Corrosion does not only damage parts: it generates recurring costs
In many industrial environments, metal components are continuously exposed to humidity, water, saline environments, chemicals or demanding outdoor conditions.
Over time, these conditions can affect structures, supports, railings, profiles, enclosures, walkways and other elements of the facility.
The problem does not end when corrosion appears. From that point on, a chain of costs begins:
- Inspection of the affected element
- Cleaning and surface preparation
- Rust removal
- Application of primers or protective treatments
- Repainting
- Repair or replacement of parts
- Use of platforms, scaffolding or other access equipment
- Personnel hours
- Possible interruptions to operations
When these operations are repeated periodically, maintenance stops being a one-off action and becomes a structural cost of the facility.
For this reason, an effective strategy for reducing industrial maintenance starts by identifying which components generate recurring interventions and analysing whether there is a more suitable material alternative for those service conditions.
Why consider GRP as an alternative to metal?
GRP profiles are manufactured by combining a resin matrix with glass fibre reinforcements through a continuous process known as pultrusion.
This system makes it possible to produce constant-section profiles in different geometries: rods, flat bars, tubes, angles, U profiles, I-beams, structural profiles and special designs, among others.
One of the main reasons for considering GRP as an alternative to metal is its behaviour against corrosion.
As it is not a metallic material, it does not rust in the same way as steel and does not need to be protected against oxidation using paints or galvanising.
This is particularly interesting in applications where a significant part of maintenance is directly related to protecting the metal.
Selection must always take into account the working environment, the type of resin, the loads and the specific requirements of the project. There is no single material suitable for every application, but in certain corrosive environments GRP profiles can provide a significant advantage throughout their service life.
Repainting is also maintenance
Repainting a metal structure may seem like a routine operation, but in an industrial facility it can involve much more than simply applying a new coat of paint.
Depending on the location of the component, it may be necessary to:
- Prepare the surface beforehand
- Remove damaged areas
- Move equipment
- Install platforms or scaffolding
- Restrict access to certain areas
- Coordinate the intervention with production
- Carry out subsequent inspections
When these operations have to be repeated over the years, their economic impact can be considerable.
The use of corrosion-resistant GRP profiles can eliminate the need for repainting carried out exclusively to protect a metal surface against oxidation.
The advantage, therefore, is not only in the material itself. It lies in all the maintenance operations that may no longer be necessary.
A maintenance shutdown can cost more than the component itself
In many industrial plants, the price of a part is only a small proportion of the cost generated by its replacement.
An intervention may require stopping a production line, restricting a work area, dismantling other components or waiting for a scheduled shutdown.
For this reason, reducing maintenance frequency can have a direct impact on facility availability.
If an element requires fewer interventions related to corrosion, painting or surface repair, the number of occasions on which it is necessary to access it, dismantle it or interrupt the operation of the area where it is installed is also reduced.
For a maintenance manager, this aspect can be just as important as the price of the profile itself.
Lower weight can simplify installation and replacement
In addition to their behaviour against corrosion, glass fibre profiles have a lower weight compared with many metal solutions.
This characteristic can make operations such as the following easier:
- Internal transport
- Handling
- Installation
- Assembly
- Dismantling
- Component replacement
In difficult-to-access areas or in facilities where elements must be handled manually, reducing weight can significantly simplify the intervention.
This does not mean that a metal profile can be directly replaced by a GRP profile with the same dimensions.
The mechanical behaviour of the two materials is different. Therefore, it is necessary to select the appropriate section taking into account loads, stiffness, distances between supports, fixings and actual working conditions.
Replacement must be approached as an engineering decision, not simply as a change of material.
Do not compare only the price per metre
One of the most common mistakes when comparing metal and GRP is to analyse only the initial cost.
For purchasing departments, a more complete assessment should take into account the total cost of ownership of the solution.
Acquisition cost
This includes the price of the profile, manufacturing, machining, transport and installation.
Protection costs
In a metal solution, there may be costs associated with galvanising, paints, coatings or specific treatments.
Maintenance costs
Inspections, personnel hours, repair materials and repainting operations must be taken into account.
Auxiliary equipment
An intervention may require lifting platforms, scaffolding, machinery or additional equipment.
Cost of shutdowns
When maintenance affects plant operations, the losses or limitations resulting from the interruption must also be considered.
Component replacement
Finally, the expected frequency of repair or replacement throughout the service life of the facility must be assessed.
Only after adding all these factors is it possible to make a realistic comparison.
A component with a higher initial price may be more economically attractive if it significantly reduces the interventions required over its years of service.
Where does it make sense to consider replacing metal with GRP?
It is not necessary to consider replacing every metal component in a facility.
It generally makes more sense to begin with those elements that are responsible for the greatest maintenance problems.
For example:
- Components constantly exposed to humidity
- Elements located in saline environments
- Supports and structures in chemically aggressive areas
- Outdoor profiles that require periodic repainting
- Railings and protective systems
- Walkways and auxiliary structures
- Angles, flat bars and U profiles
- Square or rectangular tubes
- Parts whose geometry can be optimised for a specific application
The aim is to identify those areas where corrosion is generating a recurring cost and assess whether a GRP profile can provide a technically suitable solution.
Standard profile or profile specifically designed for the application?
In some projects, the solution may be found within a range of standard profiles.
In others, replacing a metal component requires adapting dimensions, geometries, thicknesses or functional areas.
Pultrusion also makes it possible to develop special profiles with a constant section for specific applications.
This opens up the possibility of approaching the material change not as an exact copy of the existing metal part, but as an opportunity to review the design.
In certain cases, a geometry developed specifically for the application can integrate functions, simplify fixings or reduce subsequent assembly operations.
For maintenance, engineering and purchasing managers, this possibility is particularly interesting when the current component repeatedly causes problems.
When should a direct replacement not be made?
GRP offers significant advantages in certain applications, but it should not be considered a universal replacement for steel, aluminium or other materials.
Before making a change, the following factors, among others, must be analysed:
- Loads and stresses
- Required stiffness
- Section dimensions
- Distance between supports
- Service temperature
- Chemical environment
- Outdoor exposure
- Joining and fixing system
- Tolerances
- Surface performance requirements
- Applicable regulations
For profiles intended for structural applications, these factors are particularly important.
The right question is not simply whether GRP is “better” than metal, but which material provides the most efficient solution for specific service conditions.
From repairing the problem to eliminating part of the maintenance
When a company has spent years repainting, repairing or replacing the same components, it is easy to assume that these operations are an unavoidable part of maintenance.
But this does not always have to be the case.
In some situations, changing the material makes it possible to address the cause of the problem instead of simply repairing its consequences periodically.
If corrosion is one of the main reasons for intervention, considering GRP profiles can help reduce:
- Anti-corrosion treatments
- Repainting operations
- Surface repairs
- Replacements caused by oxidation
- Maintenance hours
- Certain shutdowns associated with these interventions
For maintenance teams, this means reducing recurring interventions.
For purchasing teams, it means analysing the component from a total cost perspective rather than solely according to its acquisition price.
And for the company, it means being able to design facilities that are easier to maintain throughout their service life.
GRP profiles for industrial applications
Polymec manufactures glass fibre reinforced polyester profiles by pultrusion, with a range that includes structural profiles and different standard geometries, as well as special profiles developed according to the requirements of each project.
This makes it possible to consider both the replacement of existing elements and the development of new solutions when a standard geometry does not meet the requirements of the application.
In structural projects, in addition to selecting the material correctly, it is essential to work with profiles whose mechanical properties are defined and suitable for the expected loads.
Do you have a metal component that requires too much maintenance?
If a support, profile, auxiliary structure or metal component requires recurring repainting, anti-corrosion treatments, repairs or replacements, it may be a good candidate for considering a GRP alternative.
Send us the geometry, dimensions, working conditions and requirements of the part.
At Polymec, we can analyse whether a suitable standard profile exists or whether the project requires the development of a specific geometry through pultrusion.
Reducing maintenance does not always mean maintaining a part better. Sometimes it means choosing, from the outset, a material that requires fewer interventions.
