The Right Anti Corrosion Coating for Steel | CoatingPaint.com (2022)

Steel corrosion protection coatings keep your assets in shape for longer

According to the latest data from NACE (the Worldwide Corrosion Authority), the global cost of corrosion is estimated at $2.5 trillion. In the US alone, the cost is nearly $500 billion, most of those costs incurred in the industry sector. However, 15-35% of the corrosion costs could be saved by the implementation of corrosion control practices, and a corrosion management system. Steel corrosion protection coatings are a vital part of a corrosion protection system.

Steel corrosion protection coatings actas a barrier between the metal and its environment, increasing its durability and lifespan. To determine the right anti corrosion coating for steel in your project, it isimportant to factor in the environment and type of metal.Whether corrosion is due to moisture, chemicals, salt spray, or oxidation, corrosion resistant coating for steel and metals can help protect the substrate from the elements.

Anti corrosion coating for steel available for different corrosion categories

To determine the right type of steel corrosion protection coatings for your project, you need to understand the environment and use of the substrate. Particularly its exposure to water, moisture, and other aggressive substances that might be present in the environment. The corrosivity of certain atmospheres has been classified and standardized by the International Organization for Standardization. The standard divides the degree of corrosivity into 5 categories , C1 to C5, in order of increasing corrosivity. To find the right anti corrosion coating for steel, you need to know how corrosive the environment will be.For example, a coating at C5M level is intended for offshore constructions which are constantly exposed to moisture, but also for small pipes that are equally exposed.

  • 1 – very low corrosion risk: Heated buildings with clean air, interiors only.
    Suitable for: offices, schools, hotels, shops and other heated premises.
  • C2 – low corrosion risk: Unheated buildings, rural areas.
    Suitable for: storage facilities, sports halls, garages, barns and other unheated buildings.
  • C3 – moderate corrosion risk: Buildings with high humidity, urban and industrial areas.
    Suitable for: laundries, breweries, kitchens, food processing sites and other buildings with moderate humidity.
  • C4 – high corrosion risk: Chemical manufacturers and swimming baths, industrial and coastal areas.
    Suitable for: industrial buildings, chemical plants, swimming pools, ports, and ship- and boatyards.
  • C5 – very high corrosion risk: Buildings with almost permanent condensation, offshore and industrial areas.
    Suitable for: Water pipes and other industrial applications(C5I – industrial). Offshore and maritime constructions(C5M – marine).

Once you have identified your environment, you can identify the right coating systems for your project and the right anti corrosion coating specification to protect it for years to come.Following these guidelines will allow you to pick appropriate steel corrosion protection coatings, allowing you to avoid overspending on unnecessary degrees of protection or simply making the wrong choice.

(Video) Anti-Corrosion Coating

The 3 types of industrial steel corrosion protection coatings

Steel corrosion protection coatings can be divided into three categories:

The Right Anti Corrosion Coating for Steel | CoatingPaint.com (1)

Anti corrosion coating for steel can be applied as any other coating as long as it is a barrier or inhibitor coating.

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  1. Barrier coatings (C1 – C3)– non-porous coatings designed to prevent corrosive factors coming into contact with the substrate.
    For example: powder coating, polyurethane paint, chloro rubber paints, Teflon coatings, nano coatings.
  2. Inhibitor coatings(C1 – C4)– release a chemical which interferes with the electrolyte and stops the corrosion process.
    For example: all oil based coatings withcorrosion inhibitor additives such as zinc, aluminum, zinc oxide and so on.
  3. Galvanic coatings/Cathodic protection(C3 – C5)– metal-rich coatings which provide a sacrificial layer. Prevents corrosion by providing a more easily corroded metal (such as zinc) to be the anode to the protected metal’s cathode. Also called the sacrificial anode, this metal will corrode instead of the protected metal.

Note that cathodic protection can be applied as pre-treatment and topped with a barrier or inhibitor coating.

Applying anti corrosion coating for steel

The two most common methods for applying a industrial grade steel corrosion protection coatings are hot dip galvanization and thermal (metal) spraying:

  1. Hot Dippingis the process of immersing a metal in a bath of metal, often molten zinc, in order to form a coating. The liquid metal bonds to the substrate and forms an alloy, which is then coated in zinc as it is removed from the bath. Hot dip galvanizing uses the principle of cathodic protection, as the zinc coating acts as an anode to its substrate.
  2. Thermal (metal) sprayingapplies zinc or aluminum to a substrate by taking the metal in the form of a powder or wire and feeding it into a special spray gun. The metal is melted within the gun and can then be sprayed onto the substrate. It does not alloy, but instead works by coating the surface in overlapping metal platelets.

Duplex System – The best anti corrosion coating for steel

When hot dip galvanization is used together with a topcoat of steel corrosion protection coatings (liquid or powder) it is known as a Duplex System.The systemprovides multiple types of protection and the longest-lasting results.Each layer needs to be compatible in order for the system to work effectively. Duplex systems are especially suitable for corrosion categories from C3 to C5. A duplex system includes five protective coatings to prevent corrosion which all complement each other and result in one of the best corrosion protection coatings for steel.

The Right Anti Corrosion Coating for Steel | CoatingPaint.com (2)

Steel corrosion protection coatings are applied in layers.

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  1. Surface preparation:derusting, blasting, removing grease, oil, dirt for optimum adherence.
  2. Hot dip galvanizing OR an inhibitor coating primer; metal coatings to prevent corrosion are useddepending on the coating system of your choice.
  3. Applying a sealer:To seal the metal coating to prevent corrosion from getting too close. Often epoxy based.
  4. Intermediate coat:there may be several layers necessary for optimum protection, depending on the corrosion category.
  5. Finishing coat:provides appearance and surface resistance, often first line of defense.

Paint & Spray – Corrosion protection coatings for steel in small projects

For smaller substrates orDIY application up to category C2, painting is also an option. There are alsosmall anti corrosion spray paint cansavailable for this purpose. An anti corrosion spray can be described as an ultra thin fluid film compound which you can spray on any steel or metal surface. In spray form it can protect for up to a year.But keep in mind that more exposed areas that are getting constant abuse from rain and salt will need spraying regularly.In paint form, longer lasting results can be accomplisheddepending on the coating system you choose. For the best result always opt for two component protective coatings for steel with corrosion inhibitor additives, for example a zinc rich epoxy coating.

Steel corrosion protection coatings and service in the US

Here is a selection of products on the market to give you a rough guide as to the price of corrosion protection coatings for steel. Keep in mind thatfor categories C4 and C5 it is not recommended to apply the coating yourself.Please search out a specialist in that case. There are Federal branches that produce guidelines for specific applications, such as the Federal Highway Administration, US Department of Transport’s “Steel Bridge Design Handbook” which includes Corrosion Protection of Steel Bridges.

(Video) Advanced Anti-Corrosion Coating

PRODUCTSteel corrosion protection coatingCategory
Jotun Jotamastic 90Barrier coating: Epoxy coating for above and below water, on concrete or steel, with abrasion and chemical resistance.C1 – C3
Jotun Barrier 90Inhibitor coating: Zinc-rich epoxy containing 90% zinc. Suitable for above water and on steel, with abrasion and water resistance.C1 – C4
Hempel GalvosilCathodic protection: two-component, solvent-borne, self-curing, inorganic zinc silicate with outstanding resistance against weathering and abrasion.C3 – C4
Hempel HempadurInhibitor coating: two-component, epoxy based. It cures to a flexible, well-adhering coating with good abrasion and impact resistance. Contains zinc phosphateC3 – C4
Ultrimax 1Inhibitor coating: Contains zinc phosphate anti-corrosive properties and a high volume of solids. C1 – C3

Rely on a professional when applying anti corrosion coating for steel!

If you are looking for a professional company to apply the steel corrosion protection coatings for you, it’s important to understand how prices are established before you request a quote. Different coating processes use different methods to calculate the cost of professional application.Hot dip galvanizing prices are usually calculated by weight. The galvanizer will quote a price per ton, and then use the weight of your steelwork aftergalvanizing to calculate the final cost. Unlike galvanizing,powder coating pricestend to be calculatedby size or surface area.

Regional differences in materials, labor, and equipment can all have an impact on overall costs when contracting a coating expert. If you want to receive a custom made quote for anti corrosion coating for steel, please contact us.

FAQs

Which coating is best for steel? ›

Epoxy coatings are one of the most widely used steel coatings in industrial and marine markets. Epoxies are known for having excellent adhesion to steel and provide good chemical resistance. They are also often sold as “surface tolerant”, which means they will adhere well to surfaces with minimal surface preparation.

Which coating is best for corrosion resistance? ›

Epoxy. If you need protection against rust, epoxy coatings are highly effective. These coatings are sometimes applied at a 4 to 6 mm thickness. However, sometimes a thicker application of 8 mm may be used in situations where rust is highly likely to occur.

What is the corrosion protection for steel? ›

Zinc is a great choice in protecting steel, as not only does it corrode in preference to the steel, the rate of corrosion is generally slower. This rate, however, is accelerated in the presence of ions such as chlorides in coastal locations.

What are the 3 corrosion protection methods? ›

The zinc oxidizes when it is exposed to air creating a protective coating on the metal surface.
  • Alloying. It is the method of improving the properties of a metal by mixing the metal with another metal or nonmetal. ...
  • Painting. ...
  • Greasing/Oiling.

What is the coating on new steel? ›

Black oxide or blackening is a conversion coating for ferrous materials, stainless steel, copper and copper based alloys, zinc, powdered metals, and silver solder. It is used to add mild corrosion resistance, for appearance, and to minimize light reflection.

What is corrosion resistant coating? ›

Corrosion-resistant coating is applied on metal parts for the purpose of preventing corrosion. This type of coating can be made from substances such as zinc or iron and can be applied as a base layer, primer or topcoat through various techniques.

How does corrosion coating work? ›

Corrosion coating is the process of covering a surface or substrate with another substance to temporarily or permanently protect it from deterioration or degradation as a result of its reaction with the environment or corrosive agents.

Which is a anti corrosive metal? ›

Stainless steel. Aluminum metal. Copper, bronze, or brass. Galvanized steel.

How many types of coating are there? ›

Coatings are varied, but primarily fall into three categories: Architectural, Industrial, and Special Purpose.

How do you remove coating from steel? ›

How To Remove Galvanization From Steel - YouTube

How do you make mild steel corrosion resistant? ›

Mild steel does not have a high resistance to corrosion in its untreated form, however, the corrosion resistance can be greatly improved by applying an appropriate surface protection product to the exposed parts of any project.

What are four types of coatings? ›

Here, we'll describe the benefits and tradeoffs of four of the most common generic coating types: Epoxies, polyurethanes, polysiloxanes and zinc-rich primers, providing examples of how each might be used in a total coating system.

How do coatings prevent corrosion? ›

Protective Coating

Rubber paints are the most effective because they act as a barrier that prevents the metal's chemical structure from interacting with environmental compounds like water and oxygen that result in corrosion. Applying a powder coat is another effective method of corrosion prevention.

How can we make anti corrosive coating? ›

Anti-Corrosion Coating - YouTube

What are the 6 main types of corrosion? ›

6 Types of Corrosion That Take Some Examination To Accurately...
  • Erosion Corrosion. Erosion corrosion occurs when a corrosive fluid runs past a metal surface. ...
  • Intergranular Corrosion. ...
  • Fretting Corrosion. ...
  • Cavitation Corrosion. ...
  • De-Alloying (Selective Leaching) ...
  • Exfoliation Corrosion.
Apr 24, 2017

What is the most common form of corrosion? ›

Galvanic corrosion is the most common and impactful form of corrosion. It occurs when two dissimilar (different) metals are in contact in the presence of an electrolyte.

Is corrosion and rusting same? ›

Rusting is a part of corrosion and is a chemical process which results in the formation of red or orange coating on the surface of metals. Corrosion can occur on different surfaces such as skin, wood, metals, etc. Rusting usually occurs on surfaces of iron and its alloys.

Why coating is needed? ›

They prevent corrosion.

Rust or other corrosive debris is another issue that often pops up in industrial applications. Often the materials that are hard enough to actually build machinery from are also very likely to corrode over time.

What is epoxy coating for steel? ›

What Is Epoxy Coating? Epoxy coating is a thick, protective material used to preserve carbon steel tanks from any exterior deterioration. Although Zwirner Equipment uses epoxy coating for carbon steel tanks, it is well known to be used for industrial concrete floors because of its extreme durability.

What do you use to coat metal? ›

6 Best Clear Coats for Metal
  • EverBrite 4 Oz. Clear, Protective Coating for Metal. ...
  • KBS Coatings DiamondFinish. ...
  • ProtectaClear Clear, Protective Coating for Metal. ...
  • Spraymax 2K High Gloss Spray Clear Coat. ...
  • Krylon Colormaster Metal Spray-Paint. ...
  • Krylon COVERMAXX Spray Paint.
Mar 7, 2022

What is coated steel? ›

Coated steels are steel sheets that have a metallic and/or non-metallic coating to prevent rust and corrosion that humidity and contamination can cause on the steel. Coated steel has an extra layer of metal, paint, or both to protect it from rust and wear.

How many types of coating are there? ›

Coatings are varied, but primarily fall into three categories: Architectural, Industrial, and Special Purpose.

What is the coating on raw steel? ›

The most popular coatings are waxing, galvanising, powder coating and clear coating.

What type of metal is commonly used to reduce rusting and corrosion? ›

The most common example of cathodic protection is the coating of iron alloy steel with zinc, a process known as galvanizing. Zinc is a more active metal than steel, and when it starts to corrode it oxides which inhibits the corrosion of the steel.

Will clear coat keep metal from rusting? ›

Clear coats seal the rusted metal, inhibit rust formation, and offer protection against UV rays as well. They can come in handy in the following scenarios: Extend the lifespan of metallic outdoor or indoor structures such as gates, railings, bathroom fixtures.

Does coated steel rust? ›

Powder-coated steel is highly resistant to rust in most cases, so it won't develop unsightly rust patches or leave red streaks on a patio or building facade. However, if it sustains damage, small cracks in the coating may appear, admit moisture and allow rust to form.

Why does steel need to be coated? ›

Corrosion begins from the exposed surface and damages the material layer by layer. A layer of coating will be more protective. It can keep the base metal from corrosion, chemical damage, and UV light to prolong its service life.

Can stainless steel be coated? ›

However, there are instances that may require stainless steel to have additional coatings to improve the corrosion-resisting properties of equipment. Stainless steel coatings can increase the lifespan and serviceability of stainless steel equipment by up to 60 percent.

What are four types of coatings? ›

Here, we'll describe the benefits and tradeoffs of four of the most common generic coating types: Epoxies, polyurethanes, polysiloxanes and zinc-rich primers, providing examples of how each might be used in a total coating system.

What are the two types of coatings? ›

Coatings are specified as organic or inorganic according to the nature of their binder. Organic coatings are those that have an organic binder. Inorganic coatings are those that have an inorganic binder such as a silicate.

What is the importance of coating? ›

They prevent corrosion.

Rust or other corrosive debris is another issue that often pops up in industrial applications. Often the materials that are hard enough to actually build machinery from are also very likely to corrode over time.

Learn all about Anti Corrosion Coating and how to choose the right anti rust treatment for your needs ➤ Find industrial products + specialists in the UK!

Whether corrosion is due to moisture, chemicals, salt spray, or oxidation, anti rust coating for steel and metal can help protect the substrate from the elements.. Repels water & other fluids (in case of barrier coatings) Fends off fungi, algae, and moss Weather protection against acid rain, salt water, ice and so on Chemical resistance Plus, depending on the types of anti corrosive paints you opt for: anti fouling, non slip or self cleaning properties. The standard divides the degree of corrosivity into 5 categories , C1 to C5, in order of increasing corrosivity.. C3 – moderate corrosion risk: Buildings with high humidity, urban and industrial areas.. C5 – very high corrosion risk: Buildings with almost permanent condensation, offshore and industrial areas.. The types of anti corrosive paints can be divided into three categories:. Galvanic coatings/Cathodic protection (C3 – C5) – metal-rich anti rust coating for steel which provide a sacrificial layer.. The two most common methods for applying a industrial grade metal anti corrosion coating are hot dip galvanisation and thermal (metal) spraying:. Hot Dipping is the process of immersing a metal in a bath of metal, often molten zinc, in order to form a coating.. The liquid metal bonds to the substrate and forms an alloy, which is then coated in zinc as it is removed from the bath.. Hot dip galvanisation OR applying an inhibitor coating primer depending on the coating system of your choice.. Intermediate coat: several layers may be necessary for optimum protection, depending on the corrosion category and the chosen anti rust paint.. An anti corrosion coating spray can be described as an ultra thin fluid film compound which you can spray on any steel or metal surface for an anti rust treatment.. Different coating processes use different methods to calculate the cost of professional application.

What is High Corrosion Protection and how to avoid corrosive damage in a steel structure? Read this article for more details about HCP and possible coatings.

The surface of steel frames must usually be protected to avoid corrosive damage during the required lifetime.. Sikla components with the HCP protection system are assigned to corrosivity category C4 long (complying with the requirements of DIN EN ISO 12944-2).. Hot Dip Galvanizing - HDG (DIN EN ISO 1461). A proven and well-known corrosion protection coating, which is used in categories up to C4 and C5.. 10 times more corrosion resistance than HDG The corrosion resistance of zinc-nickel coatings is around 10 times higher than that achieved with hot dip galvanising.. The layer thickness of 5 to 15 µm is also significantly reduced in comparison to hot dip galvanised components, since the resistance to corrosion is much better .

Safeguarding structural steelwork with the correct corrosion protection system will give a steel frame a long life and reduce ongoing maintenance costs. NSC provides some key facts regarding the use and application of paint coatings and hot-dip galvanizing. Paint systems for steel structures have developed over the years to comply with industrial environmental legislation and […]

In general the corrosion protection afforded by a paint film is directly proportional to its dry film thickness.. A Paint System Protective paint systems usually consist of primer, intermediate/build coats and finish coats.. Primers are applied directly onto the cleaned steel surface, or in the case of duplex systems, the sealed metal coating, to wet the surface, to provide good adhesion for subsequently applied coats and to provide corrosion inhibition.. Intermediate coats are applied to ‘build’ the total film thickness of the system.. Metallic Coatings There are four commonly used methods of applying metal coating to steel surfaces.. Since hot-dip galvanizing is a dipping process, there is obviously some limitation on the size of components that can be galvanized.. Duplex coatings For many applications, hot-dip galvanizing is used without further protection.

There's no end of variety in surface coatings, not all are equal. Each method has unique challenges and suitability - we've reviewed 5 popular techniques in this article.

Lightweight metals have emerged as the go-to choice in a wide range of industries.. Selecting the right corrosion resistance method is essential to a successful component design and manufacture.. Ultimately, for materials that require certain aesthetic qualities whilst remaining highly resistant to corrosion whilst in contact with liquids, anodisation is not the best method of corrosion resistance improvement.. This provides high corrosion resistance and retains subsequent coatings well.. Paints provide a relatively inexpensive method of increasing corrosion resistance.

Videos

1. Anti Corrosive Coatings
(Avanti Paints & Chemicals)
2. √ The Decent Corrosion Protection for Steel Explained with Fair Examples. Watch this video to find!
(iitutor.com)
3. Specialist workshop on Zinc anti-corrosion coatings
(CreamerMedia)
4. Industrial Coating System to Prevent Corrosion for 10 Years
(Professional Piping Systems)
5. Corrosion Resistant Coating that Alloys Steel | EonCoat
(EonCoat)
6. Gentoo Anti-Corrosion Coating
(UltraTech International, Inc.)

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