Corrosion
Corrosion is a natural process that converts a refined metal to a more chemically-stable form such as rust. It occurs when oxygen interacts with metals like iron, copper, aluminum and their alloys. The process usually involves an electrochemical reaction where the metal loses electrons and is oxidized. Some common corrosion environments that accelerate this process include water, humidity, exposure to chemical contaminants or corrosive gases, seawater, soil and industrial pollution. Unchecked corrosion can severely weaken infrastructure and lead to structural failures over time. It is estimated that corrosion costs organizations billions annually in maintenance and repairs.
Types
There are different types of Anti-Corrosion Coatings available depending on the substrate material and environmental conditions. Some common types are:
Paints and Enamels: Traditional paints contain corrosion inhibiting pigments that form a physical barrier against corrosion. They are fairly economical for large surface protection. However, scratches or damage to the coating expose the substrate.
Inorganic Zinc Silicate Coatings: These coatings contain over 90% zinc in the dry film. Zinc provides cathodic protection and sacrificial corrosion of the more active zinc layer instead of the substrate. They have excellent barrier protection and can withstand moderate mechanical damage.
Epoxy Coatings: Epoxy resins form durable, chemical resistant coatings suited for harsh industrial and marine environments. They combine corrosion resistance with excellent adhesion. However, surface preparation is critical for epoxy coatings to perform effectively over the long run.
Polyurethane Coatings: Polyurethane coatings are known for high gloss and color retention properties. They can flex with thermal expansion of substrates. When combined with epoxy primers, polyurethanes form durable protective systems appropriate for infrastructure exposed to weathering.
Powder Coatings: Made from 100% solids epoxy, polyester or hybrid resins, powder coatings are cured by melting and fusing onto substrates in a curing oven. They result in very thick and resilient coatings with extended life spans making them suitable for corrosive industrial environments.
Galvanizing: Hot-dipped galvanizing involves coating steel with a thick layer of zinc. Galvanizing protects steel through the galvanic action between zinc and steel. It has very good barrier properties and cathodic protection.
Application Considerations
Thorough surface preparation is critical for anti-corrosion coatings to adhere properly and achieve maximum protection life. Surfaces must be free of rust, mill scale, oil, grease or other contaminants prior to coating application. Near White Metal Blast Cleaning (SSPC-SP 10) is usually specified for steel substrate preparation.
Coating application methods depend on the specific product formulation. Rollers, brushes and airless sprayers are commonly used to apply liquid coatings like paints and epoxies for industrial and infrastructure applications. Electrostatic and tribo-charging sprayers can gain higher film builds in fewer coats. Powder coatings lend themselves well for automated electrostatic spray applications.
Important Factors in Coating Selection
When selecting protective coatings for infrastructure, facilities or equipment, the following factors need consideration:
- Environmental conditions of the substrate location like humidity, temperature fluctuations, chemical exposure etc.
- Mechanical or physical stresses the coating would need to endure like abrasion, impacts or vibration
- Required coating lifespan and maintenance costs over the service life
- Surface preparation feasibility and compatibility with substrate material
- Health, safety and environmental regulations for application and long term performance
With a holistic understanding of project needs and constraints, the most suitable corrosion protection coating system can be chosen for optimal long term performance.
Critical Infrastructure Protection
Anti corrosion coatings play a vital role in protecting infrastructure that is critical to public safety, economic activity and national security. Some key applications areas include:
Bridges and Roadways: Highway bridges exposed to de-icing salts are primed and coated to prevent reinforcement corrosion. Epoxy-mastic systems have become industry standards for bridge deck protection.
Oil and Gas Pipelines: The internal and external surfaces of pipelines transporting crude and refined fuels over long distances require multiple coatings to inhibit corrosion under insulation. Three layer polyolefin and multi-layered specialized coatings are commonly used.
Water and Waste Water Facilities: Tank lining, concrete structures and piping at water treatment plants dealing with chemical exposures rely on high performance epoxy and powder coated protections.
Energy Sector: Turbines, generators and metal structures at power plants are coated to withstand harsh operating environments and extend operational life through corrosion mitigation under insulation coatings.
The scale and complexity of critical infrastructure demands robust anti corrosion coating solutions to guard against the degradative effects of corrosion. By selecting products tailored for specific exposure conditions and substrate compatibility, asset owners can achieve coating protection lifespans often well in excess of design lifetimes. This critical layer of protection helps ensure ongoing operational reliability of facilities integral to community wellbeing and economic continuity. With advancements in coating technologies, infrastructure owners now have more options than ever to fortify assets against corrosion challenges for both new construction and maintenance purposes.
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About Author:
Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)