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Manual of for the Prevention of Corrosion on Vehicles And

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Manual of for the Prevention of Corrosion on Vehicles And Manual of Bestfor the Prevention of Corrosion Practiceson Vehicles and Equipment used by Transportation Agencies for Snow and Ice Control April 2015 W:\4w4759-CorrosionManual\Pictures Prepared by: Published by: Mehdi Honarvar Nazari Minnesota Department of Transportation Dave Bergner Research Services & Library Xianming Shi 395 John Ireland Boulevard, MS 330 St. Paul, Minnesota 55155-1899 Western Transportation Institute Montana State University Manual of Best Practices for the Prevention of Corrosion on Vehicles and Equipment used by Transportation Agencies for Snow and Ice Control Prepared by: Mehdi Honarvar Nazari Dave Bergner Xianming Shi Western Transportation Institute Montana State University 2015 Published by: Minnesota Department of Transportation Research Services & Library 395 John Ireland Boulevard, MS 330 St. Paul, Minnesota 55155-1899 This manual represents the results of research conducted by the authors and does not necessarily represent the views or policies of the Minnesota Department of Transportation and/or (author’s organization). This manual report does not contain a standard or specified technique. The authors and the Minnesota Department of Transportation and/or (author’s organization) do not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to this manual. Report Overview and Organization This manual presents ideas and innovations that can be readily implemented. The target audience for this manual is line managers responsible for fleet maintenance and/or snow and ice control operations, but can be used as an information source for vehicle operators and upper management. The manual presents a comprehensive summary of how and why corrosion occurs, the direct and indirect costs of the effects, and practical, feasible ways to prevent and remedy corrosion. Chapters 1-4 provides background on corrosion types and causes and will be of general interest to all readers. Chapters 5,6, and 8 offer most benefit to fleet managers. Chapters 6, 7, and 8 offer the most benefit to garage supervisors and staff. i Table of Contents CHAPTER 1: INTRODUCTION .............................................................................................................. 1 CHAPTER 2: CORROSION DEFINED – RUST NEVER SLEEPS ..................................................... 3 2.1 GENERAL CORROSION ............................................................................................................................................... 3 2.2 LOCALIZED CORROSION.............................................................................................................................................. 4 2.2.1 Pitting Corrosion .......................................................................................................................................... 5 2.2.2 Crevice corrosion .......................................................................................................................................... 5 2.2.3 Filform Corrosion .......................................................................................................................................... 6 2.2.4 Intergranular corrosion ................................................................................................................................ 7 2.2.5 Galvanic corrosion ........................................................................................................................................ 8 2.2.6 Stress Corrosion Cracking (SCC) ................................................................................................................... 9 2.2.7 Corrosion Fatigue ......................................................................................................................................... 9 2.2.8 Erosion Corrosion ....................................................................................................................................... 11 2.2.9 Fretting Corrosion ...................................................................................................................................... 12 2.2.10 Microbially Influenced Corrosion (MIC) .................................................................................................... 13 CHAPTER 3: CAUSES AND EFFECTS OF CORROSION ............................................................... 14 3.1. CORROSION-PRONE PARTS ON DOT EQUIPMENT ......................................................................................................... 15 3.2. EFFECT OF DEICERS ON METALS, INFRASTRUCTURE AND ENVIRONMENT ........................................................................... 17 3.3. COMMON DEICERS EXPOSED TO VEHICLES AND EQUIPMENT ........................................................................................... 20 3.4. ANNUAL EXPENDITURES TO MANAGE DEICER CORROSION OF VEHICLES/EQUIPMENT ............................................................ 21 3.5. RISKS OF DEICER CORROSION TO THE EQUIPMENT FLEET ............................................................................................... 24 3.6. METALLIC CORROSION ON TYPES OF EQUIPMENT AND COMPONENTS .............................................................................. 25 3.7. COMMON TYPES OF CORROSION-PRONE MATERIAL AND THEIR RESPECTIVE FORMS OF CORROSION...................................... 29 3.8. COST-BENEFIT ANALYSIS OF MITIGATING DEICER CORROSION TO DOT EQUIPMENT .......................................................... 29 3.9. SUPPLEMENTAL INFORMATION ................................................................................................................................. 30 3.9.1 Chloride Deicer Corrosion Problem ............................................................................................................ 30 3.9.2 Chloride Deicer Corrosion Causes ............................................................................................................... 30 CHAPTER 4: MATERIALS USED FOR SNOW AND ICE CONTROL .......................................... 32 CHAPTER 5: NEW EQUIPMENT SPECIFICATION – BUILD TO LAST ..................................... 34 5.1. METAL MATERIALS SELECTION ................................................................................................................................. 34 5.2. DESIGN IMPROVEMENTS ......................................................................................................................................... 36 5.3. CONSIDERATIONS FOR WELDED JOINTS ....................................................................................................................... 43 5.4. COATINGS FOR CORROSION PROTECTION (ANTI-CORROSION COATINGS) ......................................................................... 44 5.4.1 Surface preparation methods prior to coating ........................................................................................... 45 5.4.2 Reapplication of Coatings .......................................................................................................................... 47 5.4.3 A Successful Plan for Recoating ................................................................................................................. 47 CHAPTER 6: REPAIR, REHABILITATION AND RETROFITTING OF EXISTING EQUIPMENT ............................................................................................................................................ 50 6.1. EVALUATION PROCESS FOR FLEET VEHICLES ................................................................................................................ 50 6.2. REPAIR AND RESTORATION PROCESS ......................................................................................................................... 51 ii 6.2.1 Removal of Rust and Corrosion .................................................................................................................. 51 6.2.2 Modifications ............................................................................................................................................. 53 CHAPTER 7: PREVENTIVE MAINTENANCE PRACTICES FOR EQUIPMENT ....................... 54 7.1. OPERATOR INSPECTIONS - IN-SEASON AND POST-SEASON ............................................................................................. 54 7.1.1 Tips to Protect Your Snowplow From Corrosion ......................................................................................... 55 7.1.2 Snow Plow Storage .................................................................................................................................... 56 7.1.3 Avoiding plow breakdowns ........................................................................................................................ 56 7.2. MECHANIC INSPECTIONS – ROUTINE AND SPECIAL ........................................................................................................ 58 7.3. SUPERVISOR CHECKS .............................................................................................................................................. 58 7.4. PLOWING, SPREADING AND SPRAYING METHODS AND TECHNIQUES ................................................................................ 59 7.5. POST-STORM CLEANUP; PROCESSES AND PRODUCTS .................................................................................................... 59 7.5.1 Inhibitors for Corrosion Protection ............................................................................................................
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