CHAPTER 11

Maintenance is an expensive and

disruptive process. Long lasting systems
should be chosen at the newbuilding
stage to minimize the cost.

MAINTENANCE

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WHY MAINTENANCE?

We can divide all maintenance into two main categories:

a) Maintenance to prevent deterioration or damage to the plant or construction
which will make it unfit for its intended purpose.
b) Maintenance to improve the appearance of the structure/object/plant to
make the immediate surroundings more pleasant.
Both are equally important.

Expected cost development for typical

maintenance systems
120

Maintenance cost (unit m3)

110
100

1000 microns Baltoflake/Baltoflake Ecolife

340 microns Jotamastic 87 system
Oxidative and physically drying

90
80
70
60
50
40
30
20
10
0

10

15

20

Years in operation

[continued]
Chapter 11:
Maintenance

11.2

COATING MANUAL

WHY MAINTENANCE?
[continued]

Maintenance for corrosion protection may be a very costly exercise involving a

great deal of work. However, if we split the costs involved into paint material
and execution of the work, it may come as a surprise that the cost of the paint
amounts to less than 10% of the total value of the painting contract.
The quantity of steel required to replace corroded material around the world is
substantial and costs enormous sums of money. Reports claim that USD 1
billion must be spent to bring bridges in Great Britain up to standard. There are
around 80 highway bridges at risk and more than 1,100 bridges will need
significant repair work. Other estimates show that if the maintenance of bridges
in New York remains on 1981 levels, 95% of them will be in a dangerous
condition in about 30 years.
A North Sea operator reports that about 60% of failures over a 10 year period
were caused by corrosion whilst a survey in Japan concluded that about 75% of
failures in refineries and petrochemical plants are caused by corrosion.
Corrosion problems, if left unattended can lead to catastrophic damage such as
collapsing structures, chemical leakage, ruptured pipelines etc. When one
considers this there is no doubt that the best foundation for an economical and
easy maintenance is to choose an optimal corrosion protection system right
from the very start.
Deciding when to carry out maintenance is best linked to the internationally
accepted standard ISO 4628 Evaluation of degradation of paint coatings.
Refer also to Chapter 9 Economics of Paint Systems Evaluation of Paint
Breakdown at Maintenance.

Chapter 11:
Maintenance

11.3