Preserving Asset Value: Strategies for Corrosion Prevention

1. Types of Industrial Assets That Are More Likely To Be Impacted by Corrosion

Industrial assets are the backbone of any modern economy, and corrosion can have a severe impact on their value. It is also important to note that different types of industrial assets tend to be more vulnerable to corrosion than others.

For example, steel structures such as office buildings, storage tanks, bridges, and other large infrastructure components can easily succumb to rust if not properly maintained. The same is true for pipelines and related equipment used in oil and gas production facilities or water treatment plants.

These items can become corroded due to contact with harsh chemicals or salty sea air. Industrial machines, like conveyor belts, compressors, engines, and turbines, may also suffer from metal fatigue over time unless they’re regularly monitored for signs of wear and tear.

Finally, metal parts found in vehicles—both land-based and maritime—are particularly susceptible to corrosion due to exposure to extreme weather conditions or road salt during winter months.

Note: The impact of corrosion on an asset’s value primarily depends on its condition when it was purchased or constructed. Newer steel structures will generally require less maintenance compared to older ones that were built without proper galvanization techniques or protective coatings applied at the time of installation.

It goes without saying, then, that preventive measures must be taken whenever possible in order to avoid potential disasters associated with corrosive elements taking their toll on valuable industrial assets over time.

2. The Consequences of Corrosion for These Assets for Owners, Workers, and Communities

Corrosion has far-reaching consequences for asset owners, workers, and communities. From the financial costs of repairs to health risks associated with rust exposure, it is crucial to understand how corrosion can affect each group.

Here’s a look at what we know.

Owners face significant financial burdens when dealing with corrosion damage on their assets. Unchecked corrosion will lead to costly repairs or replacements that eat into profits. Corrosion can also cause an asset to lose value in the long run due to aesthetic issues as well as safety concerns.

Workers exposed to corroded surfaces are vulnerable to inhaling rusty particles that carry hazardous chemicals like asbestos and lead paint, which pose serious health risks. Additionally, working with rusted metal increases the chances of injuries due to sharp edges and broken pieces of material created by extensive corrosion damage over time. Hence, employers can minimize potential risks posed by these hazards by ensuring safe work environments free from corrosive materials.

Finally, nearby communities often bear the environmental impact caused by unchecked corrosion on assets located within their vicinity. Pollutants released during repair activities have been linked to increased risk of cancer and other illnesses, while decreased property values tend to lower tax revenues for local services like schools and hospitals—all leading to negative effects for residents living close by. Therefore, businesses in this sector must reduce emissions and adhere strictly to pollution guidelines set out by local authorities so as not to disrupt the quality of life enjoyed by those around them.

3. Factors That Impact Corrosion Development on Metallic and Non-Metallic Surfaces

In order to always ensure that your assets remain in top condition, it is essential to recognize the factors contributing to corrosion development on both metallic and non-metallic surfaces.

They are:

• Atmospheric conditions: Environmental conditions such as temperature, moisture levels, oxygen saturation, and pH balance will directly affect how quickly oxidation occurs on metal and other material surfaces.
• Environmental settings: Surrounding materials also impact corrosion activity on metals. Certain minerals present in soil or groundwater can act as catalysts, leading to higher levels of galvanic current between dissimilar metals when they come into contact with each other. This encourages faster pitting and crevice corrosion than would occur without these substances present nearby. In contrast, alkaline concrete acts as a barrier against aggressive forms of corrosion by neutralizing acidic environments around specific areas like pipelines or sheet piles buried underground.
• The surface profile and surface contamination: The type of surface material can also influence the rate of corrosion development. Metals are naturally prone to corrosion due to their atomic structure. However, certain metals like stainless steel and aluminum tend to be more resistant than others. Non-metallic materials may not corrode as quickly, but they are vulnerable to attack from chemicals that can cause discoloration or degradation if left untreated.
• Maintenance activities: It is essential to inspect properties properly prior to purchase so you can identify any potential issues with existing structures. It is also recommended that professionals conduct regular maintenance so any early signs of corrosion damage can be addressed before they become costly problems down the line.
• Coating compatibility and application methods: Not all coatings are created equal. Specialty coatings vary in their properties to be a good barrier to the diffusion of gases, water vapor. It is critical to minimize coating porosity during the application process.

Source: The Inspection, Maintenance and Application of Marine Coating Systems

4. Causes of Premature Anti-Corrosion Failure

There are many approaches used when it comes to protecting assets from corrosion.

However, sometimes these techniques fail and cause unforeseen failure, which can have a tremendous impact on asset value. In this section, we provide a comprehensive analysis of the various causes of premature anti-corrosion failure that could reduce asset value.

• Inadequate protection: Without proper preparation and pre-treatment, even the best coatings may not be able to protect your assets long enough before they become compromised.
• Inadequate maintenance: Without regular inspections and necessary repairs as needed, accelerated corrosion could occur due to exposed areas not being appropriately protected, causing significant losses in asset value.
• Poor quality of coating application: Choosing the wrong type of primer or topcoat for specific conditions can result in quick degradation and a decrease in performance life span. This is due to a lack of resistance to climate factors such as snow, rain, or UV radiation exposure.
• Environmental factors: Exposure to extreme temperatures, saltwater spray, pollutants, and high humidity levels all have their own impact on how long coatings last.

Further Reading:

• Common Mistakes to Avoid When Choosing a Commercial Painting Company
• 3 Types of Commercial & Industrial Painting and How to Choose the Right One for Your Facility
• 10 Questions to Ask When Hiring a Commercial & Industrial Painting Contractor

In the absence of high-quality anti-corrosion protection, an asset can be completely destroyed by rust within a span of 5-10 years. By staying vigilant about monitoring the condition of your assets over time, you’ll help maximize their lifespan and keep them looking like new for years down the line.

5. Preventing Corrosion to Extend an Asset's Lifetime

The life cycle of an industrial asset is a vital part of the success of any business. Unfortunately, industrial assets are subject to a variety of elements that can cause corrosion, resulting in expensive repairs and premature replacement.

This makes preventing corrosion a necessary measure for extending an industrial asset’s life cycle.

There are various approaches, as we point out below:

• Protective coating through industrial painting: The first method involves the use of specialized protective coatings to help prevent corrosion. In the modern context, the use of advanced robotic systems enables the performance of painting tasks with precision and efficiency. These systems are guided by artificial intelligence (AI) algorithms that help optimize the painting process for maximum efficiency.
• Adequate film thickness measurement: For an anti-corrosion coating system to meet performance expectations and provide a long-lasting anti-corrosion protection, it is essential to have a sufficient thickness of the film.
• Regular maintenance: Consistent preservation of your industrial asset is crucial towards preventing corrosion. This includes frequently checking for signs of corrosion and taking steps towards repairing or replacing any damaged parts.
• Controlled environmental conditions: Maintain the temperature of the surface to be coated, the air, and the paint or coating material within the recommended range. High temperature can accelerate drying, while low temperature can cause the coating to take longer to cure, leading to poor adhesion and reduced corrosion protection. Same applies to humidity control.
• Surface preparation: More on that below.

6. The Importance of Surface Preparation During Industrial Painting

Surface penetration is an essential factor when it comes to industrial painting, as it dictates how well the paint sticks to the surface and how long it will last.

There are several benefits to surface penetration, as we explain below.

• Enhanced adhesion: Proper surface preparation ensures that you create a durable bond between the paint and the surface, making it impossible for the paint to flake or peel.
• Smoother finish: Ensuring that the target is cleaned and primed correctly guarantees that the paint can be applied evenly and smoothly, giving a much more polished look.
• Protection from wear and tear: Thirdly, proper surface preparation helps protect the surface from wear and tear. By removing any contaminants or loose material, you can safeguard the surface from abrasion or impact—especially in high-traffic areas or harsh environments where the asset is exposed to weather, chemicals, or other hazards.
• Extended lifespan: Surface preparation helps to extend the lifespan of the paint job by preventing cracking or fading over time. When done correctly, it gives your paint a better chance of staying intact and protecting it from the elements.
• Cost-effectiveness: Surface preparation can increase profitability in the long run because you’ll need fewer coats of paint to get the desired finish. By smoothing and cleaning the surface, the paint can be applied more evenly, saving you money on paint and making the job easier.
• Time savings: Finally, when the surface is cleaned and prepared correctly, the paint can be applied more quickly and efficiently, ultimately saving time on the job.

The most common methods to prepare the surface for paint application are blast cleaning, pickling, flame cleaning and preparation by hand. Although surface penetration is an important factor to consider when it comes to industrial painting, sometimes complications can occur when dealing with hard-to-reach objects.

This is one of the instances when a painting robot could help. A slim robotic arm can access more intricate areas that were previously challenging for human workers to cover. With traditional methods, it used to take considerable time to ensure complete coverage of all surfaces with paint.

Nowadays, operator-controlled industrial robots have been designed and programmed to detect the edges of the equipment to be painted, enabling them to apply a consistent spray without any wastage.

7. The Importance of External Conditions During Application and How To Control for That

External conditions during industrial paint applications can affect the performance of the coatings, such as their drying time, adhesion, and color.

Therefore, controlling external conditions is essential. This can be done by managing the temperature, relative humidity and airflow of the environment where the coating is applied.

In the modern context, the use of AI is recommended. This is because AI-powered systems can detect, analyze, and predict changing conditions quickly, allowing for precise and efficient control of the environment.

8. Different Types of Paint Applications

In this section, we will explore the different types of industrial paint application methods and explain why spray application is the most efficient and effective one when done right.

Brushing

This is where a brush is used to apply paint manually. Brushing is best suited to scenarios that involve painting small, detailed areas or when a fine finish is desired.

Rollers

Rollers are a great way to apply industrial paint quickly and evenly. They are best used in large open areas where the paint needs to cover vast surfaces.

Conventional Air Spray

This involves spraying paint through a nozzle powered by compressed air. It is best used when painting large areas with uniform coverage, as it offers greater efficiency and accuracy. It is also one of the most cost-effective ways to apply paint, making it the best choice for most industrial paint applications.

Airless Spray

Airless spray is an industrial paint application technique that makes use of high-pressure pumps to atomize paint into tiny droplets. It is best used for large, flat surfaces and when a high-quality and even finish is desired.

Airless spray reduces wastage and provides excellent coverage and a superior finish, making it the best paint application method available.

However, airless spray-painting equipment is particularly hazardous since the paint is ejected at a very high pressure and can penetrate the skin or cause serious eye injuries. PaintJet paint and coatings are applied by robotics, keeping all operators on the ground. This ensures spray doesn’t come into contact with the face or unprotected skin.

9. Coating Types and Their Uses

The following are some of the coating types that can be used in the painting of industrial assets:

• Polyurethane coating: Versatile and durable finish that is great for interior and exterior surfaces. It is resistant to abrasion and has excellent UV protection. It is also resistant to corrosion, water and chemical spills and provides a glossy finish.
• Epoxy coating: A two-part liquid coating that is excellent for protecting surfaces from corrosion, wear and tear, and chemical exposure. It is also highly resistant to water and salt, making it an ideal choice for outdoor structures.
• Acrylic coating: A fast-drying finish that is highly resistant to water and salt. It is often used for marine, industrial, and automotive applications, is available in many colors, and provides a glossy finish.
• Alkyd coating: A traditional oil-based finish that provides a glossy, durable finish. It is highly resistant to water, chemicals, and temperature changes and is often used on wood surfaces.
• Zinc coating: A galvanized finish commonly used to protect metal surfaces from corrosion. It is highly resistant to water, salt, and chemicals and is often used in outdoor applications.
• Ceramic coating: Provides superior protection against corrosion and wear and tear. Also, highly resistant to water, chemicals, and temperature changes and is ideally used in industrial, automotive, and marine applications.
• Anti-fouling paints (for marine applications): These paints offer protection against vegetable and animal growth.

10. Conclusion

At PaintJet, we understand that corrosion control is a vital part of maintaining and protecting industrial assets. We specialize in high-precision paint application and specialty coatings through the use of robotics and AI.

Contact us today for a quote.