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Corrosion Protection

Steel is the primary structural building block for many types of buildings, transportation, pipelines, etc. These structures are typically coated with thick layers of epoxy or polyurethane overcoat to protect from the corrosion that can result from years of exposure to sun and weathering. Even decorative and primary structure metals, such as aluminum, copper, and their alloys are all vulnerable to corrosion damage.

Bridges, tunnels, buildings, dams, ships, trains, and oil, gas, & water pipelines and storage tanks, are primarily built with steel and sometimes reinforced with concrete. Structures such as these are all subject to corrosion damage resulting from moisture laden with salt and acidic gases. FLUOROSEAL® is a modified PVDF corrosion protection coating that has been proven to block the penetration of these corrosive elements and stop further damage.

"Steel corrosion constitutes the most important cause of premature aging and deterioration on reinforced-concrete structures (and all other steel-based structures) on an international scale. Its technical, financial and societal consequences are considerable. Its economic impact in particular is hard to assess as it would require incorporation of both direct costs (surveillance, maintenance, repairs and rehabilitation) and indirect costs (operating losses relating to immobilization of the structure, insurance, etc.) to define a relevant measurement of the cost relative to steel corrosion in concrete (and all other steel-based structures). Across all sectors as a whole, certain sources assess the total cost of corrosion at around 4% of GDP on average in industrialized countries." [1]

The partial collapse of the Champlain Towers South (a 12-floor condominium in Surfside, Florida) on June 24, 2021 shook the building industry. There is now a call to revamp how high-rise buildings are to be constructed [2]. Even though new buildings may be constructed with redundancy and improved concrete, there are millions of buildings in existence that still faces concerns over gradual concrete weakening and rebar corrosion.

Similar corrosion protection methods that apply to reinforced concrete can also apply to epoxy and polyurethane coated steel vehicles and infrastructure. Instead of a concrete “casing”, they are protected by a polymer coating that allow corrosive gases and moisture carrying salt ions and acidic solutes to penetrate into the steel/coating infer face over time, causing corrosion.

PVDF coatings have been proven effective in preventing corrosion. Because of their chemical composition, they are traditionally applied by the factory with the goal of preventing corrosion for many years. FLUOROSEAL® is a modified PVDF corrosion protection coating, that is VOC exempt and can be applied in the field by traditional brush, roller, and spray coating methods onto new or existing steel structures.   

To be most effective as a top-coat or over-coat, the coating must at least meet the following requirements:

  1. Field applicable in coating onto the large areas of steel structures. That is, it can be applied by roller, brush, or spray coating methods and will “cure” at ambient temperature.
  2. Resistant to UV exposure for at least 50 years, so that the coating does not require constant maintenance. Not only must the top-coating itself be UV resistant, but the coating should also block UV from reaching underneath the coating to prevent structural damage.
  3. Block moisture from penetrating the epoxy and/or other coating. Less moisture penetration will not only prevent the accumulation of water pockets inside the epoxy/steel interfaces, but also decreases the risk of Cl-, Na+ and other salt ions and acidic solutes being carried along to cause corrosion.
  4. Block corrosive gases such as CO2, H2S, SO2, NO, etc. from penetrating the epoxy/steel interface reacting with any retained moisture beneath the coating. AIT's modified FLUOROSEAL® corrosion protection coating CPC-EXT-7150 and CPC-EXT-7280 with PVDF molecular structures are proven to provide the strongest barrier among other protective coatings.

How can FLUOROSEAL® modified PVDF corrosion protection coatings extend the duration between maintenance most for steel structures?

All steel structures can benefit with the AIT FLUOROSEAL® modified PVDF based CPC corrosion protection coating. Among the industries that uses steel, construction, oil and gas, and transportation that the usage involved safety of people and contamination leakage should receive immediate attention and possible implementation.

Infrastructures and buildings using steel superstructure and reinforced concrete as structural members all suffer from slow aging and weakening that can be stopped with the field applicable modified PVDF FLUOROSEAL® concrete and corrosion protection coatings:

Ship Corrosion Protection with FLUOROSEAL Corrosion Protection Coating with Unparalleled Barrier to Ions Rich Seawater and Salt-Spray:

The upstream, mid-stream and downstream operations of oil and gas industry are some of the most vulnerable to corrosion caused by acidic gases, salt-spray and fog:

Which FLUOROSEAL® modified PVDF field applicable coatings are more adapted for specific application in block-off UV, moisture, moisture laden with acidic and salt ions, and corrosive gases from penetrating into steel-coating interfaces?

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[1] https://www.sciencedirect.com/topics/engineering/steel-corrosion

[2] https://www.scientificamerican.com/article/miami-building-collapse-could-profoundly-change-engineering/