The short answer: Most corrosion coatings on bolts, pumps, and structural steel fail at the bond line, not the surface. AEGIS builds a multilayer fluoropolymer barrier on a chemically bonded surface, verified to 4,000 hours ASTM B117 salt spray, with a one business day engineering response and a three day quote.
Why do corrosion coatings fail so early?
Because the weak point is underneath the paint. Grit blasting leaves a mechanical profile only, can embed contamination, and misses threads, pockets, and tight radii. Moisture and chemistry find those gaps, get under the film, and lift it from below. By the time you see rust bleeding through, the coating has already let go.
Which assets corrode first?
- Bolts and threaded fasteners on flanges and structural connections, where every thread is a crevice.
- Pumps and impellers handling acids, caustics, and chlorides.
- Structural steel in marine, refinery, and chemical plant atmospheres.
What makes a coating actually last?
Two things: the bond and the stack. AEGIS uses a proprietary surface preparation and cure process that creates a chemical bond and reaches threads and pockets. On top of that bond goes a layered system, an adhesion primer, a barrier midcoat, and a topcoat tuned to your environment. That combination beats single coat zinc rich, single coat epoxy, and electroless nickel in 4,000 hour salt fog comparison.
How is corrosion resistance proven?
- 4,000 hours ASTM B117 salt spray, roughly 5 times the common 800 hour pass.
- ASTM D870 water immersion testing.
- pH 0 to 14 chemical exposure.
- Minus 40 to 500°F temperature cycling.
How long will it last in my plant?
It depends on the environment. Typical service before recoat: atmospheric exposure 7 to 12 years, marine splash zone 4 to 6 years, continuous chemical service 3 to 5 years. AEGIS sizes the layer stack so recoats land in your scheduled maintenance windows instead of forcing an outage.
Can bolts be coated without taking the flange apart?
Yes. CP400F is the field deployable grade for bolts, fasteners, and structural steel that cannot come out of service. AEGIS brings the prep and cure to the asset, and most jobs need no teardown. See field deployable coatings and bolt corrosion protection.
How fast can AEGIS start?
Engineering spec within one business day, quote within three. Typical in shop turnaround is two to four weeks in our Elkton, MD shop, and onsite work is scheduled to your maintenance window. Every job is custom quoted.
When is something else the better answer?
If heat and corrosion hit together on a thin part, a Cerakote ceramic film from a certified applicator may fit better. If abrasion is the bigger problem, read why doctor blades and slurry parts wear out early. And if sacrificial thermal spray is the more economical choice for your service, we will tell you. See corrosion resistant coatings vs thermal spray.
Send us your corrosion problem
Tell us the substrate, the chemistry, the temperature, and whether the asset can ship. We will spec the right corrosion prevention system. AEGIS Advanced, a Spectrum Advanced company.