In the heart of Turkey, a battle against time and corrosion is being waged, one silo at a time. Mecit Aksu, a researcher from Düzce University’s Faculty of Arts and Sciences, has been leading a crusade to extend the lifespan of silos, those towering structures that dot industrial landscapes and are crucial for storing everything from fuels to chemicals. His latest study, published in Düzce Üniversitesi Bilim ve Teknoloji Dergisi (Düzce University Journal of Science and Technology), offers a roadmap for maintaining these vital structures, with implications that ripple through the energy and construction sectors.
Silos, particularly those used in the production of glass fiber reinforced concrete (GFRC) panels, are the unsung heroes of many industries. They store the raw materials—cement, aggregates, and additives—that fuel construction projects. But these steel giants face a formidable foe: corrosion. When steel meets moisture and oxygen, rust forms, and over time, this can lead to catastrophic failures. “In places with excessive humidity and rainfall, silos corrode faster,” Aksu explains. “This can result in production stoppages and severe financial losses.”
Aksu’s study focuses on two silos that had been in service for two decades at Fibrobeton GFRC company. These weren’t just any silos; they were heavily corroded, standing as stark reminders of the relentless march of time and the elements. The maintenance process was meticulous, following international standards ASTM D3276, ISO 8501, and ISO 12944:2018. The team used wet sandblasting to strip the old paint, followed by a patented acid solution to clean the oxide layer. This solution, containing corrosion inhibitors, is a game-changer. “The acid solution not only cleans the surface but also leaves behind a protective layer that inhibits further corrosion,” Aksu notes.
The real magic happened next. The team applied two coats of surface-tolerant epoxy paint, based on Zn₃(PO₄)₂, followed by a layer of high UV-resistant acrylic paint. This multi-layer approach creates a robust barrier against the elements, buying the silos more time in the fight against corrosion.
But Aksu’s work isn’t just about fixing what’s broken; it’s about preventing future problems. “One of the key takeaways from this study is the importance of proper surface preparation before painting,” he emphasizes. Skimping on this step can lead to a host of issues down the line, including accelerated corrosion and costly repairs.
The implications of Aksu’s research are far-reaching. For the energy sector, which relies heavily on silos for storing fuels and chemicals, this study offers a blueprint for extending the lifespan of these critical structures. By adopting these maintenance protocols, companies can avoid costly downtime and ensure a steady supply of materials. In the construction industry, where GFRC panels are increasingly popular, this research could lead to more reliable and durable storage solutions.
As the battle against corrosion continues, Aksu’s work serves as a beacon of hope. His meticulous approach and innovative solutions are paving the way for a future where silos stand tall and strong, defying the ravages of time and the elements. With studies like this, the construction and energy sectors can look forward to more resilient infrastructure and fewer disruptions, ensuring that progress marches on, unhampered by the silent enemy of corrosion.
