Combat Corrosion Costs …and win!

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Combat Corrosion Costsand win!

• By Frank Garber
• U.S. Environmental Resources

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Background

• Frank Garber holds a Masters degree in Physical
  Chemistry from the University of Iowa
• He served as an Assistant Professor of Chemistry
  for seven years before entering into the private
  sector.
• He has been an industrial chemical consultant for
  major US companies.
• He is the inventor and patent holder for several
  deicer corrosion inhibition formulations.
• In 1999, Mr. Garber founded the company U.S.
  Environmental Resources whose primary research is
  directed toward environmental issues including
  deicer corrosion inhibition, agricultural and
  industrial odor abatement and fossil fuel
  combustion enhancement.

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Summary

• How much does corrosion really cost?
• What is corrosion?
• What causes corrosion?
• What can be done to prevent corrosion?
• Benefits of using an anticorrosive deicer /
  anti-icer.
• Conclusion

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How much does corrosion really cost?
Motor Vehicles
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How much does corrosion really cost?

• Motor Vehicles1 23.4 Billion per year
  safety issues

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Motor Vehicles 23.4 Billion

• Increased manufacturing cost to improve corrosion
  resistance, 2.5 Billion
• Repairs and maintenance necessitated by
  corrosion, 6.5 Billion
• Corrosion related depreciation, 14.4 Billion
• Reduced safety in automobiles due to corrosion.

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Motor Vehicles
Depreciation example1
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How much does corrosion really cost?
Highways and Bridges
Before
After
Silver Bridge Collapse December 15, 1967 in
Kanauga, OH
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How much does corrosion really cost?

• Highways Bridges1 8.3 Billion per year
  safety issues

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Highways Bridges

• 583,000 bridges in the US1
• 15 are structurally deficient primarily due to
  corrosion of steel and reinforcements1
• Annual direct cost 8.3 Billion1
• Indirect costs may exceed 83 Billion2

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Highways Bridges

• UK Transportation Research Laboratory estimates
  damage from salt to vehicles, pavement, and
  environment at 297 Million per winter3
• For every 1 spent on winter maintenance, approx.
  8 is saved in the reduction of winter-related
  traffic accidents and delays3

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Highways Bridges

• The true cost of salt used for deicing roads is
  estimated at more than 800 per ton in the United
  States4!
• Estimated that bridges exposed to deicing salt
  have an avg. life expectancy of 15 18 years4
• Bridges in low/no salt environment have an avg.
  life of 100 years4

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What is corrosion?
Stress Corrosion Cracking
General Surface Corrosion
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What is corrosion?

• Corrosion is the deterioration of a material,
  usually a metal that results from a reaction with
  its environment. Over a period of time the
  components of a bridge may deteriorate to the
  extent that the bridge is no longer safe5.

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What is corrosion?
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What causes corrosion?
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What causes corrosion?
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What Causes Corrosion?

• Most common cause of bridge corrosion is the use
  of deicing salts5
• When a bridge is first built, concrete protects
  its steel reinforcement2
• Over time chlorides from deicers permeate the
  concrete and depassivate the steel2
• Once started, corrosion is self-sustaining. As
  steel corrodes, the byproducts occupy 3 6 times
  the original space of the steel resulting in
  concrete cracking, delaminating, and spalling.
  This further speeds up the corrosion process2.

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Time Lapse Video of Corrosion
Anderson
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What can be done to prevent corrosion?
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What can be done to prevent corrosion?

• Design the structure with corrosion prevention
  in mind
• Application of protective coatings, membranes,
  and protective sealers
• Use of direct electrical current and sacrificial
  materials to mitigate corrosion on reinforced
  concrete and bridge decks - "cathodic protection"
  
• Use of corrosion inhibitors

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What can be done to prevent corrosion?

• Protective Coatings

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What can be done to prevent corrosion?

• Protective Coatings
• Corrosion Resistant Alloys

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What can be done to prevent corrosion?

• Protective Coatings
• Corrosion Resistant Alloys
• Cathodic and Anodic Protection

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What can be done to prevent corrosion?

• Protective Coatings
• Corrosion Resistant Alloys
• Cathodic and Anodic Protection
• Use of Corrosion Inhibitors

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Benefits of using an anticorrosive deicer /
anti-icer

• Huge short and long term capital cost savings
• Safer bridges, highways, and vehicles

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Benefits of using an anticorrosive deicer /
anti-icer

• Estimate of annual cost of corrosion Direct
  cost is 31.7 Billion, Indirect cost is 83
  Billion plus safety issues and costs including
  legal medical and lost productivity.
• U.S. Uses 17.4 million tons of deicing salt per
  yearCanada uses 6.8 million tons
• Assuming 30 per ton investment for effective
  corrosion inhibition
• Estimate of annual cost savings by reducing
  corrosion on automobiles and highways
• 10 reduction 11.4 Billion (22 to 1 ROI)
• 20 reduction 22.8 Billion (44 to 1 ROI)
• 30 reduction 34.2 Billion (66 to 1 ROI)

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Conclusion

• Cost of Corrosion
• 31.7 Billion direct costs due to corrosion of
  Bridges, Highways, and Vehicles
• 83 Billion indirect cost due to traffic delays
  and lost productivity
• Reduction in life expectancy of bridges from 100
  to 15-18 years
• High cost of reduced safety
• Solutions to Corrosion
• Protective Coatings
• Corrosion Resistant Alloys
• Cathodic and Anodic Protection
• Use of Corrosion Inhibitors

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References

• 1. FHWA funds Cost of Corrosion Study CORROSION
  COSTS AND PREVENTIVE STRATEGIES IN THE UNITED
  STATES Report by CC Technologies Laboratories,
  Inc. to Federal Highway Administration (FHWA),
  Office of Infrastructure Research and
  Development, Report FHWA-RD-01-156, September
  2001.
• 2. Robert Ross and Marc Goldstein, Better Roads
  Magazine, August 2003
• 3. Thornes, J. E. An Estimate of the Economic
  Benefits of Winter Road Maintenance in the UK. In
  Proc., Cold Comfort 4th Annual Winter
  Maintenance Conference and Exhibition.
  Nottingham, UK, 1995.
• 4. Vitaliano, D. F. An Economic Assessment of the
  Social Costs of Highway Salting and the
  Efficiency of Substituting a New Deicing
  Material. Journal of Policy Analysis and
  Management, Vol. 11, No. 3, 1992, pp. 397418.
• 5. The National Association of Corrosion
  Engineers, white paper, http//www.nace.org/nace/c
  ontent/publicaffairs/media/bridge.asp

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Questions?

• Frank Garber
• U.S. Environmental Resources
• www.usenvres.com
• Email 060749_at_comcast.net
• [phone]