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methods
[German version]
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Tin plating
Galvanization
Coating
Enameling
Copper plating
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as long as several hours. The thicker the film, the longer the drying time. If the drying
process is artificially accelerated, there may be problems with adhesion between the
protective film and the metal surface.
Since protective films are very thin and soft, attention must always be paid to the dropping
point as there is a risk at elevated temperatures that the protective film will run off,
especially from vertical surfaces.
Since solvent-based corrosion protection agents are often highly flammable, they may only
be used in closed systems for reasons of occupational safety.
Water-based anticorrosion agents
Water-based anticorrosion agents contain no solvents and thus do not require closed
systems.
Drying times are shorter than for solvent-based anticorrosion agents.
Due to their elevated water content, water-based anticorrosion agents are highly
temperature-dependent (risk of freezing or increased viscosity).
The advantage of this method is that the protective film is readily removed, but the
elevated water content, which may increase relative humidity in packaging areas, is
disadvantageous.
Corrosion-protective oils without solvent
Corrosion-protective oils without solvent produce only poor quality protective films. Good
quality protection is achieved by adding inhibitors. Since these corrosion-protective oils are
frequently high quality lubricating oils, they are primarily used for providing corrosion
protection in closed systems (engines etc.).
Dipping waxes
The protective layer is applied by dipping the item to be packaged into hot wax. Depending
upon the type of wax, the temperature may have to be in excess of 100C. Removal of the
protective film is relatively simple as no solid bond is formed between the wax and metal
surface. Since application of dipping waxes is relatively complex, its use is limited to a few
isolated applications.
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2. Desiccant method
Introduction
According to DIN 55 473, the purpose of using desiccants is as follows: "desiccant bags are intended to
protect the package contents from humidity during transport and storage in order to prevent corrosion, mold
growth and the like."
The desiccant bags contain desiccants which absorb water vapor, are insoluble in water and are chemically
inert, such as silica gel, aluminum silicate, alumina, blue gel, bentonite, molecular sieves etc.. Due to the
absorbency of the desiccants, humidity in the atmosphere of the package may be reduced, so eliminating
the risk of corrosion. Since absorbency is finite, this method is only possible if the package contents are
enclosed in a heat sealed barrier layer which is impermeable to water vapor. This is known as a climatecontrolled or sealed package. If the barrier layer is not impermeable to water vapor, further water vapor
may enter from outside such that the desiccant bags are relatively quickly saturated, without the relative
humidity in the package being reduced.
Desiccants are commercially available in desiccant units. According to DIN 55 473:
"A desiccant unit is the quantity of desiccant which, at equilibrium with air at 23 2C, adsorbs the
following quantities of water vapor:
min. 3.0 g at 20% relative humidity
min. 6.0 g at 40% relative humidity
The number of desiccant units is a measure of the adsorption capacity of the desiccant bag."
Desiccants are supplied in bags of 1/6, 1/3, 1/2, 1, 2, 4, 8, 16, 32 or 80 units. They are available in lowdusting and dust-tight forms. The latter are used if the package contents have particular requirements in
this respect.
admissible final
humidity
20%
40%
50%
60%
factor a
50%
60%
20%
40%
humidity
factor e
0.9
0.7
0.65
WVP
t
0.6
water vapor permeability of barrier film under anticipated climatic conditions in g/m 2d, measured
to DIN 53 122, Pt. 1 or Pt. 2 (d = day)
total duration of transport in days
The following sample calculation reveals the location of the greatest potential risks:
A German manufacturer is to export a packaging machine to a customer in Brazil. The machine is packaged
in wooden box of the following dimensions:
Lengthinternal
7.00 m
Widthinternal
2.75 m
Heightinternal
3.00 m
This gives an internal volume (V) of: 7.00 m 2.75 3.00 m = 57.75 m3.
The area (A) of the barrier layer is calculated on the basis of the area of the internal sides of the box:
2 (7.00 m 2.75 m)
= 38.50 m2
2 (7.00 m 3.00 m)
= 42.00 m2
2 (2.75 m 3.00 m)
= 16.50 m2
Total
= 97.00 m2
The packaging machine is secured by bracing with 6 pieces of squared pinewood lumber. These are located
inside the climate-controlled package. The lumber is air dry, its water content is 15% =>factor for
moisture content of hygroscopic packaging aid (c) = 150 g/kg.
The dimensions of the squared lumber are 2.70 m 0.20 m 0.20 m (LWH). At an approximate density
of pinewood of 500 kg/m3, the mass (m) is as follows:
6 2.70 m 0.20 m 0.20 m = 0.648 m3
0.648 m3 500 kg/m3 = 324 kg of lumber
When these values are inserted in the equation, the following result is obtained:
n = 1/6 g [(57.75 m3 13.8 g/m3) + (324 kg 150 g/kg) + (97 m2 0.7 0.1 g/m2d 100 d)]
n = 1/6 g (796.95 g + 48600.00 g + 679.00 g)
n = 1/6 g 50075.95 g
n = 8346 desiccant units
The calculation demonstrates that a total quantity of 50075.95 g of water vapor is present inside the
climate-controlled package or diffuses through the barrier layer. A total of 8346 desiccant units would have
to be placed in the box to absorb this quantity of water vapor, which is not a practical proposition. Taking a
closer look at the details of the calculation reveals the greatest potential risks:
Vb
796.95 g
mc
50075.95 g
A e WVP t
679.00 g
It is clear from the above that the hygroscopic packaging aids in the climate-controlled package are
responsible for the greatest potential risk, so it would be advisable to locate these outside the barrier layer.
However, any screws, bolts or nails which pass through the barrier layer must then be appropriately sealed.
The required quantity of desiccant would consequently change as follows.
n = 1/6 g ( 796.95 g + 679.00 g )
n = 246 desiccant units
This number of desiccant units may easily be accommodated in the box in question.
When calculating the required number of desiccant units to DIN 55 474, care must be taken to assume that
all the water present in the climate-controlled package must be absorbed by the desiccant. It is accordingly
assumed that, as in the present example, the squared lumber will dry to a water content of 0%. In reality,
however, this is not the case as at a relative humidity of 40% (agreed admissible final humidity), the water
content of pinewood is still approx. 8% and this water is not released from the lumber. However, this fact is
not taken into account in the calculation, which means that the calculated number of desiccant units is
actually too high. On the basis of the above example, this would make the following difference:
drying to a water content of 0%: 150 g/kg 324 kg = 48600 g of water
drying to a water content of 8%: 80 g/kg 324 kg = 25920 g of water
48600 g - 25920 g = 22680 g of water are released on drying from 18% to 8%.
As a result, the number of desiccant units required would fall by 4320 units. The quantity of desiccant units
is nevertheless still so large that they are virtually impossible to accommodate. The fact still remains that
the hygroscopic packaging aids remain the greatest potential risk in the climate-controlled package.
Barrier films
Barrier films are available in various forms, for example as a polyethylene film or as a composite films with
two outer polyethylene layers and an aluminum core. The composite film performs far better with regard to
water vapor permeability (WVP), achieving WVP values of below 0.1 (g/m 2d). In the composite film, the
barrier layers are arranged so as to bring about a considerable reduction in permeability in comparison with
a single layer.
In accordance with current DIN standards, water vapor permeability is always stated for both 20C and
40C. According to information from the manufacturer, it may be concluded that water vapor permeability
rises with increasing temperature and falls with increasing thickness. This problem occurs most particularly
with polyethylene films, while aluminum composite films are largely insensitive to rises in temperature.
Desiccant bags are always supplied in certain basic package sizes which, depending upon the desiccant unit
size, may contain a single bag (of 80 units) or up to 100 bags (of 1/6 unit). The basic outer package should
only be opened directly before removal of a bag and must immediately be heat sealed again.
Disadvantages
Placement of the desiccant bags and heat sealing of the barrier films are relatively laborintensive.
The slightest damage to the barrier layer may negate the effectiveness of corrosion
protection.
Calculating the required number of desiccant units is not entirely simple and it is easy to
overcalculate. However, too much protection is better than too little.
Humidity indicators inside the package are not very reliable as they are only valid for
certain temperature ranges.
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Inhibitors are substances capable of inhibiting or suppressing chemical reactions. They may be considered
the opposite to catalysts, which enable or accelerate certain reactions.
Unlike the protective coating method, the VCI method is an active corrosion protection method, as chemical
corrosion processes are actively influenced by inhibitors.
In simple terms, the mode of action (see Figure 1) is as follows: due to its evaporation properties, the VCI
substance (applied onto paper, cardboard, film or foam supports or in a powder, spray or oil formulation)
passes relatively continuously into the gas phase and is deposited as a film onto the item to be protected
(metal surfaces). This change of state proceeds largely independently of ordinary temperatures or humidity
levels. Its attraction to metal surfaces is stronger than that of water molecules, resulting in the formation of
a continuous protective layer between the metal surface and the surrounding atmosphere which means that
the water vapor in the atmosphere is kept away from the metal surface, so preventing any corrosion. VCI
molecules are, however, also capable of passing through pre-existing films of water on metal surfaces, so
displacing water from the surface. The presence of the VCI inhibits the electrochemical processes which
result in corrosion, suppressing either the anodic or cathodic half-reactions. Under certain circumstances,
the period of action may extend to two years.
The mode of action dictates how VCI materials are used. At item to be protected is, for example, wrapped in
VCI paper. The metallic surfaces of the item should be as clean as possible to ensure the effectiveness of the
method. The VCI material should be no further than 30 cm away from the item to be protected.
Approximately 40 g of active substances should be allowed per 1 m of air volume. It is advisable to secure
this volume in such a manner that the gas is not continuously removed from the package due to air
movement. This can be achieved by ensuring that the container is as well sealed as possible, but airtight
heat sealing, as in the desiccant method, is not required.
The VCI method is primarily used for articles made from carbon steel, stainless steel, cast iron, galvanized
steel, nickel, chromium, aluminium and copper. The protective action provided and compatibility issues must
be checked with the manufacturer.
N.B.: The use of water-miscible, water-mixed and water-immiscible corrosion protection agents, corrosion
protection greases and waxes, volatile corrosion inhibitors (VCI) and materials from which volatile corrosion
inhibitors may be released (e.g. VCI paper, VCI films, VCI foam, VCI powder, VCI packaging, VCI oils) is
governed by the German Technical Regulations for Hazardous Substances, TRGS 615 "Restrictions on the
use of corrosion protection agents which may give rise to N-nitrosamines during use".
protection.
The period of action may extend to two years.
The wrapping need not be provided with an airtight heat seal.
On completion of transport, the packaged item need not be cleaned, but is immediately
available.
Disadvantages
The VCI method is not suitable for all metals. It may cause considerable damage to
nonmetallic articles (plastics etc.).
Most VCI active substances may present a hazard to health, so it is advisable to have their
harmlessness confirmed by the manufacturer and to obtain instructions for use.