Anti Corrosion Coating

anti-corrosion coating

The Growing Demand of Anti Corrosion Coating & Paint

Anti corrosion coating (also referred to as corrosion resistant paint) is becoming more and more popular in Canada. Anti corrosion coating comes in liquid form (paint, spray and so on) and in powder form. They are especially designed for protecting corrosive substrates. The most common materials that are prone to corrode are: iron, metal, aluminium and stainless steel. Anti corrosion coating:

  • Extends the life of various types of metal that are prone to corrosion.
  • Protects buildings from corroding on the outside due to varying atmospheric conditions.
  • Ensures a saver product (corroded structures can collapse)

The Chemical Process of Anti Corrision

Corroding is a process whereby certain metal surfaces react with the chemicals in the atmosphere and begin to wither (resulting in a red or reddish brown color). Take iron for example, it corrodes very easily in moist environments. Iron reacts quickly with the oxygen and water in the atmosphere, which leads to oxidization. Once oxidized, the iron starts to rust. This causes the iron to lose its shining outer surface and to reveal a reddish brown appearance. To stop this chemical process from happening, anti corrosion coating was invented. Anti corrosion means against corrosion or corrosion resistant.

anti corrosion coating

Types of anti corrosive paints

Corrosion resistant paint (coating) exist of four main ingredients:

  1. Binders
  2. Pigments
  3. Diluents (solvents and thinners)
  4. Additives

Out of these, two of the groups namely the binder and the pigments contribute to the prevention of corrosion. In all the cases, the painting done is always a composite system: Prepare the surface, apply one or two primer coats, follow by two or more coats of finish paint.

The important fact to remember is that “Primer protects the substrate and the finish paint (or top coat) protects the Primer.

The most effective anti corrosion materials (or pigments) are Red-Oxide, Zinc Chromate, Zinc Powder and Magnesium Powder. After this we can segment anti corrosive paint in 5 types:

  1. Epoxy Resin 
    Two coats of primer are applied followed by two coats of Epoxy Finish. The total DFT (Dry Film Thickness) being 100 to 125 microns. Epoxy resins are tough and abrasion resistant. However, the epoxy coatings are not resistant to UV Radiation. They tend to chalk in one or two years. They have however, excellent corrosion resistance to most of the chemicals and solvents. Due to the poor UV resistance, the epoxy coatings are used in the interior of Chemical and Fertilizer Plants.
  2. Coal tar epoxy
    This paint comes either in Black or Brown color, as they contain Coal Tar. Coal Tar has excellent water proofing quality and hence are used extensively where the structures are immersed in water. They are used in Ports and Dredging equipment where the corrosion due to saline water is very high.
  3. Polyurethane resins
    PU Resins or poly urethane Resins are excellent corrosion resistant paints. They are not affected by UV light. They are preferred in the place of epoxy resins in all exterior applications. The composite system could be two coats of epoxy resin primers followed by two coats of PU paints giving a total DFT of 100 to 125 Microns.
  4. Chloro-Rubber paint
    One more class of resins used in corrosion resistant coatings is the Chloro Rubber binders. They provide an excellent corrosion resistant coating in a chemical environment. However, being thermoplastic resins, they are easily corroded by solvents and cannot withstand higher temperatures.
  5. Silicone aluminium paint
    These class of paints are used as heat resistant paints. The Silicone Resin can withstand around 500 to 600 Degree Centigrade, while protecting the steel surface.

anti corrosion coating for reinforcement steel

Corrosion-Free Steel: The Solutions

Steel is used for a number of purposes both in the industry and in households. Steel, however is very sensitive for corrosion. This is because steel is simply an alloy of iron. This implies that although it contains other materials, it also has a large quantity of iron. Iron is one of the most corrosive materials which means that steel also rusts easily in moist environments.  Iron that rusts can become unstable. Due to the fact that steel rods are essential in many buildings, they are often coated with a protective layer of corrosion resistant paint. Safety is key!

The system of anti-corrosion treatment for reinforcement steel essentially consists of four steps: The integrated treatment comprised of the successive application of the following solutions:

  • Derusting Solution (acid inhibitor in solid form)
  • Phosphating Jelly (rust preventing composition)
  • Inhibitor Solution (corrosion prevention in reinforced concrete and brick construction)
  • Sealing solution (Anti corrosion coating)

Protecting your Airco for Corrosion

anti corrosion coating for air conditioners

Air conditioner with rust

Not many people immediately think about coating their air conditioners. Even though it is a good idea! Air-conditioners can be subject to corrosion as they age. Factors such as rain and heavy storms can deteriorate the air conditioning system from the outside. Furthermore, air conditioners have aluminum fins that can corrode easily without protection. Anti-corrosive coatings are hence preventing such damages from occurring so you can enjoy the cool air longer.

Popular brands in Canada for treating your air conditioner are:

Tremclad Anti Corrosive Spray| $8,19 | 340GR | Multiple colors
RONA anti rust spray paint | $6,99 | 340GR | Multiple colors
Rust Oleum anti rust spray | €10,99 | 586GR | Transparant

anti corrosion coating carAnd what about your car?

Cars, trucks and motorcycles are the most popular means to travel in Canada. Cars and motorcycle parts are made from aluminum.

Aluminum is  a type of metal that easily corrodes. Combine this with the fact that cars and motorcycles usually spend their lives riding outside in all weather conditions and it’s not hard to understand that oxidation takes place.

Using good rust protection for aluminum parts can prevent thousands of dollars in costly repairs and stop the metal body from wearing out long before the engine and other parts are ready to call it quits. Furthermore, applying anti-corrosive coating will ensure that the car does not lose its glossy lustre. And you do not have to take our word for it!

The Canadian Army has actually commissioned several studies on the benefits of rust proofing their vehicles and equipment. Read the full Research. The clear winner in the army tests is Corrosion Free (see below). They found that Corrosion Free was more than 90% effective at inhibiting rust even in the harshest climates.

Rust proofing prices

Treating your car with anti corrosion coating is also called rust proofing and can be done at local car dealers. It takes about an hour. For prolonged protection we recommend treatment every 12 to 18 months. It typically costs between $100 and $150 per year to get an oil based rust prevention product applied, which is expensive, but if keeps your vehicle on the road for 5 to 10 years longer, it’s definitely worth it. Typical choices for rust proofing your car are:

Corrosion Free (tested best by the Canadian army!)
(Multiple locations)
CANADIAN TIRE #497
5970 Mavis Road
Mississauga, ON
L5V 2P5

The price for most vehicles is $150 and it’s $20 more for larger vehicles and SUVs.  They also have convenient do it yourself kits starting from $59,00.
Rust Check
(Multiple locations)
6175 Danville Road
Mississauga, ON, Canada L5T 2H7

Starting at $119,95 for a medium sized passenger car.

Krown
(Multiple locations)
131 Sheldon Dr. Unit#18
Cambridge, Ontario, N1R 6S2

Starting at $119,95 for a medium sized passenger car.

Remember to always ask for a anti rust warranty flyer.  It provides the full details of the treatment and what the warranty covers.

How to apply anti corrosion coating yourself or by a coating specialist

There are many methods for applying anti-corrosive coating. For example by anti corrosive spray or paint. The choice of application method is dependent on the type of coating and purpose of coating. The coating process is different for decorative and industrial applications. Both, however, include cleaning and priming the surface, applying the coating and letting it dry.

Depending on the surface, one or more layers of coating are applied:

  • One layer of coating is suitable on indoor objects and objects with low influence of weather conditions. Single-layer coating is also advised for outdoor galvanised materials which are not affected by extreme outdoor influences.
  • Two layers of coating are appropriate on (stainless) steel, aluminium and galvanised materials outside.
  • Three layers of coating are applied on stainless steel, aluminium and galvanised materials in extreme weather conditions and heavy stress.

Industrial application

Industrial coatings refer to coatings that are applied on objects/surfaces during production phase (prefab). Both liquid anti corrosion coating and powder coatings are suitable for industrial applications. Nowadays, powder coatings are increasingly popular due to the fact that they do not emit harmful VOC unlike liquid coatings. This means that powder coatings are more environmentally friendly and also proven to be tougher than anti corrosion coating. Application methods for the industrial coatings:

  • Low pressure spray
  • Airless spray (also available for 2K systems)
  • Electrostatic spray (often for powder coating)
  • Robot operated spraying techniques
  • Curtain coating
  • Dip coating

Manufacturers and paint prices 

Due to the high demand of anti corrosive coatings, a variety of providers sell such coatings to meet different needs. The price is usually between $100 to $150. Some of the providers include Denso, Surface Heat Treat and Coatings, Weicon Inc. etc.

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