HRCSA: Solving steel corrosion problems others choose to ignore.
Hydro towers are surface prepared by power tool cleaning using angle grinders to remove scale, solvent wipe followed by pressure applied HRCSA Penetrant/Sealer inside the connections (as seen in the photo on left) and HRCSA Self Priming Topcoat by paint brush applied to stripe coat bolts, hard edges and final overcoating the entire zone.
Where A588, COR-TEN steels produce corrosion concerns, Chemically Active HRCSA is becoming the “go to” coating system because of it’s a) minimalistic surface preparation requirements, b) ability to chemically stop crevice corrosion, ability to fully wet weathering steel substrate, d) durability and e) HRCSA IS NON-CONDUCTIVE UP 100KVA – AN IMPORTANT FEATURE FOR COR-TEN TOWERS BECAUSE CORROSION PRODUCTS CAUSE ARCHING ON COR-TEN STEEL TOWERS.
COR-TEN steel performs impressively on flat surfaces, but, like all systems, has limitations – particularly where there are connecting plates and other regions noted below.
| Performance & Condition | Weathering Steel | Performance & Condition | Weathering Steel |
| Fatigue Life | Reduced by weathering | Road Salt Effect | Accelerated corrosion and loss of section and mass |
| Constant Wetting | Corrodes the same as unprotected carbon steel | Appearance Problems | Stains concrete |
| Faying Surfaces | Corrodes the same as unprotected carbon steel | Sea Coast Environment | Poor corrosion protection, chlorides cause pitting and rapid section loss |
| Painting | Expensive preparation and excessive paint absorption | Chemical (Airborne) Contamination | Poor corrosion protection, accelerated patina consumption |
| Tubular Shapes | Traps moisture inside, resulting in increased corrosion rate | Vegetation | Moisture may accelerate corrosion, especially on faying surfaces, enough to exert excessive force on bolted connections |
| Inspection | Can’t distinguish patina rust from loose corrosion products of accelerated corrosion | Electrical Industry | Corrosion products cause arcing |
| Corrosion Rate | Unknown | High humidity/Fog | Poor corrosion protection |
More complex joints and connections (such as the above) are surface prepared using power tool cleaning to remove scale then high pressure water cleaned to remove salts, oil, dirt, etc.
Photo above: High pressure water cleaned COR-TEN steel (with salt remover) is ready for HRCSA coating application where HRCSA Penetrant/Sealer is pressure-applied inside the bearing joint and the HRCSA Self-Priming Topcoat is applied (wet-on-wet) to the entire zone to be painted.
Inside Box Beams and other Tubular shapes.
Using a Star tip for fogging and misting HRCSA Penetrant/Sealer is fogged and applied inside Box Beams and other Tubular shapes to create a polar bonded anti-corrosive coating on the inside where humidity can otherwise cause serious corrosion damage.