Case Studies
Home Depot Assessment Test
Home Depot ran extensive tests using Our Rust Free Black Dip on screw heads for three hundred hours inside the salt chamber. The tests were conducted simultaneously with other nails and screws dipped in five different coatings, including galvanized, ceramic, and a combination of galvanized and ceramic, along with 2 sets of stainless steel screws. A stainless steel screw wasn’t treated, and the other was coated with an unknown anti-rust substance.
After three weeks, all of the screws were taken into the salt chamber. The salt chamber contained two sets screws that were treated with our rust free dip. The initial set was regular steel screws which were treated with rust-free dip on their own. The second set of screws was galvanized, then coated with the rust free product.
Home Depot indicated that it was crucial to maintain an attractive appearance, even with such rigorous tests in the salt chamber, which is a naive expectation in the conditions that are so rigorous.
Every couple of days, Home Depot observed the screws and graded them according to appearance, using a scale from 5-0 and 5, 5 being the most attractive.
Each set of screws was weighted within 200 hours. The objective of the tests was to determine what would appear after exposure. However, what happened was that, after 700 hours.
All screws were either coated, or galvanized ceramic broke down and transformed into dust. The stainless steel screws lasted than 2000 hours before they eventually broke up at this point.
When we use the term decomposed, we mean that the mass loss reached an extent where screws were no longer usable.
Home Depot continued the testing using two sets of screws treated by our rust free product. They ended this test at 3500hrs, and after that, they checked the weights and appearance.
The screws were solid in appearance but displayed the formation of a variety of discolored spots. Home Depot did not realize that the salt used for this chamber (NaCl) was not pure and was contaminated with impurities from other metals that resulted in the discoloration.
In addition, with regards to the weight of the screws, Home Depot discovered and confirmed that after 3500 hours in a salt chamber, which is about 25-30 years of standard conditions of the atmosphere, Our screws lost a little weight. These just 3 grams is equivalent to losing less than 2% of total weight.
This is absolute proof that Rust Free fully protects the metal, at the very least for many decades.
Seawater Desalination System
Mekorot has conducted tests of its Rust Free Product on high pressure pipes, pumps, and the plant’s infrastructure, which is situated near the Mediterranean Sea. Based on the success of Rust Free to prevent rust under these extreme environments, Mekorot is deciding to use Rust Free throughout their plant regularly.
The industry of desalination is built on the fundamentals of water chemistry, chemical engineering, and energy efficiency. Desalination plants are characterized by high corrosion because they process saline water in harsh operating conditions. Rust Free is the essential prerequisite to consider in selecting the appropriate materials. As such, inhibitors, as well as Rust Free Products, will be employed within these plants.
Warehouse
A warehouse constructed of steel that was not treated for several years. The top layer, which was previously exclusively used in reachable places, was recently upgraded. In November of 2016, the treatment of the shed was initiated and included preparation using High Pressure water spraying to get rid of any loose rust as well as old paint.
The Problems:
The storage space needs to be accessible 24/7. This old shed was to be cleaned in the shortest time feasible. Furthermore, the surface preparations made by blasting with abrasive in this region were not permitted. Since the environment was flammable, the paints must have a low VOC. A long-term approach, that used durable materials, was necessary.
The Solution:
The surface preparation was completed using high-pressure water (100-200 bars) to eliminate any paint and mill scale particles and corrosion. The maintenance team and the old paint were removed when the surface was dry. The paint has a lower VOC (Volatile Organic Compound), allowing the maintenance crew to operate without special protective equipment for fire. The item was returned to the original packaging to be used in the future. After 24 hours, there were regular topcoats available. The Rust Free started. After applying the Rust Free coat over the stable rust, they over-coated that Rust Free layer with their regular topcoats.
Rust Free of Oil Tanker
The Client’s name refers to infrastructure for an energy firm. They offer storage and transport services. Additionally, they provide ports for the energy industry to foreign and domestic customers. The company was founded in 1968 and currently has several steel tanks with large volumes. Because of the proximity to the ocean and an electricity plant powered by coal and the consequent rusting process is speeded up. Because of the utilization of Rust Free, the maintenance needs are reduced.
The Challenges:
Corrosion is among the most crucial aspects of keeping vessels safe and conserving asset value. In areas that are not treated, it can cause costly, complex maintenance and replacement of steelwork over time and, in extreme circumstances, cause structural integrity issues and have a serious environmental impact. Hydrocarbon storage tanks are subject to an inspection and maintenance routine that they have developed on their own. Surface preparation required blasting with abrasive, but new regulations forbid such treatment in maintenance. A new solution was required to be discovered. Storage tanks located onshore and coal ash generated by chimneys of electric power plants close to the tanks. The process of corrosion is accelerated and reduces regular maintenance. This type of project is time-consuming and comes with high expenses.
The Solution:
The roofing was washed using High-Pressure Water Jetting (over 500 bars) to get rid of old paint and loose steel. After the roof was dry, it was sprayed airless on top of the paint. White color (the previous primer used to be white). The pigment was added to the product in order to confirm that all surfaces were coated. Twenty-four hours later. A new top polyurethane layer was applied to meet the paint system’s requirements for customers. Glasses and gloves provided the most personal protection items required, and respirators were not required.
Goliath Leader
The GOLIATH LEADER (IMO 9357315) is a vehicle Carrier that was constructed in 2008. GOLIATH LEADER’s length in total is 2100 meters having a width of 30 meters, and a gross tonnage of 57,692. The vessel was inspected during regular maintenance to check the corrosion protection provided by the coating system.
The Problems:
Corrosion is among the most vital elements of ensuring the safety of vessels and preserving the value of assets. In time, the untreated areas could lead to too costly complicated maintenance and replacement of steelwork and, in extreme instances, could lead to structural integrity problems. Additionally, the regular inspection and maintenance process during sailing isn’t equivalent to that of the shipyard, and the preparation of surfaces before painting can take a lot of time using hand equipment.
The Solution:
The exterior areas of the vessels were cleaned with high-pressure (100-200 bars) water-based cleaning to remove any loose paint, mill scale, and corrosion. After the surfaces had dried and cleaned, they were cleaned until the VOC (Volatile Organic Compound) level was at 0, which allowed personnel to perform their work with no specific protective equipment, even in areas with no ventilation. They returned the substance back to its original container for further use at the end of the day. Within 24 hours, they coated this Rust Free coating with the common topcoats that are commonly utilized on vessels.
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