Make the right choice of anti corrosion coating from the start
Anti corrosion coating acts as a barrier between a metal and its environment, increasing its durability and lifespan. The estimated global cost of metal corrosion damage is billions of rupees. The good news is, a lot of this loss can be prevented by being proactive, and choosing the right anti corrosion coating from the start.
To determine the right anti corrosion coating for your project, it is important to factor in the environment and type of metal. 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.
In this article we will take a look at the multi-functional nature of anti corrosion coatings for steel, explain the corrosion categories and identify anti rust coatings suitable for each category. Here you will also find manufacturers, products and services in Pakistan.
Anti corrosion coating is more than rustproof
Anti corrosion coating is essentially a collective name for various types of coatings that protect a substrate from corrosion. An anti corrosion paint can do more than just protect from corrosion, and its multi-functional nature means you can find the exact coating you require. Corrosion is caused by a chemical reaction between a metal and its environment (water or other fluids), typically producing an oxide or a salt of the original metal. The long and the short of it is the metal is weakened, as is the structure it creates. A corrosion resistant coating prevents direct contact between water/fluids and the steel substrate and therefore prevents the corrosion process.
In general anti corrosion coating is suitable for almost any type of steel and metal, and has the following benefits:
- 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
- Additional properties depending on your needs
Define the required corrosion resistance to pick the best anti rust coating
To determine the right type of anti corrosion paint 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 standardised by the International Organisation 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, 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.
- C1 – 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).
The 3 types of anti corrosive paints for industrial steel protection
Once you have identified your environment, you can identify the right anti rust treatment for your project and the right anti rust coating specification to protect it for years to come. Following these guidelines will allow you to pick appropriate anti-corrosion coatings, allowing you to avoid overspending on unnecessary degrees of protection or simply making the wrong choice.
Anti corrosion coating types can be divided into three categories:
|Coating type & category||Explanation||Examples|
|Barrier coatings (C1 – C3)||non-porous anti rust coatings designed to prevent corrosive factors coming into contact with the substrate||powder coating, polyurethane paint, chloro rubber paints, Teflon coatings, nano coatings|
|Inhibitor coatings (C1 – C4)||anti rust treatment which releases a chemical that interferes with the electrolyte and stops the corrosion process||all oil based coatings with corrosion inhibitor additives such as zinc, aluminium, zinc oxide and so on|
|Galvanic coatings/Cathodic protection (C3 – C5)||metal-rich anti rust coating for steel 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||galvanizing and thermal spray|
Anti rust treatment by dipping or spraying
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 galvanising uses the principle of cathodic protection, as the zinc coating acts as an anode to its substrate.
- Thermal (metal) spraying applies zinc or aluminium 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 treatment for steel
When hot dip galvanising is used together with a topcoat of anti corrosion paint or powder it is known as a Duplex System. The duplex systems are applied as anti rust coating for steel and occasionally other metals.
This type of anti rust treatment provides multiple types of protection and the longest-lasting results. Each layer needs to be compatible in order for the system to work effectively. Duplex anti rust coating systems are especially suitable for corrosion categories C3 to C5.
Anti corrosion coating manufacturers – the big players in Pakistan
Anti corrosion coating is a common product which also belongs to the portfolios of most multinational coating manufacturers. Here below you can find a list of those also having business units in Pakistan.
|Anti corrosion coating manufacturer||Address (Pakistan)|
|Jotun Pakistan (Pvt.) Ltd.||2 KM Defence Road, off 9 Km Raiwind Road,، Defence Road, Lahore, Punjab 54770|
|AkzoNobel Pakistan||346, Ferozepur Road, P O Box 273, Lahore 54600|
|Hempel Marine and Commercial Services (Pvt) Ltd.||9C First Commercial Lane Zamzama,, Phase 5, D.H.A., Karachi 75600|
|Berger Paints Pakistan||Street 36, Quaid-e-Azam Industrial Estate Quaid e Azam Industrial Estate, Lahore, Punjab|
|Kansai Paint||11 – CCA, Phase V, Defense Housing Authority, Lahore|
Anti rust coating products from top manufacturers
Here is a selection of products on the market to give you a rough guide as to the anti corrosion paint availability. Keep in mind that for categories C4 and C5 it is not recommended to apply the anti corrosions coating yourself. Please search out a specialist in that case.
|PRODUCT||Anti corrosion coating TYPE||Corrosion Category|
|Jotun Jotamastic 90||Barrier coating: Epoxy coating for above and below water, on concrete or steel, with abrasion and chemical resistance.||C1 – C3|
|Jotun Barrier 90||Inhibitor coating: Zinc-rich epoxy containing 90% zinc. Suitable for above water and on steel, with abrasion and water resistance.||C1 – C4|
|Hempel Galvosil||Cathodic protection: two-component, solvent-borne, self-curing, inorganic zinc silicate with outstanding resistance against weathering and abrasion.||C3 – C4|
|Hempel Hempadur||Galvanising coating: two-component, epoxy based. It cures to a flexible, well-adhering coating with good abrasion and impact resistance. Contains zinc phosphate||C3 – C4|
|Ultrimax 1||Inhibitor coating: Contains zinc phosphate anti-corrosive properties and a high volume of solids.||C1 – C3|
Anti corrosion paint services and prices
If you are looking for a professional company to apply the anti corrosion coating 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 galvanising prices are usually calculated by weight. The galvaniser will quote a price per tonne, and then use the weight of your steelwork after galvanising to calculate the final cost. Unlike galvanising, powder coating prices tend to be calculated by size or surface area.
Regional differences in materials, labour, and equipment can all have an impact on overall costs when contracting an anti rust coating expert. If you wish to receive a custom made quote for your anti corrosion paint project, please contact us by sending an email or a message through clicking the ‘request a quote’ button below.