Case Studies
ARC Corrosion Protection for Roller Table Gearbox Internals
Challenge
Background
Heat from the passing steel plates caused condensation inside the gearbox, leading to corrosion. Rust-contaminated moisture then entered the oil, causing it to deteriorate and require replacement. To prevent oil degradation, rust had to be removed with grinders during annual maintenance.
Root Cause
No long-term corrosion protection was in place.
Goal
Prevent corrosion and protect the oil from degradation.
Condition before application.
Solution
Recommended Solution
ARC S5 was selected because temperatures inside the gearbox can reach approximately 100°C as the hot rolled steel passes through.
Application Process
- Surface preparation was carried out using Sponge-Jet #30.
- ARC S5 5L: 3 kits used.
- Sponge-Jet Media #30: 10 bags used.
ARC S5 application.
Results
Applied in May 2022. After 2 years and 7 months, no corrosion or oil degradation was observed. The ARC application cost ¥2,000,000. Previously, annual gearbox maintenance required eight workers over 10 days, costing approximately ¥2,400,000 per year.
Over two years, this resulted in an estimated ¥2,800,000 in savings ($18,000 USD).
Following the successful results, ARC was also applied to adjacent equipment in 2024.
Condition after application.
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Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
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