Corrosion Remediation: 5 Phases to Stronger Anticorrosive Paint

Posted on Thursday, April 02, 2020

Corrosion Remediation: 5 Phases to Stronger Anticorrosive Paint

What to Know About Corrosion and Paint Repair

How Anticorrosive Paint Repairs Paint Damage

Corrosion can happen anywhere in your industrial facility, manufacturing site, or commercial structure, though some areas and industries are at higher risk. Are you protected? 

Anticorrosive paint application by Kaloutas is an effective and necessary step to preventing rust and other deterioration from damaging your valuable assets. We’re here to help.

  • If you've seen signs of corrosion anywhere in your facility or on your manufacturing equipment we can correct it.

  • If you want to be sure you're protected against corrosion, we can inspect for warning signs of chemical damage or rusting.

  • If your existing primers, paints, and coatings are ineffective against corrosion, we can either clean the surface and reapply the coating, or recommend a more effective alternative.

Whatever you're facing, whether it's corrosion above food preparation areas, tanks deteriorated by chemicals, or rusting silos and equipment, we have the knowledge to correct corrosion, and to prevent it from happening again.  

Causes of Corrosion

Corrosion happens whenever caustic conditions or substances come in contact with the surfaces sensitive to them. Most often, corrosion in your facility will be attributed to one or more of these causes:

  • Temperature changes: Humidity can cause corrosion, as well as sudden, significant temperature changes. The changes in oxygen and moisture levels in the air can cause warping and damage.

  • Chemical corrosion: Chemicals, whether you work with them, clean with them, or produce them, often corrode surfaces that are improperly or inadequately coated.

  • Water and Moisture damage: Without proper testing for moisture and moisture mitigation, water and water vapor can cause costly damage and deterioration

  • Exposure: Industrial assets exposed to the elements are at high risk for corrosion, especially during heavy rains and harsh New England winters.

  • Wear and Tear: Constant use of equipment, fixtures, and mechanisms can cause them to degrade over time if they are not regularly inspected and treated for corrosion.

Understanding what's causing corrosion in your facility means any recommendations for corrosion control will be more targeted and effective. 

Check These Areas and Assets for Corrosion Damage

It is critical to inspect your entire facility for corrosion regularly. Leaving it unchecked will only cause bigger headaches down the road. Investing in corrosion inspection and remediation prolongs the life of your equipment and the structural integrity of your facility, while unplanned repairs mean your bottom line takes a hit. Checking regularly for corrosion can help you avoid reactive expense.

We most commonly see corrosion on:

  • Ceilings above tanks and equipment where significant heat, cold, or moisture is emitted regularly as part of your manufacturing process or service

  • Tanks and equipment that regularly come in contact with moisture or chemicals

  • Outdoor tanks, equipment, structural steel, rooftop dunnage, etc: The longer you've had the equipment, and the more time it's spent outdoors, the greater the likelihood it will corrode.

Facility teams should be on the lookout for damage, discoloration, and chipping. These are three sure signs that corrosion has set in. Along with the cost of having to repair or replace deteriorated equipment, corrosion also poses significant health and safety liabilities. It can increase risk of fire in your facility. It can hamper equipment from working safely and properly. And rust chips from ceilings, walls, or equipment could fall into your product supply, resulting in contamination and the safety hazards that come with it.

Don't forget: Anything kept in storage, or in an area of your facility you don't frequently use or visit, is highly prone to rust corrosion. And that risk increases if the areas are not climate-controlled. 

Corrosion Remediation and Removal: 4 Phases

Corrosion removal and remediation generally happens in 5 phases:

  • Inspection: Thorough inspection is necessary to understand where corrosion is hiding, and how extensive it is. While a more detailed inspection will be necessary when planning and executing removal projects, teams working in those areas can also develop a checklist for daily inspection, so they can be trained to spot the earliest signs of corrosion. We recommend planning remediation projects ahead of any compliance inspections, so any issues that may impact your inspection score can be resolved in time.

  • Cleaning & Preparation: When corrosion has taken over a surface, it can often be removed through industrial cleaning & preparation techniques such as hand tool, power tool and at times, abrasive blasting. These methods remove particulates damaged by rust or chemical corrosion to leave you with a clean, intact surface underneath. In some cases, cleaners and solvents may be appropriate, depending on type and level of corrosion. Industrial cleaning and surface preparation are essential steps in this process. If any particulates are left on the surface, primers, paints, and coatings you apply will not be adhered properly and will be ineffective from day one of application.

  • Maintenance: Your equipment, fixtures, or other areas damaged by corrosion may need to be repaired or replaced before primers and paints can be applied.

  •  Primer: Primers are applied after cleaning to maximize the effect of anticorrosive paints. 

  • Anticorrosive paints: Anticorrosive paints are your first line of defense against equipment and facility deterioration. The exact paints you need vary based on their use and your compliance standards. They could be:

    • Moisture resistant

    • Chemical resistant

    • Weather resistant

    • Resistant to extreme high or low temperatures

Corrosion Control for Industrial and Commercial Facilities

Applying anticorrosive paint is a heavy-duty project that requires people, equipment and materials you likely don't have on hand. Kaloutas has experience using anticorrosive coatings for industry leaders across Massachusetts and New England. Hiring us gives you these benefits:

  • Extensive knowledge of proper cleaning, preparation, coating, and painting techniques for equipment, walls, ceilings, and industrial flooring

  • A "one-stop shop" of experts for every phase of corrosion remediation

  • Thorough surface preparation for maximum paint durability and effectiveness

  • Proper containment and protection of surfaces to avoid messes and the threat of cross-contamination

  • No-work-stoppage guarantee so your anticorrosive paint application gets done without halting productivity or stopping work

  • Preventive facility maintenance support to get ahead of common facility issues like corrosion so you can prevent them from happening, and stop them in their tracks at the first threat or sign of corrosion damage

  • Partnership with an ISNetworld member.

Anticorrosive coating systems are an asset your facility can't afford to do without. Kaloutas is ready to improve performance and longevity of your industrial painting projects with expert industrial cleaning, priming, and paint/coating application.

Paired with our proactive facility maintenance approach, you can expect great results for years to come. We can also check your concrete flooring to ensure any coating and sealing is moisture retardant and corrosion resistant. Don't leave your industrial assets vulnerable to rust, warping, or decay. Call Kaloutas for an anticorrosive painting estimate today.

Kaloutas is New England's premier contractor for commercial & industrial painting, flooring, and related services. Established in 1987, Kaloutas has become a trusted resource for general contractors, facilities managers, and building owners from Connecticut to Maine. Our team prides itself on high quality workmanship, jobs done on time & budget, and tackling complex projects that other contractors don't have the experience or resources to handle. Contact us today for a painting or flooring estimate, or give us a call at 978-532-1414 to learn more.

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