Corrosion: A Costly Threat to Fleet Readiness 3 Feb 2025, 5:34 pm

Did you know that corrosion costs the U.S. Navy billions annually – more than the price of entire ships and weapons systems? Without proper surface preparation, marine structures are vulnerable to rapid deterioration. Understanding the impact of corrosion and the role of effective surface preparation is essential for maintaining long-term structural integrity. 

The Role of Surface Preparation in Marine and Industrial Coatings

In the harsh marine and industrial environments, protecting a ship’s hull and exposed surfaces from rapid degradation is crucial. While specialized coatings provide a protective barrier, the success of these coatings depends on proper surface preparation. 

Proper Surface Preparation

Ensuring the surface is clean and adequately profiled helps prevent peeling, flaking, and corrosion, ultimately extending the lifespan of assets.

Main Industries applies proven surface preparation techniques backed by extensive experience. With millions of square feet prepared annually, our team works across a wide range of projects, from routine maintenance to major overhauls.

Why Surface Preparation Matters

Preparing a surface before applying a coatings is a critical step that removes contaminants, rust, grease, old paint, and other debris. Without this process, coatings may fail prematurely, leading to maintenance costs and reduced effectiveness.

Challenges in Marine and Industrial Settings:

Marine Environments: Constant exposure to saltwater, UV radiation, and mechanical wear accelerates corrosion. 

Industrial Environments: Harsh chemicals, extreme temperatures, and abrasive materials require coatings to adhere securely to withstand wear and tear.

Main Industries follows industry best practices to ensure surfaces meet the highest standards of durability and protection, particularly for maritime and defense sectors.

Surface Preparation Techniques

Ultra-High-Pressure (UHP) Water Jetting

For efficient material removal, UHP water jetting exceeds 40,000 psi to clean and prepare surfaces. This method effectively removes tough contaminants while preserving the integrity.

Key Benefits:

• Removes rust, coatings, and debris without damaging the substrate
• Environmentally friendly, using only water with no harmful chemicals
• Effective for various surfaces, including steel, concrete, and composites

Abrasive Blasting

Abrasive blasting is widely used to clean and prepare surfaces by propelling abrasive materials at high speeds. This method effectively removes rust, old coatings, and contaminants to create a clean textured surface for coatings to adhere to. 

Key Benefits:

• Provides a surface that enhances coating adhesion
• Suitable for steel, aluminum, and composite surfaces
• Adjustable to meet specific project needs

Environmental Considerations

To minimize environmental impact, containment systems are used to control dust, while ventilation and waste management practices ensure proper disposal of hazardous materials. These measures help maintain compliance with environmental regulations while safeguarding workers and surrounding ecosystems.

Selecting the Right Surface Preparation Method

When determining the most effective surface preparation method, we consider multiple factors:

• The type and extent of corrosion present
• The substrate material and its condition
• Operational requirements and longevity expectations

Main Industries applies the chosen surface preparation method while keeping environmental impact considerations in mind, ensuring compliance with regulations and maintaining a safe work environment.  

Ready to Get Started?

Protect your assets with Main Industries’ expert surface preparation services. Contact us today to discuss your project and learn how we can help you achieve durable, high-quality results.

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Staging Project 12 Jun 2014, 9:31 pm

LRS – Credit: NASA

In 1963, the first lunar landing was tested at the NASA Langley Research Center in Hampton, Virginia. The test facility is now used for crash testing of small aircraft. The test gantry structure stands 220 ft tall and 380 ft long, and is now called the Full Scale Dynamics Research Facility. The gantry is used to lift and then drop aircraft in a controlled manner to analyze the effects of a crash.

In 2001, the facility tested Beeche’s ability to develop a safe and effective platform system to provide access that would enable Main Industries, Inc. to blast and re-coat the massive steel truss structure. Mike Challoner, the President of Main Industries, surveyed the magnitude of the project and enlisted the services of Beeche. The companies worked together previously on the re-coating of the aircraft carrier U.S.S. Enterprise as well as other ships being overhauled at the Newport News Shipyard. Portions of the structure were re-coated in phases due to its size and the facility’s schedule for testing. The portion of the structure for this phase of the project included three sections of the uppermost trusses.

Beeche developed an access platform system that utilized a combination of the Steel Modular Truss Frame Platform and Aluminum Space Frame Platform Systems. Five Truss Frame Platforms were utilized, two measuring 24 ft by 44 ft and two others being 24 ft by 48 ft. The fifth Truss Frame platform measured 16 ft by 20 ft. The Aluminum Space Frame platform utilized for the end truss of the gantry measured 24 ft by 64 ft. All of the platforms needed to safely support the weight of the workers, their equipment, a containment structure and blast media and paint debris generated in the operation. Due to the height of the structure and its proximity to the Virginia shore, wind was also a significant consideration. An analysis of the gantry structure was also required in order to determine its ability to support these loads.

Beeche also provided extensive on-site technical support services, including supervision and training of Main Industries personnel for the project during assembly, hoisting and relocation of the platforms.

Click here for more images of scaffolding and staging.

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