Corrosive Environments Composite Materials

The Toughest Conditions Use Composite Materials

Mar-Bal, a leader in thermoset composites, produces corrosive environments composite materials for some of the harshest industrial environments. Due to the anti-corrosive properties of composites, it is the material of choice for these conditions since the 1940s. Advancements in the 1950s led to composite utilization in the paper, pulp refinement, and chemical processing industries.

Field testing validated the ability of composites to withstand corrosion. One example of an early test occurred when a 25-year-old composite gasoline storage tank was unearthed, examined, and put back into service. There were no signs of damage from the gasoline or the acidity and conditions of the earth.

By the 1990s, 40 years of case studies and industrial experience proved the lasting performance of corrosive environment composite materials. Today, the advancements continue and thermoset composites are widely used and accepted for use in corrosive environments in a variety of industrial applications.

Diverse Industries and Applications

Composites do not rust or corrode, which are especially important characteristics in harsh operating environments. The corrosion-resistant composite solutions perform within many industries that rely on non-deterioration for safety and end-product delivery. These include air pollution control, chemical processing, desalination, food and beverage, wineries, breweries, mineral processing and mining, oil and gas, pulp and paper, solid waste landfill, and water and wastewater treatment.

Applications within these industries and others include:

  • Pipes
  • Tanks
  • Fans
  • Hoods
  • Grating
  • Pumps
  • Cabinets

Non-Corrosion Composite Properties

With thermoset composites, there are three areas that offer reinforcement protection in harsh environments. At the inner surface, an inner veil creates the first corrosion barrier and prevents microcracks from compromising the structure. The second layer provides a backup for the veil. This layer combines with the veil to make a thick corrosion barrier. The final layer, the thickest, provides the composite structure.

Mar-Bal knows the science behind corrosive environment composite materials and has the experience to produce the anti-corrosive components best able to perform in specific environments.

Industry Design Standards

Designs for projects utilizing corrosion-resistant composites usually must comply with established industry standards. The American Society for Testing and Materials (ASTM) International and the American Society of Mechanical Engineers (ASME) issue and maintain the most widely-used standards for corrosion applications. The criteria include the scope of applicability, design, materials, construction, quality control, testing, and record keeping.

Design related to composite corrosion applications in construction will most often be governed by ASTM C582. It is widely accepted as the standard for corrosion-resistant thermoset composite applications. The standard includes specifications composition, thickness, fabrication procedures and physical property requirements for corrosion-resistant tanks, piping, and equipment manufactured by contact molding.

Market Demand

It is estimated that corrosion-resistance accounts for 11 to 15 percent of the composite market. With its long history of success in corrosive environments, the development of construction standards and work practices have combined to create a healthy and growing market for composite applications in these harsh settings.

The market is expected to grow as chemical and engineering discoveries advance and refine the materials to meet an even greater need. Advancements including dual corrosion-resistant and heat-resistant products will better serve evolving industrial environments

Industry Experience

Mar-Bal’s commitment to quality, service, and on-time delivery have led to its ever-increasing knowledge base in the corrosive environment composite materials development and production. The science of the products and the customization to particular specifications ensure that the composites remain anti-corrosive in the most challenging situations.

Mar-Bal is ready to produce the best thermoset composites for any corrosive environment. When you work with Mar-Bal, you get composites engineered and molded to your exact specifications, every time.