Corrosion is responsible for 40 percent of all HVAC failures, according to CED Engineering. The culprit comes from both inside and outside sources that damage the structure of coils within an HVAC unit. The problem is especially exacerbated in industrial climates due to the surrounding environment and associated levels of higher contaminants and chemicals.
High-humidity regions and contact with saltwater can negatively impact the function of an HVAC system. Excessively harsh conditions can erode the metals inside an HVAC unit, and more specifically the coils themselves. FMLink identified eight key items that can cause damage inside of coils:
- Dissolved gases
- Dissolved solids
- System deposits
- Water velocity
- Galvanic corrosion
- Ph levels
- Microbiological matter
To combat these factors, an HVAC system has to effectively regulate these levels at all times. Though many companies rely simply on coil cleaning, it may not be enough to fully eradicate the problem of corrosion and prevent future failures.
Depending on the location of an industrial facility, outside determinants like temperature, moisture, air pollutants and harmful particles can play a large role on the quality of air that is entering into an HVAC system. Though filters and controls are designed to remove the majority of contaminants, the toll they take on the HVAC coils can add up over time.
“Premature corrosion of air conditioning heat exchangers, specifically condenser coils can be a serious problem in seaside or industrial environments; coils installed in these environments have been known to fail in less than a year,” according to a report form CED Engineering. “The result is the costly replacement of the coil and/or entire unit. If these units are improperly applied or left unprotected, they can experience rapid corrosion from exposure to aggressive environments.”
Review our Heat Exchanger Replacement Cost Guide.
Coating prevents corrosion
The main deterrent against corrosion is the coating of coils. Vanguard Resources indicated that a simple 18-degree change in water temperature can double the amount of corrosion taking place. Factoring in poor air quality and old coils, the rate of corrosion can increase exponentially.
Within the first year of installing an HVAC system, coils can become 50 percent corroded. Further, corrosion can begin to manifest within weeks, according to CED Engineering.
The advantage that coated coils have over traditional coils is a protective layer that acts as a resistant. While there are different types of coatings, the industry standard is a Dip & Bake method from Rahn Industries.
An epoxy material with flouro Teflon is applied to a coil, which is then baked in an oven to provide a complete seal that can prevent corrosion from occurring. Not only does it make the coil stronger and more durable, but it also improves the lifespan of the entire HVAC unit, thus saving on maintenance and repair costs.
One of the most intrusive problems facing coils is the buildup of excess particles. Everything from dust, mold, fungus and other organisms accumulate inside HVAC systems, which inhibits the proper flow of air and the process of heating and cooling. Evaporator coils can become ineffective in cooling filtered air, while condenser coils can become incapable of lowering the temperature of the room.
The result is that energy costs rise due to the lack of working coils. Rahn Industries Dip & Bake coating prevents against buildup and reduces the amount of wattage necessary for operation. Once the coils are protected with corrosion coating levels decline dramatically, which can enhance the bottom lines of businesses in industrial settings.
As opposed to replacing an expensive HVAC system, coil coating can be a cheaper, more energy-efficient way to lower utility costs and improve airflow. Contact Rahn today for top-of-the-line coating services.