Varnish, Wax and Underbody Coating: This Is How We Test Products For Area Protection

Because we want tests to be realistic we almost always conduct tests using already rusty metal sheets. To get an even layer of oxidation we only use sand-blasted sheets.

The sand-blasted sheets are fastened on a rack and are weathered for several months according to a standardized procedure defined by DIN (German Institute for Standardization).

Half a year later: after weathering the testing sheets look like this: they are evenly corroded on both sides.

When we are in a great hurry we use our “corrosion turbos”: these are altered dishwashers. With the sheets inside they run permanently for about a week. Of course we do not use detergent and cleaning salts. Using this procedure, corrosion builds up even faster.

Testing sheets for a new test: Quite a lot of corrosion, isn’t it?

We see corrosion damage like this on ships, industrial facilities, and on the underbody of cars almost every day! And this is the reason why we treat out testing sheets like that: We want realistic testing conditions!

Now we will show you what follows next. Before the corroded testing sheets are coated the rough rust has to be removed.

As in practical use only rough rust is taken off: The corrosion is not removed completely. The rust remains in the steel!

The test we show you now is about proving that the products work on very strong corrosion as well: instead of a steel brush we use a simple brush with pig’s bristles for “cleaning”!

For the employees in our company this is noting new: we have been working like this for many years.

Only the upper surface of the sheets matters for the test. To prevent corrosion from creeping round the sheet from the back and the edges tampering with the results we apply “edge protection”!

On the back the edge is treated with corrosion protection paint, the edges are “dabbed” with a relatively thick layer. This is called “edge protection”.

The sharp edges always have to get extra protection during testing. Otherwise the result will be falsified and the whole test backfires! In professional corrosion protection the cumbersome word “edge protection” is a well-established and common term.

How Testing Sheets Are Coated

Just like for the rusting shown above there are special regulations and norms for coating, i.e. the application of corrosion protection agents. Not all of these regulations are really of importance for us. For the tests to be meaningful, however, it is important that the conditions are the same for all samples.

This includes the following examples:

– The respective products are used strictly according to the instructions of use.
– The coatings are applied using the required tools.
– Layer thickness is measured after each step.
– The required drying times are adhered to.

The workshop is empty, phones are switched off. For this work we need calm and quiet.

Winter 2015: Working overtime for a test on Tenerife. Here we are testing five products by the competition against a new product of our own. We want to do two tests at the same time, so this time there is twice the effort: Two times six, that is 12 sheets, have to be coated. We spray whenever the workshop is empty: from half past 5 in the morning and in the evenings when everybody has left.

With materials not produced by us we also make sure to process them correctly. Otherwise all our efforts would be in vain.

Strictly according to the instructions of use: two layers of each product are applied.

This is what the completed frames look like. On the lower (now hidden) perforated sheet six testing sheets have been mounted.

The transport to the testing site has to be conducted very carefully so the frames and the delicate sheets will not be damaged. For this we use simple aluminium suitcases bought at a hardware store. But they have extra cushioning on the inside.

Test Environment: This Is Where We Conduct Tests

The sheets are mounted at places where the exposure to corrosion is decidedly strong. This means, among others, the following factors:

– Salt water: accelerates any kind of corrosion.
– Temperature: the higher, the better.
– Ultra-violet light: regardless of the kind of coating, ultra-violet light destroys the long molecular chains of corrosion protection agents rather quickly. They are downright hacked apart by the radiation. Thus the products lose their protective effect.

One example of many on the isle of Tenerife. On this tuna fishing cutter we conduct our tests.

The testing sheets are mounted where the exposure is highest: on top of the bridge. Here there is endless salt-water spume and ultra-violet light.

To speed things up the frames are fastened using binders.

Here, on the highest deck of the ship the exposure is so high that the test does not take long. After just half a year the differences in the protective effect are clearly visible.

For further information on testing on the tuna fishing cutter refer to:
http://www.timemax.de/industry/teneriffa-2/

How We Test Products For Area Protection

Varnish, Wax and Underbody Coating: This Is How We Test Products For Area Protection

How Testing Sheets Are Coated

Test Environment: This Is Where We Conduct Tests

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