Rustproofing– Product History

The need for specific rust proofing formulas

The rusting of steel and the corrosion of alloys and other metals, changes the nature of the initial product, creating waste.
These changes include:

1. Change in size and surface contour i.e on beams or machined surfaces
2. Reduction of strength e.g Frames or Bridges
3. Unsightly appearance
4. Adverse effect on the price of programmed maintenance painting
5. Loss of utility
6. Ultimate destruction requiring complete replacement

The rusting/corrosion mechanism

Broadly speaking this is a process of slow or rapid oxidation (change of state)
The most common contributing factors are:

1. Oxygen in the air
2. Presence of excessive humidity in the air or presence of water.This may be geographic but is more commonly an output of the processes the structure encloses
3. Corrosive chemicals in the atmosphere.These may be natural (volcanic) , urban acid rain or production process related.
4. Stray electrical currents
5. Combinations of the above

Usually rusting is a reddish brown, but other colours are possible due to a variety of chemical reactions other than oxidation.Stray currents usually produce pitting

The origin of Goldseal Industrial Rust Proof Formulas

In the 1940’s estimates of losses due to corrosion in America ran at $10 billion per year in losses and replacement. Demand from theatres of war for machinery and lack of covered storage, meant much machinery arrived in an unusable condition. Funds were made available for a serious research effort initially focusing on rail toad assets. The brief developed for this program was simple but the pathway to results was demanding.

The brief called for:

1. A product that was easy to apply, by all normal application techniques to optimize end use
2. Safety during application was important. Minimal preparation and lack of catalysts, toxic solvents, curing times and temperature sensitivity was desired.
3. Maximise the protection of surfaces against all causes of rust
4. Good penetration of existing rust and scale with minimal cleaning requirements, particularly in hard access areas .
5. Aid mobility of moving parts and disassembly
6. Easy removal (by common degreasers or simple solvents like Kerosine) for maintenance painting or welding ( without release of toxic fumes).

Rust – Taming The Silent Destroyer

Over a period of 4 years, two in the laboratory and 2 in the field, 313 different products were formulated using 74 different raw materials.
In the course of this many new test methods had to be developed, as common test methods were found wanting
During field trials the final contenders were adjusted for application characteristics.
Vast amounts of military equipment stored outside and shipped into all climatic environments allowed rapid evaluation of the final formulas.
Major bridges in America were coated, such as the James Town Highway Bridge on Rhode Island, the T&NC Railroad bridge in Houston Texas and the Santa Fe Railroad Bridge in Wentworth Chicago were coated, as paints of the day were only lasting a few years.

An Optimised Formula for cost effective corrosion control

The formulas that outperformed all others were based on a relatively viscous, non hardening material that is smooth , soft and readily workable at summer temperatures
They produce a firm, self healing, penetrating, slightly lubricating , non hardening film.
The formulas could be thinned with non toxic solvents, could be heated without damage for different applications, are easily cleaned off with common degreasers or petroleum based spirits and could even be hand applied to pipe sections (sprinkler systems) and wire cables without overspray loss or control.

The Trade off?

Not suitable as floor coatings
Not suitable for walls and frames in high traffic areas
Not suitable on high temperature surfaces such as exhausts or smoke stacks

The Goldseal Industrial Rust Proof Compound

The formula is a direct descendant of that research which has been optimized for use in Pacific rim countries.
The product is applied hot producing a semi transparent film with a high flash of 440 deg F (207 deg C).
Corrosion inhibitors are carried into the steel surface while hot.The coating sets up immediately to provide a high build, self healing coating that can be coloured to suit different end uses.

The initial research showed that these compounds (neither a paint nor a grease) can be applied with little or no surface preparation to scaled or prepainted steel surfaces.A thick application will penetrate heavy scale, protecting the sound steel underneath and commonly cause large scale to fall off. Hand reinforcement of the compound at that point is then simple..if necessary. The most economical and effective method of application was found to be manual cleaning, scraping or descaling.The compound is usually spray applied in a single high build coat to produce a barrier to moisture, air, salt deposits and other chemicals.Sand or bead blasting was not found to be a prerequisite to performance or service life.

For deck cargo and machinery in exposed conditions , the surfaces were found to need wiping but did not actually have to be dry.This was found to be a distinct advantage in refrigeration units, coils and in cool store environments or other processes creating condensation

Over the last 40 years more technical coatings have evolved but for lack of preparation, predictable performance and long service life in extreme conditions Goldseal Industrial Rustproof still excels.

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