Today, we will be comparing anti-corrosion coating costs vs. replacement costs. Corrosion is a serious threat to businesses, operations, and the global economy. But what is the best way to tackle corrosion? Coating protection or replacing corroded parts? Read on for our cost comparison.
The Economic Impact Of Corrosion
Corrosion takes a significant toll on the strength, durability, and lifespan of metal components. For that reason, once a part has succumbed to corrosion, it requires maintenance and in most cases replacement.
Corrosion is inevitable for many alloys, especially when they are exposed to corrosive environments, particularly in high levels of moisture, salt, or oxygen. However, for a lot of industries in those environments, metal is the primary material.
For marine structures, buildings, industrial applications, infrastructures, manufacturing, and several other industries, corrosion can be extremely hazardous. The weakening of metals necessitates urgent replacement to ensure operational safety.
For public security, replacing and maintaining corroded parts is necessary. It does, however, cause immense economic impact. According to the Financial Times, corrosion repairs cost the global economy $3 trillion annually. This cost is solely associated with the replacement and treatment of metal worldwide. If we then factor in the cost of mining, transporting, and environmental impacts… The cost is unsurmountable.
Understanding Anti-Corrosion Coatings
Anti-corrosion coatings offer a solution to the threat and destruction of corrosion.
A molten material is sprayed onto a substrate, forming a protective barrier that blocks the external, corrosive environment from the underlying material. Many applications require corrosion protection, and various materials are used for various purposes. Therefore, anti-corrosion coatings must be versatile and tailorable.
The three main types of anti-corrosion coatings that are widely used are sacrificial, inhibitive, and barrier. For more information on these, check out our previous blog post What Are The Main Types Of Anti-Corrosion Coatings?
Anti-corrosion coatings are used to help marine structures withstand their corrosive environment, maintain the integrity of infrastructures, prolong the aesthetic appeal of automotive vehicles, and ensure the airworthiness of aerospace applications. There are many more ways that anti-corrosion coatings can enhance applications, which you can read about in our blog When To Use Anti-Corrosion Coatings?
Anti-Corrosion Coating Costs vs. Replacement Costs
Initial Cost
When it comes to the cons of anti-corrosion coatings, the initial cost may deter businesses from investing. While long-term benefits and cost savings are guaranteed, some businesses may not have the financial capacity to make the initial investment or may be hesitant to do so. Large-scale projects that require more coatings tend to inflate prices.
The initial cost of replacing parts is extremely varied. If it's only a small part, then the initial cost may not seem too impactful. Albeit, without corrosion protection, you can expect that cost to be repeated.
It is, however, unlikely that corrosion only impacts a small, individual part. As it is the surrounding environment that causes corrosion, it will likely impact more than just one confined component. Therefore, the cost of replacement may be significant.
Long-Term Costs
The lifespan of anti-corrosion coatings is varied. Factors that influence the longevity of coatings are the spraying material, environmental conditions, preparation and application, thickness of the coating, quality of materials, and maintenance. Find out more on this with our blog How Long Do Metal Coatings Last?
Effective corrosion protection guarantees an easing of maintenance pressures. Though they will require periodic inspection to ensure performance quality, there is a definite assurance of reduced component failure.
When it comes to the expense of replacement over the long term, it is sure to be a greater financial burden. Once a part is replaced, it is only so long until those parts need to be replaced again. Not only is the sourcing of new materials costly, but the downtime required for maintenance is also impactful on a business's profitability.
Impact On Operational Efficiency
Once anti-corrosion coatings are applied, they help maintain and prolong the integrity of components or equipment, thereby lessening the chance of unexpected failures. While touchups and inspections may be required, this is easier to predict and manage for businesses. Scheduled maintenance can be factored into project timelines.
Without corrosion protection, disruption to operations will likely be more consistent and impactful. Replacing parts or equipment is usually far more disruptive and requires a temporary halt to operations. Prolonged and regular downtime stilts operational efficiency and profitability.
Anti-Corrosion Coatings From Alphatek
When it comes to comparing anti-corrosion coating costs vs. replacement costs, there is a clear winner. Businesses that administer corrosion protection are proven to achieve significant financial savings.
Alphatek will develop proprietary corrosion protection coatings for clients with unique application requirements. All our services are delivered to the highest standard and represent great value.
Our anti-corrosion solutions have been used across several industries. Whatever is compromising your component's performance, we have the expertise to guide you toward lasting solutions. Keep up to date with our blog for industry insights on all things metal spray coatings.
If you need more convincing when comparing anti-corrosion coating costs vs. replacement costs or would like a direct quote, please don't hesitate to get in touch.
