups, the pitting and corrosion are "due to a variety of factors in the chemistry of the water" from the Freedom District Water Treatment Plant. "The bottom line is that our water was not treated properly relative to the alkalinity and hardness levels of the raw water coming into the treatment plant. The subsequent lack of the formation of a protective coat affected new and old plumbing."

The homeowners sent the study to the county last week. A county water official says a county study also concludes the protective layer is not forming, but he does not draw a direct link between treatment and corrosion. The corrosion inhibitor -- zinc orthophosphate -- was used for a few years in the early '90s but was discontinued in 1996 when the plant changed filtration procedures to meet EPA regulations. Baltimore City, which owns Liberty Reservoir, approved the new filtration system with the condition that the chemical not backwash into the reservoir. On March 6, the group was told that the county commissioners had authorized a study. But in April he said the county had determined the $ 20,000 price tag was "prohibitive." Carroll Square and two other groups raised $ 1,200 to do their own study.

THE CHIPPING AND PAINTING OF NAVY VESSELS COSTS 16 TO 32 MILLION DOLLARS PER YEAR  top

At the West Coast home of the U.S. Navy, officials predict that a painting-reduced Navy will be a happier Navy, possibly boosting reenlistment rates. One admiral rates chipping and painting as the most hated job aboard ship, followed by cleaning heads (toilets) and working in the mess deck (kitchen). "I don't think anybody's self-esteem was ever enhanced by chipping and painting," said Vice Adm. Pete Nanos, commander of the Naval Sea Systems Command. "It's an absolute burden."

The Navy has hired a Chula Vista-based firm called Corrosion Engineering Services to paint ships in San Diego and Norfolk, Va. This year, the firm also will send painting crews to bases in Hawaii, Japan, Washington, Florida and Texas. Last year the budget was $ 16 million; this year, $ 37 million.

Chipping and painting was so onerous that the Marines used it as punishment for enlisted men who could not behave on their way to war. The sergeant would come with 15 Marines and say: Here are your chippers and painters for today.

With the use of stronger paints and better cleaning equipment, Corrosion Engineering Services promises that its paint jobs will last longer. Historically, the Navy has used low-cost paint, which had the unfortunate effect of requiring numerous paint jobs on the same surfaces in short periods of time.

Last week, Corrosion Engineering Services workers were painting interior sections of the Ogden while sailors were painting the hull. Decreasing the amount of chipping and painting done by sailors is meant to boost morale and allow sailors to spend more time training, in the case of the Ogden, for the task of delivering Marines to combat.

TWO MIRAMAR JETS GROUNDED; CORROSION AND CRACKS FOUND DURING MANDATORY INSPECTION  top

Two Miramar-based Marine Corps jets were grounded this week after cracks were found in a critical wing part during a Navy and Marine inspection of their top-line fighter and attack jets. The Navy issued a mandatory "red-stripe" inspection order for 774 F/A-18 Hornet jets after Marine Corps mechanics in Yuma, Ariz., found two cracked wing-fold lugs on a Hornet jet from Miramar Marine Corps Air Station. Also, another locally based Hornet with a cracked lug was found at Yuma Marine Corps Air Station. The jets were in Arizona for a training exercise. Both jets were single-seat models built about 11 to 12 years ago. So far inspectors have found five Marine Corps F/A-18 Hornet jets with cracked parts. All have been grounded until replacement parts can be installed.

The order requires mechanics to inspect the hinge mechanism that allows the Hornet's wings to fold up for stowage on aircraft carriers and hangars. The crews are looking for corrosion and cracks in the steel H-shaped lugs that attach the hinge mechanism to the wing sections.

When the Navy experts first noticed the corrosion problem, it hired a new manufacturer to make replacement lugs and began a program of refurbishing lugs found with minor corrosion. But the production of new parts has been slow. Once the parts are available, it takes four days to replace the hinge and re-install the wing tips.

The Hornet is the chief strike and fighter aircraft for the Navy and Marine Corps. It comes in one- and two-seater models and can take off and land from aircraft carriers. Built by Boeing, the last Hornet was completed last year. An updated version, called the Super Hornet, is being built now and will join the fleet in coming years. The Super Hornet, also known as the E and F models, are not affected by the inspection order.

WATER SAFER TO DRINK AT A COST OF $500,000 AIMED TO REDUCE CORROSION  top

The Swansea Water District has become one of the first water suppliers in the area to comply with what has come to be known as the lead and copper rule, part of the Safe Drinking Water Act passed by Congress in 1986. In many areas, the natural acidity of drinking water is enough to slowly eat away lead and copper pipes, causing corrosion in the pipes and leaching lead and copper into the drinking water that passes through those pipes. The lead and copper rule requires water suppliers to control the acidity of the water in their systems so that lead and copper pipes are not affected.

Swansea has spent more than $ 500,000 on capital improvements to comply with the lead and copper rule. That money has gone toward building a corrosion control facility at the Vinnicum wellfield, as well as installing other equipment elsewhere throughout the water system.

State regulations limit copper levels to a maximum of 1.3 milligrams per liter and lead levels to.015 milligrams per liter. Tests of samples collected in Swansea last month found.86 milligrams per liter of copper and.008 milligrams per liter of lead, both well below the limits.

INDIANA COUNTIES STRAINED BY FAILING BRIDGES; PURDUE REPORT SAYS 30 PERCENT ARE DEFICIENT - $616 MILLION TO FIX VERSUS $60 MILLION ANNUALLY TO MAINTAIN  top

Since 1952, the bridge on Johnson County Road 550 East has carried traffic from Amity to Edinburgh and back. But signs warning of a 15-ton weight limit greet approaching drivers, who can't help but notice that the bridge is slowly falling apart, its concrete cracking and dropping piece by piece into Sugar Creek.

Lavern King knows the bridge is dangerous. The weight limit forces him three miles out of his way when he drives heavy farm equipment. "We obey the law," said King, who lives on one side of Sugar Creek and farms property on the other. "I've got equipment that weighs more than 15 tons." The bridge is one of six in Johnson County and more than 2,000 in Indiana described as deficient in a new report from Purdue University. Engineers and other experts who gathered Thursday in West Lafayette saw a potential crisis in its findings:

About 30 percent of all county-maintained bridges in the state are either structurally or functionally deficient. Replacing them would cost about $616 million. The average-size school bus is too heavy to safely cross 14 percent of all county bridges in Indiana. Twenty-nine percent of Indiana's county bridges are more than 50 years old; 55 percent have an estimated remaining life expectancy of less than five years.

"I think these are frightening numbers," said Bill Haan , president of the Indiana Association of County Commissioners. The small, mostly rural counties that he represents don't have nearly enough money to repair or replace their bridges, he said.

Indiana's problem reflects a wider dilemma -- 500,000 bridges nationwide, many of them obsolete, according to the report. But the report found that Indiana has more deficient county bridges than any neighboring state except Ohio, and twice as many as Kentucky and Michigan. State funding, however, is about to be scaled back.

Next year, county highway departments expect to lose about $60 mil lion annually when the state stops using its general fund to boost local road and street budgets. The Purdue study proposes some possible solutions. One is sharply increasing the property-tax rate that generates money counties use to build and maintain bridges. The average rate among Indiana counties is 14 cents per $100 of assessed valuation; the study proposes increasing it to 30 cents. More than 40 percent of the bridges in each of these rural counties are classified as deficient.

What makes a bridge dangerous: A bridge can be in good condition but still be unsafe because it's not appropriate for the traffic it will bear. Engineers use a three-page inventory sheet to identify structural deficiencies in bridges. Here's an example of what they look for:

Traffic count - If the count has increased sharply over previous years, the bridge should be re-evaluated to see whether it is still functional. Deck - On concrete bridges, inspectors look for cracks or corrosion; on wooden decks, rotting boards and loose nails. Rails - Engineers look for missing or out-of-place rails. Rust on a rail usually is not a problem. Under the bridge - Engineers look closely along the waterline, where the structure is most vulnerable to corrosion. Inspectors look for erosion that has exposed the structure and its pilings to water and the elements.

SCIENTISTS TO GRILL ENERGY OFFICIALS ON YUCCA MOUNTAIN WASTE PLAN AND CORROSION EFFECTS  top

A panel of presidentially appointed scientists will quiz Energy Department officials today on the government's plans to build a repository for highly radioactive waste in Yucca Mountain. The Nuclear Waste Technical Review Board is holding a two-day meeting to discuss scientific issues facing the effort to safely entomb 77,000 tons of high-level nuclear waste. Most of the waste is in the form of metal rods holding spent fuel pellets from commercial power reactors.

The acting director of the Energy Department's Office of Civilian Radioactive Waste Management is scheduled to give an update of the program. He will be followed later in the day by discussions on corrosion of waste packages, water movement in the mountain and design of the proposed repository located 100 miles northwest of Las Vegas.

The board's chairman wrote Congress and former Energy Secretary Bill Richardson in December to express technical concerns as the Energy Department approaches its goal this year to decide on whether to recommend the site to President Bush for development into a repository. In the board's view, the DOE has not yet demonstrated a firm technical basis for its present high-temperature 'base case' repository design.

AMERICAN AIRLINES EMPLOYEE PROGRAM SAVES $150 MILLION - ENOUGH TO BUY NEW BOEING 777  top

American Airlines employees who helped purchase a new Boeing 777 through IdeAAs, the company's Employee Solutions Program, are headed to Seattle to pick up the new plane. The Boeing 777, which cost approximately $150 million, will be branded "American Spirit, IdeAAs In Flight," the second of two branded planes in the fleet. The 777 will make its "Maiden Voyage" on January 30 from Seattle to American's maintenance base in Tulsa and then on to the Dallas/Fort Worth Airport. The IdeAAs program enables American Airlines employees to submit suggestions to the company about ways to reduce cost, while rewarding innovative thinkers with 8-10 percent of the savings, up to $25,000 per idea.

Some of those cost-saving ideas have included adding tape to seat tracks during overhaul maintenance checks preventing seat track corrosion. This is saving American Airlines $209,000 in materials annually.

GROWTH POTENTIAL FOR CORROSION RESISTANT METAL SEEN IN POLLUTION ABATEMENT  top

This year is shaping up to be a banner year for nickel. Demand has increased at an average rate of 4 percent every year for the past 10 years, and 2001 may very well be no exception, giving the nickel industry-including producers and their customers-every reason to celebrate.

Demand for nickel is expected to be highest in seven broad market sectors, according to theToronto-based Nickel Development Institute (NiDI). While NiDI does not make projections on the rate of growth in demand for nickel, the institute does track potential new applications of nickel materials.

Chief among these is in the transportation industry (cars, buses, trucks and aircraft) where 15 percent of all nickel produced worldwide is used. While there are numerous nickel-containing components in any car or truck on the road today, one area that presents interesting growth opportunities is exhaust manifolds, according to Barry Waters, a director of NiDI. To reduce harmful gaseous emissions, automakers are designing engines that operate at higher temperatures, and conventional ductile iron engine manifolds simply do not have the necessary thermal fatigue resistance. Therefore, manufacturers are beginning to turn to stainless steel castings, containing 13 percent nickel. At up to seven kilograms each, in a market that numbers in the tens of millions of units, the potential is obvious. Reducing corrosion in brakeline assemblies by using nickel-containing materials is a minor area of potential growth.

Another sector of the economy that holds potential growth for nickel is energy (electricity) production. The major environmental concern relating to the generation of electricity is the emission of greenhouse gases into the atmosphere. Major investments are being made worldwide to clean up existing power plants and build alternative energy plants.

Nickel alloys are also used extensively, says Dr. Peter Cutler, technical director of NiDI, in flue gas de-sulfur-ization plants. These massive plants are required as a result of new environmental regulations aimed at reducing emissions worldwide. Inside these plants, corrosive sulfur dioxide gases, created by the burning of coal and oil, are combined with calcium carbonate (or limestone) to form calcium sulphate (gypsum), which is then used to manufacture wallboard. Much of the duct work and chimney linings in these plants are constructed of high nickel alloys, containing up to 57 percent nickel. These alloys are chosen for their resistance to corrosion and the consequent prospect of lower maintenance costs and greater plant reliability. As the number of flue gas de-sulfur-ization projects grows worldwide, so too will the use of nickel in this sector. In Korea, for example, 76 flue gas de-sulfur-ization plants are planned by 2015.

Other energy production applications for nickel include: the use of nickel alloys in the manufacture of natural gas-fired turbines, such as those used in co-generation plants; the use of corrosion-resistant nickel alloys in waste-to-energy plants; nickel-containing stainless steel castings for large turbines in conventional hydroelectric plants; stainless steels in solar energy collection dishes; and corrosion-resistent alloys in geothermal energy plants where hot, corrosive geothermal brines are used to generate electricity.

Water distribution hardware, such as water mains in major cities and even the distribution pipes in individual buildings, represent a potential growth area for the grades of stainless steels that contain about 8 to 12 percent nickel. Because these materials resist corrosion, society benefits from reduced leakage rates. Lower leakage rates mean less wastage of water resources.

Nickel-containing stainless steels have also become the materials of choice for food-handling and processing equipment worldwide. With increasing pressure on food safety and hygiene, and as emerging economies adopt western preferences for prepared and refrigerated foods, demand for non-tainting, easily sterilized stainless steel facilities is sure to spread rapidly, says William Molloy, NiDI vice president, Europe.

The building and construction industry is also expanding, says Waters, and the use of nickel in the industry is growing as architects become more confident about using nickel-containing materials. Although the use of stainless steel in decorative and structural applications is relatively widespread, there is potential for growth. In particular, the use of nickel stainless steel reinforcing bar in concrete structures is increasing worldwide, especially in northern countries where deicing salts are used. Whenever chlorides make their way into concrete that is reinforced by carbon steel bar, the carbon steel subsequently corrodes and expands, causing the concrete to crack. The consequent deterioration of concrete bridges, highway overpasses and parking garages is costing hundreds of millions of dollars in rehabilitation work. Therefore, the number of projects that are specifying stainless rebar to combat the problem is increasing.

Lastly, the chemical process industries, such as pharmaceutical, pulp and paper, oil and gas production and petroleum processing are already big users of stainless steels and nickel alloys-about 18 percent of all nickel produced. Significant new oil and gas production and processing capacity is being installed in countries such as China, India and Indonesia, however. Therefore this geographic area is emerging as a growth market for nickel, says Gary Coates. Future growth will depend on growth in the global economy.

Presented by Patrick Whiteway is manager of communications for the Toronto-based Nickel Development Institute (NiDI).

NONDESTRUCTIVE TESTING OF CORROSION UNDERCOATINGS  top

A report by Northrup Grumman Corp.addresses nondestructive corrosion testing of undercoatings. Surface corrosion on aluminum aircraft skins, near joints and around fasteners, is often an indicator of buried structural corrosion and cracking. Aircraft paints are routinely removed to reveal the presence of corrosion on the surface of metal structures, and the aircraft is subsequently repainted. This process is expensive, time consuming, and results in the generation of air pollution and process waste. A method is needed to detect the early onset of corrosion on metal substrates covered by protective coatings, so that aircraft paints do not have to be stripped without cause. By employing nondestructive techniques to inspect the aircraft exterior structure without removing coatings, the amount of stripping and reapplication of coatings that occurs at the military rework facilities can be substantially reduced.

AIRWORTHINESS DIRECTIVE - REPAIR COSTS $30,000 NOT INCLUDING LOST TIME   top

PC-7 airplanes (Docket No. 2000-CE-46-AD) - proposes to supersede AD 98-08-22, which currently requires inspecting the elevator and rudder attachment brackets for cracks and corrosion, and replacing any found cracked or corrosion-damaged. AD 98-08-22 resulted from mandatory continuing airworthiness information (MCAI) issued by the airworthiness authority for Switzerland. Since the issuance of AD 98-08-22, Pilatus has redesigned the brackets. Installation of these brackets should eliminate the cause of corrosion, which resulted in cracks or corrosion damage. The proposed AD would require replacement of the elevator and rudder attachment brackets with parts of improved design. The actions specified by the proposed AD are intended to prevent failure of the elevator and rudder attachment brackets because of cracks or corrosion damage. Such failure could result in the elevator or rudder separating from the airplane with consequent loss of airplane control. The proposed AD affects eight airplanes on the U.S. Registry at a cost of $ 3,840 for the fleet. The manufacturers will supply the parts free.

COMPUTER-BASED ASSETS MONITORING SYSTEM HOPE TO REDUCE $400 MILLION IN LOSSES ANNUALLY  top

Shell Group in its efforts to minimize corrosion now uses PACER-CM, a computer-based system that enables the efficient monitoring of the integrity of the company's assets by providing information required to conduct a comprehensive corrosion analysis. According to Shell Petroleum Development Company of Nigeria (SPDC) in-house journal, Shell Bulletin, the company loses more than $400 million to corrosion annually and had launched a campaign against it. Corrosion management activities were better focussed through acquisition of duty through the use of PACER-CM. All data on cathodic protection, ultrasonic inspection, load data can be stored by PACER-CM.

UK GUIDELINES AVOIDS WINTER AUTO PROBLEMS AND CORROSION TOO   top

WINTER'S here with a vengeance again. The cold mornings, frost on windscreens and cold car seats are back and it's important to make sure your car is geared up to cope with the inevitable chilly weather with damp, rain, snow and slush.

Driving styles must be adjusted to cope with the different and often difficult driving conditions. To minimise motoring problems with your car this winter, the Retail Motor Industry Federation (RMI) suggests following these sensible tips:

Keep the car's ignition system dry. Your garage or petrol forecourt can supply a suitable aerosol spray for the ignition leads and the distributor.

Antifreeze should be changed every two years due to the deterioration of the corrosion inhibitors. Refill with the recommended type and quantity of antifreeze for your vehicle.

Clean battery terminals and smear them with petroleum jelly to prevent corrosion.

RESTIVO TO REJOIN CORRPRO AS DIRECTOR  top

Former Chief Financial Officer and Executive Vice President Neal R. Restivo has been elected to the board of directors of Corrpro Companies, Inc. (NYSE: CO), the leading provider of corrosion protection engineering services, systems and equipment. Mr. Restivo, whose resignation as CFO was effective January 26, 2001, was elected by Corrpro's Board to fill a vacancy created in 2000 by the resignation of a former director for health reasons. As previously announced, Mr. Restivo has become Vice President Finance and Chief Financial Officer for Grand Eagle Companies Inc., a provider of motor, transformer, and power system repair services.

CORROSION PROGRAM WEIGHS PREVENTION  top

The developers of software that compares life-cycle costs of corrosion protection systems for concrete structures are looking for users they can give it to, and then train in its use as part of a bid for industry standard adoption. LIFE-365 was developed by a consortium established under the aegis of Farmington Hills Mich. -based American Concrete Institute. The project was funded by $ 50,000 contributed by the consortium members, who intend to give ownership to ACI if it is adopted. The model was based on research directed by civil engineering professor Michael Thomas of the University of Toronto.

''There's a huge number of products out there to address corrosion, says Terence Holland, executive director of Washington, D.C.-based Silica Fume Association, an admixture trade group and one of the consortium's participants. ''LIFE-365 is at least a first pass at helping a designer or owner understand what these chemicals are doing to benefit concrete and provide some life-cycle costs.''

LIFE-365 can be obtained by contacting consortium members Master Builders Inc., Cleveland, Ohio, at (216) 831-5500; Grace Construction Products, Cambridge, Mass., at (617) 498-4493; or the Silica Fume Association at (440) 834-1697.

INNOVATIONS HELP REDUCE CORROSION  top

Some jobs are just too big for a can of Rust-Oleum - For such outsize corrosion problems, the Scanning Kelvin Probe may soon help find a solution. Developed by Australia's Commonwealth Scientific & Industrial Research Organization (CSIRO), the probe is able to detect and characterize in unprecedented detail the electrochemical interactions that cause corrosion on metals. Using the data collected, Aaron K. Neufeld, the scientist who masterminded the probe, hopes to design new protective treatments for exposed metal surfaces. ''Structures such as the Sydney Harbour Bridge may need painting only once every 33 years, instead of every 11 years,'' he said.

FLAT-ROLLED STEEL LOSING AUTO PARTS TO PLASTIC COMPOSITES GIVE BOOST IN CORROSION RESISTANCE  top

The use of plastic composites in cargo boxes, tailgates and middle-gates of pickup trucks and crossover vehicles equipped with cargo beds is driving an increase in the domestic auto industry's consumption of such material as a substitute for. flat-rolled steel--an increase that's expected to amount to 117 million pounds annually by 2004, according to the Automotive Composites Alliance (ACA), Troy, Mich.

ACA officials said that automakers are expected to use 350 million pounds of reinforced thermoset composites this year and 467 million pounds by 2004, a 33.4-percent upswing. The anticipated increase is the result of composites "being chosen by automakers to replace steel in body-type panels and structural components," said Mike Dorney, vice president of sales and marketing for the Plastics division of Budd Co., Troy, Mich., and chairman of the ACA, a partnership of 25 companies that mold composite parts and supply the raw materials and tools for making such parts.

Dorney also cited the 8-foot-long rear wheel fender/cargo box outer moldings on some models of the 2001 Chevrolet C/K pickup trucks and the 2002 Chevrolet Avalanche crossover vehicle with General Motors Corp.'s new "Convert-a-Cab" system. That system--which gives vehicle owners an opportunity to customize the layout of their trucks--relies on plastics for the cargo bed, midgate and tailgate inner panels to achieve weight reductions, corrosion resistance and dent resistance.

"Now, more than ever before, automakers are looking for ways individually to beat their competitors by adding value-enhancers for consumers, such as cost-savings, fuel-efficiency and improved resistance to dents and corrosion," he said. "This also includes creating a car or truck that is visually appealing yet meets their need for practicality."

CLEANING CAUSED N-PLANT LEAK  top

A vapor leakage on Dec. 30 from a secondary pipe at the No. 1 nuclear reactor at Shikoku Electric Power Co.'s Ikata nuclear plant in Ikatacho, Ehime Prefecture, was caused by careless cleaning of a pipe immediately above disassembled valves that were being inspected, it was learned Thursday. The pressurized light-water reactor has a generating capacity of 566,000 megawatts.

Shikoku Electric said the leakage occurred after salt contained in dust corroded the valve and caused cracks. The dust was disturbed above the valve due to careless cleaning, the company said. To prevent similar accidents from happening in the future, Shikoku Electric said it has decided to inspect disassembled valves outside in a facility made from plastic sheeting and ban other cleaning near the facility.

The valve was reassembled without the dust being completely wiped off, and therefore, after operations at the reactor resumed, the remaining salt was exposed to high temperature steam, which likely caused corrosion. The agency said there have previously been instances of salt corrosion at nuclear reactors when salt found its way into equipment during construction, but this is the first time salt has caused damage when a reactor was in operation.

FLIGHT 261 HEARINGS SPOTLIGHT JACKSCREW  top

The crash of Alaska Airlines Flight 261 on Jan. 31, 2000, marked the first inflight failure of a jackscrew assembly. The National Transportation Safety Board's Dec. 13-16 preliminary hearings, which convened to gather more evidence for its investigation, focused primarily on the assembly's operation and scrutinized design/certification, maintenance and oversight factors that may have led to its failure.

A factual report develop by a materials laboratory indicated that metallic filaments found on the accident aircraft's jackscrew, tentatively identified as remnants of the gimbal nut's internal threads, accounted for an estimated 75-83.5% of the total length of the original threads. Examinations revealed that most remnants showed areas with green patina typical of oxidized copper alloys. Extensive corrosion pitting and red rust spots appeared all along the jackscrew. There was no evidence of grease or other lubrication in the center working region of the screw threads.

ABANDONED SHIPS MAY POSE THREAT TO ENVIRONMENT IN BRAZIL  top

A fleet of ships abandoned over the past 15 years in Rio's famous Guanabara Bay has turned the site into a floating cemetery that could begin leaking fuel, a government agency said Wednesday. The 25 ships, all privately owned vessels once used to transport cargo, show signs of corrosion, state environmental officials say. Each of the ships is loaded with diesel and water to keep them from capsizing, said Carlos Fraga of the state Foundation of Environmental Engineering, or Feema. No significant leaks have been detected but the risk of spills is high, said Gerci Rangel of the Ministry of the Environment, which is working with Feema.

LUBRIZOL LOOKS BEYOND LUBRICANTS  top

Lubrizol's recent purchase of antifoam and defoaming agents maker Ross Chem (Fountain Inn, SC) advances its strategy to move into markets outside its core lubricant additives business. The acquired business adds $ 12 million/year in sales to Lubrizol's chemical process group, which had estimated sales of $ 300 million in 2000.

Lubrizol purchased RPM's $ 20-million/year Alox metalworking additives operation last spring. Alox makes additives for corrosion prevention in metalworking products.

The lubricant additives market has been hit by rising costs, forcing Lubrizol to expand into new markets. "Lubrizol is making the right strategic moves," says Ottenstein. "It faces high raw material costs, and there isn't a lot it can do but raise prices." Lubrizol announced three price increases for its petroleum additives in 2000, but those were only partly successful.

RUSSIAN SHIP SETS OUT TO HAUL IN MIR  top

A Russian cargo vessel has blasted off from Kazakhstan for the Mir space station to guide the doomed orbiter back to Earth to be safely ditched in the Pacific Ocean, Mission Control said. The Progress craft is ferrying more than 2.5 tonnes of fuel to Mir. Earthbound engineers will use the craft to nudge Mir out of orbit late next month and start its descent. The Progress vessel is also carrying extra oxygen supplies in case an emergency crew has to be dispatched from Earth to prepare the station manually for its demise, space officials have said.

Corrosion in Earth orbit and age have taken the shine off the jewel in Russia's space crown and made Mir a safety hazard, a series of technical glitches bedevilling preparations for its descent and sparking fears of an uncontrolled re-entry into the Earth's atmosphere. If all goes as planned, most of Mir will burn up on re-entry, the remainder falling into the Pacific Ocean some 900-1,200 miles off Australia.