Your high-value components and spares are an investment, so why let them corrode and be damaged simply because the preservation system isn’t up to scratch? The DAYWALK 4VAP (four-step visual asset preservation) system gives you a step-by-step method and layered protection process that provides optimum protection for metal components. Read on to learn more about this asset preservation system.
4VAP: Visual Asset Preservation Step-by-step
To help you provide complete asset protection for your spares and components, we’ve created the step-by-step guide to help you prevent corrosion. By using this system, you can maintain your high-value assets, so they are long-lasting, in good condition and ready for the job ahead.
STEP 1: SKN Peelable Coatings
Apply to carbon or mild steel to eliminate oxygen, and prevent corrosion starting in the first place. The three wins that end-users have proven by utilising peelable coatings are as follows:
- Fast-drying properties – 2-3 minutes touch dry so an extremely quick process to apply
- Effective prevention of rust-creep
- Non-residue coating, so highly efficient and effective removal process
This is a specialised formulation that is used for stainless steel and other specific alloys.
STEP 2: DAYWALK Desiccants
There are a number of moisture absorbent/adsorbent materials to help prevent corrosion and damage to metal components.
The e-Gel is a popular option as it also has an in-built indicator: the gel is orange when it is unspent or thirsty; the gel turns dark green when it is spent (filled to capacity) – approximately 30% of its weight. Typically, in the 4VAP process, e-Gel is used in sachets, e.g. 100g, 200g, 500g and 1kg.
DAYWALK e-Gel is environmentally friendlier than conventional blue to pink silica gel; blue to pink gel typically contains cobalt chloride; while e-Gel is still Silica Gel – SO2, the indicator is Methyl Violet. As a rough indicator, 1kg of e-Gel will protect 1m3 of void within a covered nucleus for up to 12 months (depending on conditions e.g. high humidity areas this will be closer to six months.
STEP 3: VCI – Volatile Corrosion Inhibitor
Because of the VCI paper’s Kraft properties, the VCI will absorb moisture, then as the temperature within the covered nucleus heats up, the VCI paper will allow the moisture to dissipate. Where this often comes about is when you might have a piece of equipment covered by a plastic pallet bag or engine bag. Because of the temperature range – cold at night and hot during the day – there will commonly be beads of condensation form on the underside of the plastic cover. While there is no real issue if there are beads of moisture on the plastic, the potential is there that a drop could get too heavy and fall from the plastic onto a bare metal shaft, thus setting off a rusting process, as the VCI microscopically thin protective film is now broken.
VCI paper is impregnated with VCI masterbatch: this enables the paper to emit corrosion inhibitor and thus protect the metal surfaces and mitigate the usual effects of moisture that might be present. In fact, volatile corrosion inhibitors rely on a presence of moisture to work.
STEP 4: The Outer Cover
This is often done with an LDPE (plastic) bag. The most common bag sizes would be the pallet and skid cover bags, as follows:
- 1220+1220×2100 (full pallet size1220+610×1600 (half pallet size)
- 610+600X1100 (quarter pallet size)
- 820+810×1600 (two-thirds pallet)
- 2400+1600×2700 (tall engine bag)
- 2400+1600×2200 (regular engine bag)
In the above products, there are a mixture of options, such as:
- Plastic Gauge/thicknesses ranging from 50um up to 250um
- Regular plastic with no masterbatch added – for short use applications, such as contamination control during or between shifts
- UV stabiliser masterbatch added, giving integrity to the plastic
- UV stabiliser and VCI masterbatches added, ensuring greater plastic integrity and rust inhibiting properties
There is also a range of smaller bags – what we call “component bags” – complete with UV stabiliser and VCI masterbatch. These bags range from 200mm wide up to 600mm wide. In the component bag range, there are UV stablised (and not VCI) options. The two most commons width of bags are 300mm and 750mm.
DAYWALK Maintain Solutions
There are three product ranges offered by DAYWALK. Their products are divided into the following core areas: Retain, Restrain, and Maintain. Generally, most warehouses only have a real need for the former two, but recent trends in warehouse advice show that there’s a growing need within the industry lately for the third silo.
What are these silos exactly, and what are their products dedicated to?
RETAIN products cover items such as pallets (such as the steel pallet and hardwood pallets), bins, and cages (like the metal cage and pallet cages) – these are products used for product retention and transitory handling, such as shipping and end-user stocking. RESTRAIN products include rated strapping and tie downs, which are used to prevent damage to cargo during transit, such as breakage prevention. MAINTAIN products, finally, are products that focus on the preservation and long-term protection of critical equipment and spare parts.
However, with over 2 trillion dollars being spent on preservation annually, MAINTAIN is a core focus area for guys in the heavy industry wanting to save money by preserving their spares.
The MAINTAIN silo is made up of the 4VAP system. The 4VAP stands for 4-step Visual Asset Preservation. This is a step-by-step layered protection process intended to provide full surface coverage for your equipment.
Products belonging to this category include the following:
- Outer foils and plastics and scrim/foil/plastic laminate
- VCI paper that absorbs moisture before it manages to come into contact with exposed or rust-prone metal surface
- E-Gel desiccant (such as silica gel) and VCI emitters, wherein e-Gel absorbs moisture
- Integral protection for metal surfaces through the Peelable Coatings range
MAINTAIN also aims to protect both large and small components – whether it’s through a UV/CI resealable zip-bag seal or a pallet or engine bag. Commonly available in 300mm and 750mm bag widths (as well as other widths upon inquiry), the component bags are replete with UV stabilisers and VCI masterbatch. Component bags are available with UV stabilising only, as well.
Talk to the Preservation Specialists
Have any issues with preservation? 4VAP is for you. Get in touch the DAYWALK team to discuss preservation and complete asset protection for your critical components and high-value spares.
