A brief discussion on the factors affecting anti-corrosion costs

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This post was last edited by Wang Wei2 on 2023-8-22 at 11:59. A brief discussion on the factors affecting anti-corrosion costs: With the development and application of high-tech coating products, choosing the appropriate anti-corrosion coatings can reduce coating costs and extend the lifespan of the coating film, thereby saving on investment expenses. 1. Coating cost The coating cost includes the cost of the paint, the cost of applying it, and the cost of pre-treatment. 　　When considering the comparison of coating costs, the unit price of the coating is merely an intuitive factor affecting it; it is the solid content (volume) that represents the true cost of the coating. Solid volume refers to the proportion of volume occupied by the substances that can cure into a film in solvent-based coatings. The higher the solid volume, the larger the coating area that can be covered with the same film thickness; there is a direct proportional relationship between them. This can be calculated using the formula: Theoretical coverage area (m2/L) = [Solid volume (vs%) x 10] / [Dry film thickness (μm)]. Note: The solid content is expressed as a weight percentage, and when calculating it, the weight of the solid components must be converted into solid volume. 　　The coating has a high solid content and a high coating efficiency, which allows for a reduced amount of coating to be used ； A single application results in a thicker film, which reduces the number of applications and painting costs; it also shortens the interval between repaints, thereby improving work efficiency. 　　Among the coating costs, the cost of pre-treatment accounts for the largest proportion. When conventional anti-corrosion coatings and high-performance anti-corrosion coatings are used, the required rigorous surface treatment results in pre-treatment costs that are higher than the sum of the coating cost and the application cost; these pre-treatment costs account for over 60% of the total coating cost. Therefore, choosing high-performance anti-corrosion coatings that require minimal surface treatment – allowing painting on rusted or wet surfaces – can significantly reduce pre-treatment costs, which is a key factor in lowering the overall coating cost. 2. Extending the lifespan of the coating film The lifespan of the coating film is an important factor affecting corrosion prevention costs. 　　For conventional coatings or high-performance anti-corrosion coatings that require strict surface treatment, in practical use, due to the structure of the equipment components or the conditions of the installation environment, sandblasting for rust removal can be inconvenient, or it may inadvertently leave behind risks of corrosion ； Or due to changes in climate humidity, there may be imperceptible dew or rust formation on the surface of the substrate, leading to a rapid cycle of rusting even after painting. If the pre-treatment is not done properly, it significantly reduces the lifespan of the coating layer. There are countless large and small anti-corrosion repairs required each year, costing hundreds of thousands to millions of yuan. Many manufacturing companies also have to suspend production for these repairs, resulting in additional economic losses. Therefore, throughout the entire lifetime of the equipment components, the direct and indirect costs associated with anti-corrosion measures are extremely high. 　　With the development and successful application of high-performance anti-corrosion coatings that can be applied with rust and in wet conditions, these products effectively address the problem of corrosion caused by residual rust or re-rusting, as well as the issue of moisture causing internal corrosion to the coating under various environmental conditions. This makes anti-corrosion coating applications simpler and easier in different environments, facilitates ensuring the quality of the coating application, and guarantees a long-lasting anti-corrosive lifespan for the coating film. Compared to maintenance once a year, performing maintenance only every few years can save substantial costs associated with anti-corrosion measures, and it also avoids the economic losses resulting from production interruptions due to maintenance – having a very significant impact on a company’s profitability.