Published on October 7, 2016
1. No fuss, practical applications of newtechnologies for economical, efficient corrosion control Utilizing environmentally sound advanced technologies to prevent & control deicer-influenced corrosion.
2. Define the Problem Corrosion from Metal ImpuritiesGalvanic corrosion Pitting corrosion There are a variety of corrosion forms which can take place in a vehicle. Corrosion on equipment is caused by many factors such flash rust; weld issues; pitting; galvanic reaction; mineral buildup; certain microbes; stress; abrasion; UV degradation; and mold, mildew, or other organic decay, to name a few. Images below depict types of corrosion commonly found on ice & snow and dual-use equipment. General corrosion Filiform corrosion Crevice corrosion Microbially influenced corrosion UV induced corrosion
3. Deicer exposure leads to asset losses equipment value equipment downtime equipment reliability & safety equipment service life premature repair and replacement
4. Corrosion for Standard Deicing Solutions
5. Electronics/wiring Chassis/brakesEngine/exhaust/fu el system Hydraulics/attache ments Body/salt applicators Cab Drive train/axle Other Corrosion related spend for a typical snow removal dump truck fleet 95% of fleet corrosion costs are applied to dump trucks ($200 to $2000 per dump truck, depending onregion) $3.5m total repair costs $417k on corrosion repair (the rest in replacement and corrosion control measures) Snow removal operation efficiency depends on effective & economical corrosion control & corrosion prevention strategies
6. ‘Atrisk’ Equipment
7. Corrosion vs. Chlorides Applied: WA Dump Truck Study
8. Adoption of new corrosion control technologies in Washington State Washington’s DOT took a look at the high cost of corrosion in 2011 and implemented the use of corrosion-inhibited ‘snow materials’, along with new coatings and regular washing to reduce the effects of corrosion on vehicles and roadways. By evaluating and implementing new technologies, they were able to begin to control corrosion across their fleet, but there will likely always room for improvement as new, and improved technologies become available. Five years have gone by, time to gain measures of the actual ROI of those technologies – just in time to evaluate even newer, more advanced technologies that may augment or outperform ‘older’ products and processes.
9. Corrosion is a problem throughout Brackets & supports Brakes Bumpers Body panels &trim Wiring Engines Drive Train Exhaust Fittings Frames Fuel tanks Radiators Transmission Wheels Granularhopper Spreader Spray bar Storagetanks Plow blade Hydraulics
10. Deicers degrade many materials, not just steel Chemicals used for ice & snow control are highly corrosive to metal. However, determining what steps to take to control corrosion is a complex process, because different components, made of different materials, may be impacted by the ice control chemicals used. Consider more than just steel. Think about materials found in the wiring and elsewhere on the fleet, such as aluminum, copper, fiberglass and plastic.
11. Understand the solutions Currently, there are several types of corrosion control products on the market. Not every solution addresses every corrosion problem. Using the right combination of products for the specific corrosion you are dealing with is key. General corrosion can be reduced by • Washing technologies • Use of coatings • Use of inhibitors • Cathodic protection Crevice corrosion can be reduced by • Use of thin film coatings • Use of inhibitors Pitting corrosion can be reduced by • Washing technologies • Use of coatings • Use of inhibitors • Cathodic Protection Filiform corrosioncan be reduced by • Use of marine coatings • Use of zinc-rich coatings Galvaniccorrosion can be reduced by • Use of barriers • Use of coatings Cathodic protection Stress crackingcan be reduced by • Surface preparation Microbially influencedcorrosion (MIC) can be reduced by • Surface preparation • Marine coatings • Superhydrophobic coatings UV induced corrosion can be reduced by • Use of coatings
12. Don’t Throw the Baby Out With the Bath Water Many new technologies can be integrated into your existing procedures, but it’s a good idea to get product training so you won’t waste time figuring out where and how to implement them. New technologies are created to work better than traditional methods, so you will need to revise your procedures. You’ll likely discover some processes and products that you had been using are now redundant or completely unnecessary. Another tip: keep an eye on replacement part inventory. More durable corrosion protection technologies result in less repair and fewer replacements. Ramping up for each season should require less on hand. New Technologies • Surface Preparation • Salt Neutralizing Wash • Nanotechnology Coatings • Marine Coatings 0 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Series2 Series3
13. New Scenario, New Requirements The new reality is that contaminants become more and more concentrated with each new generation of recycled steel, in spite of diligent efforts by those in the steel industry to lessen the amount of impurities that remain in post-production steel. Corrosion caused by micro-impurities and interference materials within the metal itself is of special concern considering their contribution to corrosion problems such as stress cracking and coating failures. The same can be said for aluminum and other metals. Surface preparation is essential as the first stage in treating any metal substrate before the application of a protective coating. Cleaning the metal helps coatings adhere better. However, the presence of micro-contaminants within the metal surface cannot be sandblasted, washed or ground out. Mechanical cleaning is not enough. Coating over ‘clean’ white metal that has not been decontaminated is like putting a bandage over a festering wound. It may have been wiped clean, even rinsed clean, but if it is not decontaminated, the wound may become aggravated. Moreover, the corrosion inducing contaminants within the metal will eventually bloom and detach the coating from the metal, the strain of which can often breach the coating, leaving metal vulnerable. Chemical decontamination is a requirement given this new reality.
14. New technology has to address ‘old facts’, as well as new concerns. For example, it is still true that neither mill scale nor welding residue on steel surfaces form a satisfactory base for modern, high performance protective coatings. It must be removed – completely – along with other surface contaminants in and on the steel surface, such as oil, grease and films. Unique Surface Preparation Technology Toour knowledge at this date, there is only one surface preparation technology that addresses micro-impurities in metal, weld issues, mill scale, flash rust, as well as general degreasing/cleaning. CleanWirx chemical treatment decontaminates metal after abrasive blasting (does not replace blasting) and directly before applying any coating. However, it makes steps like re-blasting, acid washing and dehumidification redundant, and can be performed in an hour or less to an outcome of zero detectable contaminants, which may save time and money for some operations. The technology has been adopted and specified in petroleum and other high-corrosion industries to meet strict pre-coating surface preparation requirements and to significantly enhance coating performance and, by extension, asset service life. No special equipment is required to implement this technology. The product is coating-neutral and non film-forming. As an eco-friendly, biodegradable technology, there are no special shipping requirements (Hazmat/Dangerous Goods); at well under 1% VOC it meets most guidelines for greener product options, which may also be a benefit to some municipal operations. Speaker is affiliated withCleanWirx. Image of technology in action Before: Micro-contaminants present After: Micro-contaminants have been removed
15. Washing Technologies Evaluation of the Effectiveness of Salt Neutralizers for Washing Snow and Ice Equipment US DOT / ODOT / University of Ohio Study: Akron OH January 2014 Effectiveness on metal varies, and may decrease or increase corrosion depending on the substrate used. Protective coatings should be used in conjunction with salt neutralizers in cases of steel, copper or brass surfaces to avoid ramping up corrosion rates. “The cost to thoroughly wash a single truck is significant and can vary by more than 300% depending on the neutralizer product. For the two top performing (at “modified” dose to achieve corrosion reduction) neutralizer products (Salt-Away and BioKleen) and Neutro-Wash, the neutralizer cost for a full 350 gallon wash per truck would be $567 for Salt-Away, $1,043 for BioKleen, and $1,810 for Neutro-Wash. Assuming replacement cost of ODOT tandem truck is ~$140,000 ($125,000 single axle) and the neutralizer solution can increase the useful life of the truck by 6 months to 1 year, washing the trucks with Salt-Away 5 to 18 times per year (depending on facility location and replacement cycle) is cost-effective. “ Speaker is not affiliated with any deicing detergentcompany.
16. Washing/Barrier Film Technology Salt Shield is low pH liquid detergent that cleans and neutralize road salts and deicers from the chassis and wiring on the underside of vehicles, removing sodium, calcium, and magnesium chloride deicer salts, including those mixed with cheese brine or sugar beet juice carriers. The detergent includes chemicals reactive on exposed iron and steel surfaces to provide a barrier film that temporarily protects against corrosive winter materials as well as calcium chloride in dust suppressants. The product does not remove months or years of undercarriage salt, rust, mud, and dirt build up, but it will loosen up crud and begin the removal process if used regularly. Vehicles with heavy deposits of road salts and rust can initially be treated with a compatible low pH presoak for quicker removal. There are no special shipping requirements (Hazmat/Dangerous Goods) associated with this product, which may be considered a greener alternative. Reclaim compatible. Speaker is not affiliated with any deicing detergentcompany.
17. Nanotechnology Coatings • Extremely dense coverage at microscopic level prevents moisture seepage through micropores. • Half the weight of conventional coatings, relieve structural stress, pull away & cracking failures. • Fill and smooth surface defects to create smoother surface and reduces blast profile effect. • Extremely low surface energy & low flow resistance increase durability. Considerations: • Adhesive technologies employed to apply Bucky Balls and Carbon Nanotubes are less effective. Mechanically adhered coatings depend on the effective life of their adhesive technology to prevent flaking, delamination or compromise from abrasion. • Mechanically adhered coatings stick to surfaces, do not penetrate or unite with substrates. • Covalent & ionic crosslinked bonds unite with the substrate they protect are more effective. • Chemical bonds, the strongest in nature, avoid many underlying causes of coating failures. • Environmentally safe nanotechnology: low VOC, non-carcinogenic, no heavy metals or pesticides.
18. Marine Coatings Marine paints and anti-fouling coatings have been investigated for possible application on de-icing equipment due to their confirmed performance in protecting bridges and infrastructure from corrosion in high-chloride environments. However, a marine coating that could withstand corrosive high salt and marine conditions and provide for adequate protection in the automotive industry had not yet been established as of 2013. New Technology with Potential Crossover Since then, Coval coatings developed a new marine coating with fouling release and corrosion protection applications on vessels, bilges, cargo holds, infrastructure and boat trailers. The marine coating has been tested, with positive results, for use on vehicles, though not specifically on DOT equipment. Investigating this promising product in conjunction with automotive and metal coatings in your on-site tests of new technologies is recommended, as it shares many affinities with the metal coat by the same manufacturer and may provide additional protection in areas exposed to extremely high deicing salt concentration. Speaker is affiliated with Coval.
19. On-Site Testing Metal Coupons On-Site Testing Gives More Accurate Results Obtain Coupons and or Product Samples of New Technologies at Little or No Cost Order from Manufacturer vs. Prepare On-Site Equipment & Facilities Actual Components & Equipment Actual Components & Facilities Delineate Test Areas Clearly to Prevent Possible Interference TestSetup Account for Variables – Be Consistent Multiple Dates & Locations Decide on Acceptable Time Span Test in Extreme Conditions Document, Document, Document Example: WA DOT did an excellent study on corrosion in 2013 see atmospheric (exposure to on-site elements) corrosion testing p. 137 / A-39. www.wsdot.wa.gov/research/reports/fullreports/796.1.pdf !
20. Go Data Mining Create a cost base with which to compare new productROI. • How much did you spend on repairs? • What kind or parts & how often? • Cost to repair or replace, by type of item? • What was replaced and how often? • What are your current corrosion control materials? • How much do they cost in terms of time & resources? • How many trucks are projected to be out of service? • How long will they be out of service? Corrosion RelatedRepairs RepairFrequency Materials Labor Time Out ofService Replacement Frequenc Materials Labor Time Out ofService Current CorrosionControl Materials Labor Time toMaintain/Implement System System Out of ServiceProjections #of trucks per week # of trucks permonth #of trucks per year (Avg) % of fleet availableper event Time Labor Parts Type Type Type Type Item Item Item Item Item Item Item Item Item Item
21. Evaluation Criteria • NEEDED NOW! - Locally Available • Non-Negotiable Must-Haves – Price, Performance • Preferred Attributes – Ease of Use/Integration • Additional Merit – Added Benefits Economy Coverage Labor costs Cost across equipment service life (cost of ownership) Implementation Compatibile with existing equipment & knowledge Ease of application Compatibility with other systems in place Versatility Works on a variety of substrates Applicability to facilities &other types of equipment Corrosion Control Testing TestPeriod(Date,Duration) SurfaceA SurfaceB Compatiblewith: Compatiblewith: Pricepersq.ft. OtherApplication(s) Outcome Health&SafetyConcerns EquipmentNeeded TrainingNeeded ProductA Product B Product C ProductD Product B ProductE ProductF ProductG ProductH Product I Surface Preparation Details:
22. Selecting Test Products Price: • Shelflife • Coverage • Maintenance Manufacturer TestingData: ASTM D1654-08 Corrosive Elements• • ASTM D5894-10 Cyclic Salt Fog/UV Exposure • ASTM D714-02(09) Degree of Blistering • ASTM D610-08 Degree of Rusting • Electrochemical Impedance Spectroscopy (EIS) • Scanning Electron Microscope Spectroscopy (SEM) • AmbientTesting • FiliformTesting Technical Specifications Sheets/Instructions for Use: • Cure Time • Humidity • Temperature • Substrate Variables • Preparation Procedures Safety DataSheets: • Transportation • Storage • Health Hazards • Environmental Hazards Years Cost Speaker is affiliated withCoval.
23. Ensure Integration & Compatibility Step 1: Compare current processes with technical application specifications for new products Step 2: Determine impact of implementing new product application specifications into your existing processes. • Will using this new technology add steps to your process? If so, where? • Will using this new technology make steps redundant/reduce steps in your process? • Will you need more equipment, staff, training & support needed to implement new technology? • Will implementing the application of the new technology need to be outsourced? • Do the new technology’s technical specifications conform to applicable environmental guidelines? • Is the new technology compatible with other corrosion control products and processes? • How much will it cost to implement the new technology , including materials and labor?
24. Document Time, Duration, Conditions & Outcome 1 2 3 4 Clearly Define the TestArea Document All Preparatory Steps Avoid Interference Document Outcome
25. Widening the Scope Winter road use chemicals can also damage vehicle storage and ‘salt’ storage facilities. Crossover exists between the means of protecting equipment from damage due to winter chemicals and that involved in protecting structures, in terms of cleaning, coating and sealing concrete, metal or fiberglass structures. Many salt storage buildings have built in features that make them less susceptible to corrosion. Depending on the cost of repair/replacement, investigating crossover between facility protection and robust equipment corrosion control technologies to extend service life and decrease maintenance costs may be worth looking at, especially in ‘double duty’ products. In addition, nearly every municipal buildings suffers from road chemical related corrosion. For example, in Denver CO, magnesium chloride migrates across surfaces to concrete stairways, stainless steel handrail bases, stone building walls, etc. Bolts that anchor bus shelters to concrete along bus routes corrode and fail constantly. The beautiful, historic main train station in downtown is affected from the ground up to about 5’ due to magnesium chloride migration across concrete 50’ from the street to the buildingitself. Thus, you may want to include facilities in your on-site product evaluations.
26. Find your sweet spot New technologies recently released to the commercial the market promise to bring down both expenses and environmental impacts of corrosion control. Snow removal departments that take the time to select, evaluate and compare new technologies (against each other and traditional methods) put themselves in a position to allocate resources more efficiently. Examples below and to the right give you some idea of what can be gained by evaluating corrosion control products and procedures. Speaker has not Included a direct comparison related to snow removal /deicing operations, as the purpose of this illustration is to demonstrate the importance of comparing & evaluating new technologies vs. established products and procedures.
27. Michael Hudgins Rugged Coatings email@example.com (360) 216-0136