Asset Owners: “What is your primary investment Objective?”
When seeking out maintenance and rehabilitation solution sets, functionality usually overrides aesthetics on existing, aged, in-place structures. Ultimately, solution offerings for maintenance and rehabilitation challenges should have a field proven history at addressing the targeted issues as well as having evidence of it’s field proven history. Ideally, performance warranties should also be included in their offerings.
Preventive maintenance.
- Extends the service life of functional elements.
- To protect the structure from damage or deterioration.
- To ensure continued dependability and reliability.
Rehabilitation.
Reinforcing compromised elements. Replacing worn-out parts. Stabilizing existing functional elements.
Replacement.
Replacing functionally obsolete structures that no longer satisfy demand. (Expanded capability and functionality.)
Regarding steel corrosion mitigation, which chemistry best addresses the corrosion issues on the structure?
Traditional Barrier and Sacrificial Barrier Coatings (epoxy – zinc-epoxy-urethane)?
- Highly effective on flat surfaces.
- Zinc demands a salt free, white abrasive blasted steel substrate.
- Zinc coatings last longer with additional barrier coatings.
- Zinc does not work inside crevice corroded and pack-rusted joints and connections.
- Hard barrier coatings micro-crack at connections and fasteners.
Chemically Active HRCSA?
- Works inside corroded crevices and flat surfaces.
- Requires salt free steel and or tightly adhered paint substrate.
- Low surface energy single coat application with integrated UV blockers.
- Self-priming topcoat melds with HRCSA penetrant which a) displaces moisture, b) scavenges oxygen, c) neutralizes acids inside connections (corroded or not).
- Elastomeric: Moves with the structure without microcracking at connections.
In both lab testing and in the field, HRCSA’s unique chemistry outperforms traditionally prescribed coatings particularly in the area of rust creepage.
30 years of field history confirms: HRCSA is the most effective corrosion protection for in-place, corroded, flexible steel structures.
HRCSA Meld coat
HRCSA Penetrant + Topcoat
Photo of 15 year HRCSA treated pack-rust connection. (Left panel, bottom photo).
HRCSA is elastomeric and chemically active. Once applied to specification, HRCSA inside pack-rusted joints and connections remains chemically active.
This is most notable because structures move – as do their connections.
Performance (Corrosion) Warranty?
Zinc + multi-coat (NO)
No corrosion warranty for crevice corroded and pack-rusted joints and connections.
HRCSA (YES)
5 year corrosion warranty on crevice corroded and pack-rusted joints and connections.
* ONLY HRCSA has the chemistry to chemically stop crevice corrosion and pack-rust.
Implementation Costs
Abrasive Blast
True Cost of SSPC SP10
Negative Air Containment
Abrasive Collection Unit
Abrasive Recycler
Blast Machinery ~ $35,000 + / month
Fuel 1000 liters per day
Abrasive material & Disposal
Salt Remover
Negative air Containment
Scaffolding for SP10 requires 120 kgf/m² load capacity
HRCSA Overcoat
True Cost of SSPC SP/WJ4
No negative air containment required!
High pressure water cleaner ($7,500 / month)
Fuel 100 liters / day
Potable water (1000 US gallons / shift)
Flocculating Tank / pump / filters
Hazmat disposal: Paint chips only.
Salt Remover (same)
Flow through Containment (screen siding to capture paint chips).
Scaffolding for pressure washing 60 kgf/m² (1/2 the cost)
Surface Preparation Cost Comparisons [Note: ALL surface preparations require a salt mitigation wash to remove salts and other deleterious matter prior to coating.]
Abrasive Blasting Costs
High Pressure Water Cleaning
Field applications of HRCSA typically cost ~ 50% less than abrasive blasting with project completions being achieved in ~ 2/3 the amount of time – and often less.
Environmental Impact
Abrasive Blasting
Fuel Up to 3,500 l/shift negative air
33% more time for surface preparation.
33% (or longer) to paint. [Lane closures – detours, etc.]
Curing time (delays) required for application of each coat of paint (Zinc, Epoxy, Urethane)
Resin, catalyzer, in pails and gallons (multiple hazardous waste streams created by wasted catalyzed coatings and flushing solvents.)
Moisture cure coatings are humidity sensitive.
High Pressure Water Cleaning
Up to ~100 l/day fuel for pressure washer.
~3,800 l/day potable water
No hazardous waste stream (paint chips only).
33% LESS lane closure and detour time, etc.
Single coat wet-on-wet (2 step) process.
No mixing – from drum to steel.
HRCSA chemistry is not humidity sensitive (must be applied on dry surface.)
HRCSA Maintenance Procedure
HRCSA – easy to repair.
- Abrade active corrosion.
- Solvent wipe with HRCSA thinner.
- Open HRCSA tin, brush on a new coat.
- Seal containers, clean and store equipment.
Like all things, scheduled maintenance is the most efficient and effective way of maintaining your structure’s integrity.
- You have the right to a corrosion control coating system that will stop structure critical corrosion on your asset – including crevice corrosion and pack rust.
- You have a right to ask for case histories and proof of performance to validate the corrosion control system’s capabilities and durability.
- You have the right to ask for a joint warranty, from the contractor applicator and the coating manufacturer, that states their product and process can stop the existing corrosion on your structure, specifically in structure critical crevice corroded and pack rusted connections.
Thank you! Happy Preservation!