Maintenance of corroded silos: A case study
Abstract
Silos used for storing fuels, foods, and chemicals are specialized structures designed to safely contain and dispense various types of chemicals commonly used in the construction industry, such as cement, aggregates, and additives. Most of the materials required for glass fiber reinforced concrete (GFRC) panel production are stored in silos. The required materials are taken from the silos with the help of pumps equipped with an automatic dosage system. Steel is prone to corrosion when exposed to moisture and oxygen in the air, resulting in the formation of rust. In the open air, especially in places with excessive humidity and rainfall, silos corrode faster over time. Therefore, punctured silos due to corrosion can lead to production stoppages and severe financial losses. Painting is one of the primary methods for protecting steel from corrosion as it creates a barrier between the metal surface and the environment, preventing direct contact with corrosive agents and extending the life of the steel structure. In this study, the maintenance work of two heavily corroded silos, which had been in use for 20 years by Fibrobeton GFRC company, was carried out step by step according to ASTM D3276, ISO 8501 and ISO 12944:2018 standards. Wet sandblasting was used to remove the paint from the surface, followed by cleaning of the oxide layer with a patented acid solution (TPE Patent Application No: 2017/11354) containing corrosion inhibitors, followed by the application of two coats of surface tolerant (Zn₃(PO₄)₂ based) epoxy paint and then acrylic paint with high UV resistance. During this maintenance process, attention was also drawn to the problems caused by not preparing the metal surface in accordance with the standards before painting.
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