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Combat Corrosion Costs …and win!

Combat Corrosion Costs …and win!. By Frank Garber U.S. Environmental Resources. 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.

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Combat Corrosion Costs …and win!

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  1. Combat Corrosion Costs…and win! By Frank Garber U.S. Environmental Resources

  2. 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.

  3. 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

  4. How much does corrosion really cost? Motor Vehicles

  5. How much does corrosion really cost? • Motor Vehicles1: $23.4 Billion per year + safety issues

  6. 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.

  7. Motor Vehicles Depreciation example1

  8. How much does corrosion really cost? Highways and Bridges Before After Silver Bridge Collapse December 15, 1967 in Kanauga, OH

  9. How much does corrosion really cost? • Highways & Bridges1: $8.3 Billion per year + safety issues

  10. 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

  11. 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

  12. 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

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

  14. 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.

  15. What is corrosion?

  16. What causes corrosion?

  17. What causes corrosion?

  18. 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.

  19. Time Lapse Video of Corrosion Anderson

  20. What can be done to prevent corrosion?

  21. 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

  22. What can be done to prevent corrosion? • Protective Coatings

  23. What can be done to prevent corrosion? • Protective Coatings • Corrosion Resistant Alloys

  24. What can be done to prevent corrosion? • Protective Coatings • Corrosion Resistant Alloys • Cathodic and Anodic Protection

  25. What can be done to prevent corrosion? • Protective Coatings • Corrosion Resistant Alloys • Cathodic and Anodic Protection • Use of Corrosion Inhibitors

  26. Benefits of using an anticorrosive deicer / anti-icer • Huge short and long term capital cost savings • Safer bridges, highways, and vehicles

  27. 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)

  28. 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

  29. 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. 397–418. 5. The National Association of Corrosion Engineers, white paper, http://www.nace.org/nace/content/publicaffairs/media/bridge.asp

  30. Questions? • Frank Garber • U.S. Environmental Resources • www.usenvres.com • Email: 060749@comcast.net • (612) 889-9171

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