The problem of vehicle corrosion has worsen over the years as of new formulations of more aggressive anti-icing chemicals have been employed to more effectively deal with the chief challenges of winter maintenance: mobility and safety.
The problem of vehicle corrosion has worsen over the years as of new formulations of more aggressive anti-icing chemicals have been employed to more effectively deal with the chief challenges of winter maintenance: mobility and safety.
The problem of vehicle corrosion has worsen over the years as of new formulations of more aggressive anti-icing chemicals have been employed to more effectively deal with the chief challenges of winter maintenance: mobility and safety.
The problem of vehicle corrosion has worsen over the years as of new formulations of more aggressive anti-icing chemicals have been employed to more effectively deal with the chief challenges of winter maintenance: mobility and safety.
The problem of vehicle corrosion has worsen over the years as of new formulations of more aggressive anti-icing chemicals have been employed to more effectively deal with the chief challenges of winter maintenance: mobility and safety.

Is the ‘Big C’ threatening the integrity of your fleet?

Aug. 10, 2016
No area of a vehicle is immune to the damaging effects of corrosion.

Back in the 1930s, sodium chloride (rock salt) started being used for de‐icing – the melting of ice and snow on roadways – along with sand strategies to improve traction. Then came de-icing chemicals. These were introduced to better deal with the chief challenge of winter maintenance: mobility and safety.

A problem with de-icing operations is that they can be inefficient. Without reliable weather information, road crews have to wait until a storm hits before they begin to salt, sand and plow. But by then, the storm has the advantage and crews struggle to keep clear roadways that are already covered with snow or ice.

Throughout the years, snow and ice management, as well as the chemicals used to keep roads safe for motorists, have evolved. The winter road maintenance strategy of anti-icing began in the U.S. and Canada in the late 1990s.

Anti-icing is a proactive approach to winter road maintenance. It involves the application of ice control chemicals – before or at the very beginning of a storm – that will lower the temperature at which water freezes This prevent or minimizes frozen precipitation from bonding to a road’s surface. If the snow or ice can be prevented from bonding to the pavement, the roadway will remain wet or slushy, rather than slippery.

Vehicle corrosion has always been an issue, especially in those parts of the country with frigid winter weather that do anti-icing or that are near the ocean.

Essentially, corrosion is the degradation of a material by reaction with its environment. Degradation implies deterioration of physical properties of the material.

CAUSES OF CORROSION

Corrosion is derived from the Latin word “corrodere,” meaning to eat away. The most common form of corrosion is called rust.

Road debris, road salts, sand, gravel, etc., can sandblast a vehicle’s underbody and frame. Chips, scratches and any damage to treated or painted metal surfaces resulting from this abrasion or minor accidents – even to a minor degree – exposes those areas to the caustic environment of road salts, de-icing materials and anti-icing chemicals.

Compounding the problem of corrosion is the accumulation of road salt, dirt, debris, moisture and/or chemicals in hard-to-reach areas of the vehicle underbody or frame. Any damaged areas ought to be repaired as soon as possible to prevent spot corrosion from spreading.

Environmental conditions like dust control chemicals, sea air, industrial pollution, high humidity, moisture and severe temperatures also play a role in accelerating the rate of corrosion on vehicle parts, especially those parts that are not well ventilated to permit quick drying.

NEW CHEMICALS

Corrosion on vehicles has become an even greater concern because of new formulations of more aggressive anti-icing chemicals that have been introduced over the years. These include salt brines, agricultural-based liquid products and potassium acetate.

Two of the more popular ones are magnesium chloride- and calcium chloride-based products. In addition to their ease and speed of application, and being more effective at low temperatures, they tend to be less expensive, less corrosive to concrete and less harmful to the environment.

However, magnesium chloride- and calcium chloride-based products have become a serious maintenance problem for vehicle owners and operators, says the Technology & Maintenance Council (TMC). The use of these products by certain states has resulted in increased corrosion on vehicles, particularly to the underbody and electronics, causing damage in as little as a single winter season.

TMC (www.trucking.org/Technology_Council.aspx) is the only industry association that is focused solely on truck technology and maintenance.

Magnesium chloride and calcium chloride are especially destructive because they cling to the underbody of a vehicle and crystallize as they slowly dry out.

These crystals are hydrophilic, meaning they have a strong affinity for water and readily dissolve in water or a watery solvent. Because they absorb moisture, the crystals remain in a semi‐solution state for extended periods of time, and this multiplies their corrosiveness.

ALL OVER

Corrosion on vehicles operating in the states that most often uses magnesium chloride- and calcium chloride-based products has been reported on chrome, aluminum and even stainless steel, notes TMC. Other areas affected include electrical systems, various sections of vehicle frames and bodies, suspension components, brakes, wheels and wheel fasteners and radiators.

In fact, no area of a vehicle is immune from the effects of corrosive materials and chemicals. However, TMC says the areas generally affected are splash-prone areas on the front, underside and lower portions of vehicles.

Damage from corrosion to the underbody and frame of a vehicle – along with its engine components, brakes and electrical systems – is a cost burden to the vehicle owner. Of greater concern is that this corrosion can result in vehicle safety issues for drivers and passengers.

There are a number of factors that affect the corrosiveness of a chemical, says a report on roadway de-icing by the Idaho Transportation Department. It noted that vehicles contain several different metals, and each metal reacts uniquely to the various chemicals used for winter road maintenance. A de-icer that is minimally corrosive to steel may cause serious corrosion to aluminum, for example.

Moreover, the report says climatic conditions, methods of use and application rates all affect the corrosiveness of a given chemical as well. Corrosion inhibitors further complicate matters, as there are many unique formulations on the market and their effects also vary, based on conditions and the metals they come in contact with.

Vehicle OEMs and suppliers are working on many approaches, such as metal plating and better coatings on new structural components. Fleets are adding aftermarket protective coatings to the underside of existing vehicles and other areas that that are susceptible to corrosion.

INSPECTION

An industry best practice to mitigating the effects of chemical road treatments is to be proactive and regularly inspect vehicles, plus perform the proper preventive maintenance (PM). Included should be a thorough examination of the electrical system and lighting, as even small surface cracks and holes in a wire or cable can cause moisture to wick into the system.

Be on the lookout for early signs of corrosion so that corrective action can be taken before the damage becomes severe.

WASH AND CLEAN

Another best practice is to regularly wash and clean vehicles, especially in winter conditions. This gets rid of the road grime, salt, chemicals, dirt build-up, etc., that can contribute to premature wear on dozens of vehicle parts, along with wear on the exterior finish.

Vehicles should be washed to remove road salt and chemicals within a couple days of exposure.

Chemical additives can be mixed into the water for washing to achieve some degree of protection against road salt and chemicals. However, it is important to use additives with the right chemistry to get the best results. Using an additive with the wrong chemistry can aggravate the problems.

Washing vehicles by hand is preferred to automated or commercial washing facilities. Commercial facilities often use high-pressure wands that emit higher than necessary water pressures and use stiff brushes that can mar or damage a vehicle’s surface. Scratches can penetrate the clearcoat finish, causing delamination and/or other paint related issues not covered under warranty.

The application of neutralizing chemicals to areas of a vehicle that are most susceptible to rust and corrosion can pay benefits as well. 

Applying wax to a vehicle’s finish to act as a buffer will extend the life and beauty of a vehicle’s paint.

Sadly, there is no simple or easy solution to preventing or stopping vehicle corrosion. Vigilance and proper maintenance practicesare the keys to minimizing the impact of the Big C, corrosion. 

About the Author

David A. Kolman | Contributor - Fleet Maintenance