Project Background
Holyhead station, a prominent railway station situated in Wales. Strategically located near a harbour and high street, it serves as a key transport hub, seamlessly connecting the region’s rail and maritime networks. Situated on the harbour, the Grade II listed train station has endured persistent exposure to salty sea air, high humidity, heat from the trains and diesel fumes. This relentless environmental assault has resulted in significant corrosion of the structural steel canopies, causing progressive deterioration of the exposed steel.
The Challenge
Network rail’s current coatings manufacturer could not guarantee their product’s effectiveness due to the harsh location. They needed to find an enhanced paint system that outperforms the currently specified paint system to: Maintain structural integrity Preserve the station’s historical features Reduce maintenance and repair costs.
Solution
The solution implemented was Hexigone’s “smart” corrosion inhibitor, Intelli-ion® AX1, chosen for its superior corrosion protection in harsh environments. Achieving C5-level corrosion resistance, AX1 effectively combats corrosion in highly aggressive environments, such as coastal areas, while delivering longer-lasting corrosion protection. Intelli-ion® AX1 has also endured 1440 hours in salt spray testing (ASTM B117), and offerred enhanced adhesion and colour retention in both laboratory and live testing.
Methodology
To compare performance, two protection systems were applied simultaneously: • 50% of the train station was painted with astandard system. • The remaining 50% was painted with a system enhanced with Intelli-ion®
Laboratory Test Results
Panels with both standard paint and paint enhanced with Intelli-ion® AX1, were tested side by side. The addition of AX1 improved corrosion resistance, significantly increased adhesion levels and the bonding of the aluminium primer to the metal surface. 1000 Hours Salt Spray ASTM B117.
Real-World Results
The addition of intelli-ion® AX1 significantly enhanced the 50% repainting process of the mile-long station’s surface, comprised of tool-prepared Victorian cast iron. Contractors observed the following improved application properties; “the paint applied more easily, spread more evenly, and provided more coverage.” By enhancing surface tolerance, AX1 improved adhesion by 163.16%, resulting in a 33% increase in performance. This improvement led to reduced maintenance requirements, delivering a highly efficient, cost-effective solution with enhanced long-term asset protection.
3 Years After Application
Intelli-ion® AX1 demonstrated superior performance compared to the standard system – designed to provide 15 years of corrosion protection.
