CORROSION PROTECTION
Corrosion Protection is the application of anti-corrosion chemicals to prevent damage to equipment like water pipelines, structural membranes, effluent pipelines, steel pipelines, etc., affected by corrosive agents. Quality corrosion protection can extend your equipment's lifespan and reduce maintenance costs. Sunanda Global has a variety of products, Rusticide, Rustovert, Polyalk Fixoprime, Polyalk CP 293, etc., which prevent corrosion.
RUSTOVERT: Polymeric bituminous rust-converting coating
- Used on new or old reinforcement steel
- Embedded steel in repairable structures
- Used in various structures like water pipelines, effluent pipelines, trusses & structural membrane
- One component ready to use, water-based material
- Converts rust & passivates the surface
- Excellent adhesion to the surface
- Easily applied by brush, roller, or spray
- An advantage of the product is that gunniting rebound loss is reduced
- Clean the surface, free from rust, dirt, oil, grease, etc
- Apply RUSTOVERT to the cleaned surface with a brush, roller, or spray
- Allow it to dry for 24 hrs
- Two coats are recommended
RUSTICIDE: Rust remover and passivator
- Removes rust and prevents further rusting of new/ old reinforcement steel in new construction
- Embedded steel in repairable structures and other structural members
- Various steel structures like tanks, water pipelines, effluent pipelines,
- Trusses, purlins, rafters, and other structural members
- Conforms to I.S. 9077-1979 (reaffirmed – 1997) Appendix B, Clause 5.3.3 for the application procedure
- RUSTICIDE performs rust removal and rust prevention in one operation in mild conditions
- First, remove the loose rust
- Apply sufficient RUSTICIDE on the affected metal surface with a cotton swab
- After a minimum of 24 hours, remove the freed loose rust particles by brush
- Apply RUSTICIDE again by brush
- After the surface dries up (around 48 hours later)
- Apply a passivating coating like POLYALK FIXOPRIME
POLYALK FIXOPRIME: Rust-preventing polymeric coating
- Passivation of exposed steel in repairs to structural members
- Coating of reinforcement bars in new RCC structures
- Steel-pipeline, structures, bridges, arches, etc., especially in marine environments
- H. T. wires/cables/strands etc., in the pre-stressing job
- Conforms to BS 5896-1980, I.S. 2074/1962
- Conforms to I.S. 9077 – 1979 (reaffirmed – 1997) appendix B. clause 5.3.3
- The high alkalinity of cement
- High flexural strength and extra adhesion
- Coated bars do not suffer bond loss when embedded in concrete
- Clean the steel surface with a stiff wire brush
- Mix 1 Kg POLYALK FIXOPRIME with 1 to 1.25 Kg cement
- Mix it to form lump-free consistent slurry using a mechanical mixer
- Apply this slurry to the steel surface using a brush, taking care to avoid pinholes
- Allow setting for 6 hrs
- Apply a second coat of the slurry and allow this coat to set
- Take definite precautions to avoid pinholes
- Ensure that no area is left uncovered
POLYALK CP 113: Concrete penetrating corrosion inhibitor
- RCC and steel structures exposed to corrosion, like bridges, docks, jetties, etc., in marine environments
- Simultaneous cathodic and anodic protection of steel
- Penetrates deeply, hence, protecting rebars from all sides
- Extends the effectiveness and durability of RCC repairs
- Effective even in the presence of a high amount of chlorides
- Alkaline in nature, eco-friendly, nitrite and chromate free
- With a stiff wire brush, clean the rusted surface thoroughly of any loosely held rust particles, scales, etc
- Spray POLYALK CP 113 on the cleaned surface of steel and the concrete in its vicinity
- Ensure that no area is left uncovered
- After about 15 minutes, wipe the steel and concrete surface with a moist cloth
- The above action removes any residual material
- Apply the bond coat followed by polymer-modified mortar in the usual manner
- Clean all equipment immediately with water
POLYALK CP 293: Bipolar concrete penetrating corrosion inhibiting admixture
- Steel-reinforced concrete in or near marine environments
- Piers, piles, and concrete dock structures
- RCC structures exposed to corrosive environments
- Bridges, highways, chlorinating plants, sewerage systems
- Building facades and balconies
- Simultaneous cathodic and anodic protection of steel
- high penetrating power resulting in total protection of rebars
- No adverse effect on properties of hardened concrete
- Effective even in the presence of a high amount of chlorides
- Eco-friendly, nitrite, and chromate free
- Alkaline in nature
- POLYALK CP 293 is added to the batch water during the mixing of cement, sand, and aggregates
- It may be added to the ready-mix truck at the concrete plant or the job site
- It is compatible with other Sunanda Global admixtures but should be added separately
POLYALK CP 293+: Migrating corrosion inhibiting admixture
- Steel-reinforced concrete in or near marine environments
- Piers, piles, and concrete dock structures
- RCC structures exposed to corrosive environments
- Bridges, highways, chlorinating plants, sewerage systems
- Building facades and balconies
- Simultaneous cathodic and anodic protection of steel
- High penetrating power resulting in total protection of rebars
- No adverse effect on properties of hardened concrete
- Effective even in the presence of a high amount of chlorides
- Eco-friendly, nitrite, and chromate-free
- Alkaline in nature
- POLYALK CP 293+ is added to the batch water during the mixing of cement, sand, and aggregates
- It may be added at the concrete plant or ready mix truck at the job site
SUNANODE: Sacrificial galvanic anode
- RCC structures exposed to corrosive environments
- Self-regulating
- No maintenance
- No continuous adjustment
- Very easy to install and effective
- It is compact in design
- Straight-forward design
- Remove concrete from around and behind the reinforcement steel completely
- Use a wire brush if required
- Clean the reinforcement steel thoroughly
- Tie the anode around the cleaned reinforcement steel with appropriate pliers to fasten the connector wires
- The placement, numbers, and spacing of the anodes depend on two factors
- The two factors are the extent of corrosion and the area to be covered
- Ensure that the anode is attached correctly to the rebar so that it is steady and in connection with the steel
SUNZILIKOTE: Self-curing inorganic zinc-rich primer
- Structural steel
- Exterior surfaces of storage tanks
- Bulk handling equipment, pipelines, etc
- Simultaneous cathodic and anodic protection of steel
- High penetrating power resulting in total protection of rebars
- No adverse effect on properties of hardened concrete
- Effective even in the presence of a high amount of chlorides
- Eco-friendly, nitrite, and chromate-free
- Alkaline in nature
Application:
- Use good quality rollers, short-haired brushes, or airless spray.
Nozzle pressure:
- Air Spray: 2.0-3.0 mm, 0.3-0.4 mPa.
- Airless Spray: 0.48-0.64 mm, 15 mPa.
FAQs
What is corrosion resistant coating?
Corrosion-resistant coatings are protective layers applied to metal surfaces to prevent rust and corrosion. These coatings, often made from materials like zinc, epoxy, or polyurethane, act as a barrier against moisture, chemicals, and environmental elements that can degrade metal. They’re essential in extending the life and maintaining the integrity of metal products.
Which coating is used to protect steel?
To protect steel, coatings such as zinc (galvanization), epoxy, polyurethane, and alkyd are commonly used. Zinc provides sacrificial protection, while epoxy and polyurethane form durable, moisture-resistant barriers. These coatings prevent rust and corrosion, prolonging the steel’s lifespan.
What is corrosion protection used on?
Corrosion protection is used on metal surfaces, especially steel, iron, aluminum, and alloys, to prevent rust and deterioration. It’s vital in infrastructure like bridges, vehicles, industrial machinery, water pipelines, structural membranes, effluent pipelines, and steel pipelines, where metal integrity is crucial. This protection, achieved through coatings, galvanization, or cathodic protection, extends the lifespan and safety of these assets.
What are the different types of corrosion coatings?
Corrosion coatings can be broadly categorized into metallic, organic, and inorganic types. Metallic coatings, such as galvanization, provide a physical barrier or sacrificial protection. Organic coatings, including epoxy and polyurethane, create a protective film against environmental elements. Inorganic coatings, like ceramics and enamels, offer robust protection, particularly in extreme conditions.
How are corrosion coatings applied?
Corrosion coatings are typically applied using methods like spraying, brushing, or dipping, depending on the coating type and the surface. The surface must be clean and free from rust or debris. After application, the coating needs to cure, which may involve air drying or heating, ensuring a durable, protective layer.