Breaking the corrosion cycle

Why are Surface Conditions Important?

What Factors Affect Surface Condition?

$300 billion every yearCORROSION COSTS THE U.S. ECONOMY NEARLY

$100 billion OF THOSE COSTS COULD

BE AVOIDED WITH:

Proper application of corrosion-resistant

coatings, etc.

Use of climate control and other corrosion prevention tactics

Cause 80% of all coating failures

Water molecules penetrate microscopic pits in the metal

1Oxygen dissolves into the water and bonds with the iron

2

The bonding creates a brittle, crumbly surface unsuitable for coating

3

Abrasive blast cleaning is required to remove rust before coating

4

Environmental control and monitoring stops corrosion until protective coating can be applied

5

How corrosion affects coating

Rust can begin to form within

minutes on exposed metal

stop

Why Do Surface Conditions Affect

Surface Preparation & Coating Jobs?

Why Do Surface Conditions Affect

Surface Preparation & Coating Jobs?

When you rely on structures and tanks, corrosion is your worst enemy. Structures and tanks can protect against rust for decades—or it can fail

within a few years. It all comes down to surface conditions.

Humidity

Increased corrosion ratesCuring and adhesion problems while coating

Exposure to moisture, including condensation, can cause:

Temperature

Condensation if the metal’s surface temperature reaches dew pointImproper curing of coating if temperatures are too high or lowDefects such as blistering, pinholing, cratering, dry spray and mud cracking

Unregulated air and surface temperatures can cause:

As the weather shifts, a controlled environment must be constantly adjusted to compensate

Altitude

3.6° F drop in temperature per 1,000 ft.1° F drop in dew point temperature per 1,000 ft.Condensation if both temperature and dew point are not monitored

A job site’s elevation can cause:

Creating Ideal Application Conditions

Regulating surface conditions

90°

80°

70°

60°

50°

40°

30°

Surfacetemperature

70°FBy creating a

dew point minimum

differential of 17 ˚F, you will be protected from quick changes in

climate.

90°

80°

70°

60°

50°

40°

30°Dew pointtemperature

53°F

90°

80°

70°

60°

50°

40°

30°

Minimum difference:

17°F

Too rough Coating may not cover the peaks, leading to pinpoint rusting

Too smoothCoating cannot adhere to the surface

Improperly regulated surface conditions:

Why use Climate control

Changes in weather

80%

Cost 4-5 times more to prepare for coating

Can extend the length of a coating job

$

Heaters DehumidifiersHelp stabilize surface temperature

Reduce relative humidity

Lower dew point

Help maintain minimum difference between dew point and surface temperature

Sources: ASM International, National Physical Laboratory, Planet Engineering, Coatings and Fabrication Magazine, Materials Performance Magazine

Copyright 2015 © POLYGON Infographic designed by Mad Fish Digital

Will deliver a better prefinished product

Keeps the projects on schedule

Reduces long terms maintenance costs

Provides a better environment for coatings to cure

Increases productivity thus reducing overall costs

Reduces warranty related costs due to rework

Surface condition is the #1 factor in effective rust prevention