Here’s Alphatek’s guide to maintaining anti-corrosion coatings. If you are unfamiliar with corrosion protection, why it is necessary in multiple applications and industries, and how best to maintain it… Then you have come to the right place.
The Importance Of Anti-Corrosion Coatings
Anti-corrosion coatings ensure the lifespan and safety of numerous applications used in a wide range of sectors.
In a worst-case scenario, the effects of corrosion can be fatal- buildings, marine structures, and bridges collapsing, automotive and aerospace applications failing, or chemical spills. Corrosion protection is the only solution to preventing the damage caused by corrosion.
With anti-corrosion coatings, engineers can achieve safe, compliant, and durable designs, that are guaranteed to be both structurally sound and cost-effective.
Types Of Anti-Corrosion Coatings
1. Barrier Coatings
Barrier coatings do essentially what it says in the title. By forming an impermeable layer that blocks out corrosion elements, such as moisture, oxygen, and chemicals. The barrier stops these elements from impacting and reacting with the substrate, so it may keep its original form and integrity.
The main properties of barrier coatings-
- Non-permeable barrier
- Highly durable and resistant to corrosion
- Materials used for barrier coatings are commonly epoxy, polyurethane, and zinc
- Used for marine structures, oil and gas plants, and infrastructure where exposure to corrosive elements can be highly destructive and unsafe
2. Inhibitor Coatings
Inhibitor coatings work effectively by releasing chemical compounds over time. These compounds will react with metallic surfaces to slow down the rate of corrosion. In this instance, the substrate is protected, as the corrosion process takes place elsewhere.
The main properties of inhibitor coatings-
- Neutralising corrosive elements
- Protecting the substrate without isolation
- Materials used for inhibitor coatings are commonly chromates, phosphates, and silicates
- Used for automotive vehicles, aerospace applications, and industrial machinery to prevent rusting, which can lead to malfunctions and loss of profitability.
3. Sacrificial Coatings
Instead of corrosive elements damaging the substrate, sacrificial coatings work as an anode that corrodes instead. This protects the metal surface, as the sprayed layer essentially ‘sacrifices’ itself. Corrosion still occurs, just not for the underlying material.
The main properties of sacrificial coatings-
- Galvanic protection
- Durable properties, even in harsh environments
- Materials used for sacrificial coatings are commonly zinc or aluminium
- Used for offshore structures and pipelines, or any application that requires long-standing protection
Why Is Maintaining Anti-Corrosion Coatings Important?
Prolongs Asset Lifespan
Corrosion can occur rapidly when constantly exposed to moisture, chemicals, and salt spray. Without adequate protection, this can lead to regular component or equipment failure and replacement.
For companies to dodge the costly, time-consuming issues caused by corrosion, they must administer corrosion protection. However, anti-corrosion coatings can only remain effective for prolonging component lifespan if they are properly maintained.
Reduced Maintenance Needs
There are various ways in which metal spraying protects your assets. Anti-corrosion coatings can only effectively protect against the harsh and damaging effects of corrosion if they are well maintained.
While coatings do guarantee your assets will require less maintenance, they do still need to be replenished. This is sure to be less consistent than without corrosion protection, yet it is required to ensure the protective layers remain efficient.
Well-maintained corrosion protection will avoid significant, costly repairs on major parts and equipment.
Ensure Safety & Compliance
Corrosion isn’t just disruptive to project timelines. It doesn’t just impact the aesthetics of completed applications, be it cars or buildings. It can put lives in jeopardy if not managed properly.
Ensuring anti-corrosion coatings are well maintained and working to their maximum potential indicates the safety of personnel and the integrity of metal surfaces. Failure to maintain protective coatings can lead to legal liabilities for companies wherein corrosion protection is a regulatory requirement.
Steps To Maintaining Anti-Corrosion Coatings
- Identifying maintenance needs- such as visual, performance, physical, and functional indicators. You can find out more about these in our blog The Lifespan of Anti-Corrosion Coatings.
- Knowing the typical lifespan of coating materials. Different types of coatings materials- sacrificial, inhibitive, and barrier coatings all have lifespans, ranging from 5 to 25 years. Materials used for the different types of coatings can also impact their lifespan.
- Monitor the extremity of the corrosive environment. In some cases, like marine structures, there’s a guarantee that corrosive elements will be high. In others, this may need to be more closely monitored, to ensure the right materials are used and offer suitable protection.
- Ensuring proper application of coatings and preparation of the substrate is integral to maintaining anti-corrosion coatings.
- Choosing the most appropriate application method for the anti-corrosion coating and substrate will lead to optimal results.
How Alphatek Can Help Maintaining Anti-Corrosion Coatings
After reading our guide to maintaining anti-corrosion coatings, we hope you recognise the importance of corrosion protection and well-maintained metal spraying.
Alphatek is a leading independent thermal spray coating specialist. We administer metal spraying, corrosion protection, and finishing services to a wide range of industries.
If corrosion is a constant nemesis to your applications or corrosion protection is a requirement for your project, why not work with the best in the business? Alphatek works closely with our clients to guarantee the best value and most effective solutions, no matter the project requirements.
If you would like to know more about maintaining anti-corrosion coatings or are interested in any of our specialist coating products, please contact us today.
