Cortec® coating system helps automotive manufacturer postpone equipment replacement and achieve estimated savings of millions of dollars.
Replacing corroded industrial equipment can represent a substantial capital investment, particularly in large manufacturing facilities where multiple units operate simultaneously. A recent case study released by Cortec® Corporation demonstrates how a targeted water-based anticorrosion coating system enabled an automotive manufacturer to extend the service life of its air supply units by 10 years, avoiding premature replacement and generating estimated savings of millions of dollars.
The automotive manufacturer operated more than 100 rooftop air intake units supplying compressed air to paint spraying systems. Over time, corrosion had developed on the galvanised steel surfaces, raising concerns about equipment deterioration and the potential need for costly replacements.
Seeking to postpone replacement by five to 10 years, the manufacturer selected a water-based corrosion protection system developed by Cortec®. The corrosion protection strategy involved three complementary products, each designed to address specific surface conditions and provide long-term protection.
- The first step consisted of treating corroded areas with CorrVerter®, a water-based rust-converting primer
formulated to adhere to deteriorated metal surfaces where the original galvanisation had failed.
- Areas where the galvanised coating remained intact were treated with VpCI®-373, a wash primer
designed to promote adhesion on galvanised steel and other plated surfaces.
- Finally, VpCI®-395 Aluminum, a two-component waterborne epoxy coating formulated for demanding indoor environments, was applied as the protective topcoat. Its metallic finish provided the treated surfaces with a uniform appearance.
This combination allowed the manufacturer to address both existing corrosion and the protection of remaining galvanised surfaces without immediately replacing the equipment. According to Cortec®, the coating system enabled the automotive manufacturer to postpone replacement of its air supply units for an additional 10 years.
The extended service life reportedly translated into estimated savings of millions of dollars in premature equipment replacement costs. Beyond the financial benefits, the case illustrates the potential role of protective coatings in industrial asset management, where maintenance decisions must balance equipment reliability, operational continuity and capital expenditure.
Industrial ventilation systems and metal equipment are continuously exposed to conditions that can accelerate corrosion. Moisture, airborne chlorides, aggressive chemicals and manufacturing fluids may gradually compromise protective surfaces, including galvanized steel.
Regular inspections and timely maintenance are therefore essential for identifying early signs of deterioration and determining whether equipment requires restoration or replacement. When corrosion is detected before structural or functional integrity is seriously compromised, suitable protective coating systems can offer an alternative to immediate replacement.
The automotive manufacturer's experience demonstrates how water-based anticorrosion technologies can support a more cost-effective approach to industrial maintenance, extending asset service life while helping facilities optimise their maintenance budgets.