• Todd Olson

Achieving the Ultimate Goal of Corrosion Control Strategies

Updated: Jul 27

COMMON PROBLEM AMONG CORROSION CONTROL STRATEGIES: Corrosion control strategies should do more than simply chase corrosion. Surface preparation, coating, and inspection all play key roles in corrosion control. Unfortunately, standard practices tend to overlook and even fail to address a major cause of corrosion and the reason why even high-tech coatings fail: the presence of strongly-bonded iron sulfides and chlorides in metal surfaces.

HUGE GAP IN CONVENTIONAL PROCESSES: Conventional corrosion control procedures seek to temporarily inhibit contaminants, but fail to eradicate stubborn, strongly-bonded microcontaminants, thus setting up a ticking time bomb that results in unexpected underfilm corrosion. Even the best, most expensive high-tech coatings and linings are dependent on adhesion to prevent corrosion. If microcontaminants in metal surfaces are not eradicated before application and installation, all linings and coatings remain vulnerable to adhesion problems like blistering and delamination triggered by microcontamination and corrosion sites that spontaneously occur due to osmosis and moisture transfer under coatings. Moisture in vapor or liquid form reacts with sulfides and chlorides to create ultimately destructive corrosion reactions.

CHASING CORROSION IS NOT EFFECTIVE: Eradication of strongly bonded contaminants must occur to prevent underfilm corrosion and allow optimal adhesion and uniform coverage. Otherwise, operators and maintenance crews end up endlessly chasing corrosion, rather than preventing it. This approach results in haphazard control and inability to predict or effectively manage corrosion, delays maintenance and coating projects, fails inspections, contributes to welding problems and wastes resources while failing to meet the ultimate objective: preventing corrosion in and weakening of metal assets.

MEETING THE PROBLEM HEAD ON: Corr-Ze is proven to completely remove strongly bonded sulfides, chlorides and microcontaminants known to interfere with proper coating and lining adhesion. Corr-Ze allows operations to make the logical switch from chasing to preventing corrosion. Corr-Ze optimizes surface condition to promote not only stronger adhesion, but also improved weldments though a revolutionary system that simply but effectively eradicates the major causes of underfilm corrosion that contemporary corrosion control methods like pickling, blasting, dehumidification and inhibitors fail to address. Corr-Ze streamlines surface preparation by allowing continuous-process surface preparation and coating projects that cut labor, energy and materials costs. Complete decontamination results in no underfilm corrosion reactions, improved surface condition, no weld puddling issues and optimized, uniform coating adhesion.

GREATER GOOD: Corr-Ze is biodegradable and environmentally conscious, which results in lower health and safety risks to workers and the environment while improving the condition of metal surfaces so projects are easily completed on schedule and pass pre-coating inspections the first time, every time, even in high contamination environments.

SWITCHING TO THE CORROSION PREVENTION APPROACH: Corr-Ze is designed for easy implementation into existing surface preparation SOP after blast cleaning, in continuous process blast-to-coating that is not dependent on interruptions, weather incidents, humidity. Corr-Ze decontaminates surfaces to hold the blast without resorting to redundant, stop-gap measures like environmental controls, reblasting, dehumidification, pickling or inhibitors.

DOLLARS AND SENSE: Corr-Ze provides more for the money all the way around.

Implementing Corr-Ze and eliminating the specification (and the cost) of redundant, stop-gap measures from procedures shrinks time, labor, material and energy costs up to 50%, while eliciting surface condition inspections results well above previously expected standards. As noted time after time in field testing from brine pits to refinery tanks, Corr-Ze treated surfaces uniformly resist corrosion up to four times longer than those identically coated but prepared using conventional surface preparation methods, thus lowering maintenance frequency and cost of asset ownership by extending coating life (a key factor in asset service life).

#corrosioncontrol #specification #metal #surfacepreparation #coating