Layup of Manufacturing Facility

April 30, 2020

When evaluating the layup of a manufacturing facility, the task can be broken down by classification of equipment and systems into categories as follows:

  • Structures
  • Equipment
  • Work in progress
  • Finished goods
  • Air systems
  • Water systems

Each category will be broken into subsets with specific recommendations for products and applications.

Structures:

  • Concrete foundations, walls, ceilings, etc.
    • Wash all surfaces to remove all contaminants (10% solution of VpCI®-414)
    • Visually inspect for damage
    • Repair damaged areas using MCI® repair mortar (https://www.cortecmci.com/)
    • Coat all concrete surfaces with MCI®-2020 or MCI®-2022
  • Structural steel
    • Inspect for areas of rust and/or peeling paint
    • Power wash or use high pressure air to remove all loose rust and contaminants
    • Determine if cross-section in rusted areas meets acceptable design parameters
    • Options to address rust
      • Option 1: Convert hematite to magnetite using CorrVerter® Rust Converter Primer; then topcoat with EcoShield® 386 clear or color match
      • Option 2: Remove rust with VpCI®-423; remove VpCI®-423 with 10% solution of VpCI®-414; and topcoat with EcoShield® 386 clear or color match
    • Loading bay doors
      • Clean with 10% solution of VpCI®-414
      • Spray all hinges, rollers, and roller trac/guides with CorShield® 369 Wet Film Corrosion Inhibitor and Lubricant
    • Fasteners, locks, hinges, etc.
      • Spray with CorShield® VpCI®-369 Wet Film Corrosion Inhibitor and Lubricant

Fire Protection Systems:

  • Wet systems
    • Drain the system
    • Recharge the system adding VpCI®-649 at 1% by weight to the water
  • Dry systems
    • Set up system to force air being fed into system through a bed of VpCI®-308 Powder

Electricals:

  • Control panels, power panels, and MCC
    • Deenergize the system
    • Spray all contacts and exposed metal with ElectriCorr® VpCI®-239
    • Insert appropriately sized emitter
      • VpCI®-105 – 5 ft3 (0.14 m³)
      • VpCI®-111 – 11 ft3 (0.31 m³)
      • VpCI®-308 Pouch – 35 ft3 (1 m³)
    • If vented, shrink wrap with either MilCorr® VpCI® Shrink Film or VpCI®-126 HPUV
  • Motors
    • Deenergize system
    • Closed frame motor
      • Remove any rust with VpCI®-423
      • Remove VpCI®-423 residual with 10% solution of VpCI®-414
      • Coat exposed machined surfaces with VpCI®-391
      • Insert VpCI®-101 Device into junction box
    • Open frame motor
      • Remove any rust with VpCI®-423
      • Remove VpCI®-423 residual with 10% solution of VpCI®-414
      • Coat exposed machined surfaces with VpCI®-391
      • Insert VpCI®-101 Device into junction box
      • Fog ElectriCorr® VpCI®-239 into motor core
      • As a minimum, shrink wrap fan end with either MilCorr® VpCI® Shrink Film or VpCI®-126 HPUV
    • Air systems
      • Piping
        • Purge and fill air lines, gauges, reservoirs with air pumped through VpCI®-308 Powder
      • Compressors
        • Air side – Fog with VpCI®-337 at 0.5 oz./ft3 (0.5 mL/L)
        • Lubrication side – depending on type of lubricant, apply one of the below products by fogging at 0.5 oz./ft3 (0.5 mL/L), or add to oil at 5% by volume
          • M-528 – PAG
          • M-529 – PAO
          • M-530 – Mineral
          • M-531 – PAO
  • Manufacturing equipment – lathes, drills, grinders, etc.
    • Deenergize equipment
    • Remove any rust with VpCI®-423
    • Remove VpCI®-423 residual with 10% solution of VpCI®-414
    • Lubrication side – depending on type of lubricant apply one of the below products by fogging at 0.5 oz./ft3 (0.5 mL/L) or add to oil at 5% by volume
    • Guides, screws, etc. (surfaces subjected to relative motion) – Coat with VpCI®-369D
    • Cross slides, headstock assembly, tailstock (components with lubrication oil)
      • Depending on type of lubricant, apply one of the below products by fogging at 0.5 oz./ft3 (0.5 mL/L) or add to oil at 5% by volume
        • M-528 – PAG
        • M-529 – PAO
        • M-530 – Mineral
        • M-531 – PAO
      • Work in process and finished goods
      • Boilers
        • Drain
        • Add Boiler Lizard® pouches (one per 1000 gallons [3.8 m³]) to water side or fog with Boiler Dragon at 1 oz./ft3 (1 L/m³)
        • Fog fire side with Boiler Dragon at 1 oz./ft3 (1 L/m³)
        • Fog all piping with Boiler Dragon at 1 oz./ft3 (1 L/m³)
        • Spray all valve stems, bushings, packing body, and bonnet nuts with CorShield® VpCI®-369 Wet Film Corrosion Inhibitor and Lubricant
      • HVAC systems
        • Spray evaporator and condenser coils with 10% solution of VpCI®-414 to clean
        • Spray evaporator and condenser coils with VpCI®-337
        • Place VpCI®-308 Pouch (35 ft3 [1 m³]/pouch) inside HVAC enclosure
        • Shrink wrap with either MilCorr® VpCI® Shrink Film or VpCI®-126 HPUV
        • HVAC ducting
          • Close air register
          • Fog with VpCI®-337 at 1 oz./ft3 (1 L/m³)
        • Toilets
          • Secure water, flush, and add either of the below products to the tank and bowl
            • ECO-SEPT
            • PORTA-TREAT
ProductNSN (National Stock Number)Qualified Mil Spec Standard Test Methods
Boiler Lizard® (powder contents)MIL-I-22110C
commercial equivalent
NACE Standard TM0208-2008
NACE RP0487-2000
OECD 306, BOD-28
EPA/600/4-90/027F
CorrVerter® Rust Converter PrimerASTM B-117
ASTM D-1748
ASTM D-3359
ASTM D-522
ASTM D-532
ASTM D-3960
ASTM D-3363
ASTM D-3363
NACE RP0487-2000
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
CorShield® VpCI®-369 Wet Film Corrosion Inhibitor and LubricantMIL-PRF-16173E, Grade 2 commercial equivalentASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
NACE RP0487-2000
SSPC (Minimum Surface Preparation Guideline)
ECO-SEPT™EUCAST – Antimicrobial susceptibility testing – disk diffusion method, Version 6.0, January 2017 (components)
OECD Method 301D (for active ingredients)
EcoShield® 386ASTM B-117
ASTM D-1748
ASTM D-3359
ASTM D-522
ASTM D-532
ASTM D-3960
ASTM D-3363
ASTM D-3363
NACE RP0487-2000
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
ElectriCorr® VpCI®-2396850-01-600-4422ASTM D-1748
ASTM B-117
NACE RP0487-2000
M-528OECD Method 301D
ASTM D-4172
ASTM D-130
ASTM D-665
ASTM D-974
ASTM D-1748
ASTM D-2196
M-5298030-01-630-5244MIL-PRF-46002
commercial equivalent
MIL-PRF-85062
commercial equivalent
ASTM D-4172
ASTM D-130
ASTM D-665
ASTM D-974
ASTM D-1401
ASTM D-1748
ASTM D-2196
M-530/ M-531MIL-PRF-46002
commercial equivalent
MIL-PRF-85062
commercial equivalent
ASTM D-4172
ASTM D-130
ASTM D-665
ASTM D-974
ASTM D-1401
ASTM D-1748
ASTM D-2196
MCI®-2020ASTM G-109
NSF Standard 61
MCI®-2022SS-W-110C
NCHRP 244 Series II
EIS – Corrosion Protection to Rebar
MilCorr® VpCI® Shrink Film8340-01-629-6601MIL-PRF-121 commercial equivalent
MIL-PRF-22019 E (Performance Requirements)
commercial equivalent
ASTM D-882
ASTM D-882A
ASTM D1709, Method A
ASTM D-1922A
ASTM D-3420
ASTM D6988-07
ASTM D1748
ASTM D2732-30
ASTM F3429
ASTM D3985
NACE TM0208-2008
NACE RP0487-2000
PORTA-TREAT™EUCAST – Antimicrobial susceptibility testing – disk diffusion method, Version 6.0, January 2017 (components)
OECD Method 301D (for active ingredients)
VpCI®-101 Device6850-01-338-1392MIL-I-22110C
commercial equivalent
NACE TM0208-2008
NACE RP0487-2000
VpCI®-1056850-01-406-2060MIL-I-22110C
commercial equivalent
NACE TM0208-2008
NACE RP0487-2000
VpCI®-1116850-01-408-9025MIL-I-22110C
commercial equivalent
NACE TM0208-2008
NACE RP0487-2000
VpCI®-126 HPUVMIL-PRF-22019E (Performance Requirements)
commercial equivalent
MIL-PRF-22020E
commercial equivalent
ASTM D-882
ASTM D-882A
ASTM D-1922
ASTM D-3420
ASTM D6988-07
ASTM D1748
ASTM D1735
ASTM D2732-30
NACE TM0208-2008
NACE RP0487-2000
VpCI®-308 Pouch/PowderMIL-I-22110C
commercial equivalent
NACE TM0208-2008
NACE RP0487-2000
VpCI®-3376850-01-629-9146
VpCI®-345ASTM D-1748
ASTM D-4627
ASTM G-31
NACE RP0487-2000
VpCI®-369DMIL-PRF-16173E, Grade 2
commercial equivalent
ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
NACE RP0487-2000 – Selection of Rust Preventives
SSPC (Minimum Surface Preparation Guideline)
VpCI®-369M (1 qt. [0.9 L])8030-00-244-1295MIL PRF-16173E (Grade 2)ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
VpCI®-369M (1 gal. [3.8 L])8030-00-244-1297MIL PRF-16173E (Grade 2)ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
VpCI®-369M (5 gal. [18.9 L])8030-00-244-1298MIL PRF-16173E (Grade 2)ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
VpCI®-369M (55 gal. [208 L])8030-01-149-1731MIL PRF-16173E (Grade 2)ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
ASTM D-1735
ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
VpCI®-3868030-01-481-8897ASTM B-117
ASTM D-1748
ASTM D-3359
ASTM D-522
ASTM D-532
ASTM D-3960
ASTM D-3363
ASTM D-3363
NACE RP0487-2000
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline)
VpCI®-391ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE RP0487-2000
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline
VpCI®-414ASTM D-1748
ASTM B-117
ASTM D3690
ASTM D522
NACE RP0487-2000
NACE (Minimum Surface Preparation Guideline)
SSPC (Minimum Surface Preparation Guideline
VpCI®-4236850-01-482-4536ASTM F-519
ASTM D-6866-11
OECD Method 301D
VpCI®-6496850-01-535-2531NOEC/LOEC – Toxicology Testing
ASTM D4627
ASTM G-31

Case Histories:

Copper Mine Layup
https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch124.pdf

Boiler Lizard® Protecting College Boiler https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch146.pdf

Layup of Offshore Rig
https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch662.pdf

For a PDF version please click here.