Background Introduction

　　Corrosion is a common phenomenon that everyone is accustomed to. However, by chance, we came across rust prevention, and a set of data was shocking! Corrosion losses in developed countries in Europe and America account for 3%-5% of GDP, exceeding the GDP growth rate. Can such huge losses be avoided through effective measures? After raising this question, we couldn't wait to find the answer.

　　As a comprehensive institution focused on manufacturing research, with the sole purpose of discovering industrial value and promoting enterprise development, the Zhonggong Lianchuang International Equipment Manufacturing Research Center has the responsibility, obligation, and ability to do something in researching the hazards of corrosion, discovering the value of rust prevention, and promoting rust prevention experience. Thus, a research group on corrosion and rust prevention in the equipment manufacturing industry, consisting of four researchers and one expert, was quickly established. The group first investigated the current corrosion losses and rust prevention awareness in China, and found that corrosion losses are shocking. Then, a typical domestic rust prevention enterprise was selected for a case study to gain an in-depth understanding of the current level of rust prevention technology, the status of the rust prevention industry, and future development trends; furthermore, the application and development of rust prevention in the fields of metallurgy, machine tools, automobiles, construction machinery, shipbuilding, and electronic components were investigated.

　　The survey results are encouraging. Although rust prevention is a small industry and is generally ignored by the manufacturing sector, more and more people are beginning to pay attention to it. More encouragingly, China's rust prevention technology level is not backward, and the industry is developing well. The research results of the group have been formed into several articles published in various media, hoping to make more people understand, recognize, and value rust prevention, and ultimately reduce losses and improve efficiency through effective rust prevention.

　　Construction machinery refers to the general term for mechanical equipment necessary for comprehensive mechanized construction projects required for earthwork and stonework construction, road construction and maintenance, mobile lifting and loading/unloading operations, and various building projects. It is an important part of China's equipment manufacturing industry. With the end of explosive extensive growth, the construction machinery industry has entered a refined growth phase that focuses more on technology and quality. To provide customers with more satisfactory products, enterprises must give products more care! Rust prevention is an issue that needs attention.

　　Construction Machinery Needs Rust Prevention "Care"

　　The corrosion losses of construction machinery are staggering every year! According to global statistics, corrosion losses are between 3% and 5%. In 2012, China's construction machinery output value was 601.8 billion yuan. Based on this ratio, the Zhonggong Lianchuang International Equipment Manufacturing Research Center estimates that the annual corrosion loss of China's construction machinery is between 18 and 30 billion yuan. This is a huge profit that cannot be ignored by any enterprise.

　　After more than a decade of expansive development, China's construction machinery market has shifted from a seller's market to a buyer's market. The market's requirements for product performance and quality are increasingly high, and customers are increasingly picky about products. In order to gain an advantage in competition, construction machinery enterprises have gradually begun to look for ways to reduce costs and enhance product added value. Rust prevention is a very good approach.

　　In a seller's market, customers demand fast delivery and quick deployment into projects. Getting the product as soon as possible is what they value. Rust on the body or other parts, although unsightly, does not immediately affect the use of the product, and no one cares about these details. In a buyer's market, customers demand higher product quality and lower prices. In order to stand out among many competitors, enterprises will pay more attention to improving the overall quality of products and to details. The previously insignificant rust problem has now gradually become an urgent problem to be solved.

　　In fact, corrosion of construction machinery is not just a matter of unsightliness. The appearance quality of a product represents the level of the enterprise. An enterprise that cannot even do a good job in appearance gives customers the impression that it will not do well in other aspects either. More importantly, corrosion of the product will affect the performance of the machine and reduce the service life of the product.

　　A survey by the Zhonggong Lianchuang International Equipment Manufacturing Research Center on rust prevention in the construction machinery industry shows that many people in the construction machinery industry have realized the hazards of corrosion, but professional rust prevention is still in its infancy. Most enterprises do not yet have a dedicated rust prevention team. Encouragingly, leading enterprises in the industry have begun to try rust prevention and protective packaging for products and have achieved good results, with a significant demonstration effect. In addition, in the Chinese market, the only enterprise that specifically provides rust prevention solutions for construction machinery is currently Shenyang Rust Prevention Packaging Materials Co., Ltd. (hereinafter referred to as Shenyang Rust Prevention). Below, we introduce the rust prevention of complete construction machinery and components through several cases.

　　Rust Prevention Technology for Complete Machines Is Maturing

　　Construction machinery is large equipment. The storage, transportation, and rust protection after use of the complete machine have a great impact on machine performance and equipment use. At present, most equipment rarely takes protective measures. Many machines show corrosion shortly after leaving the factory, or even before leaving the factory. Rust prevention work for construction machinery is a very complex systematic project. Different processes require different rust prevention measures for different parts, and some require comprehensive rust prevention measures. Here, based on some practical cases of Shenyang Rust Prevention, we introduce the most important storage rust prevention and transportation rust prevention.

　　Storage Rust Prevention

　　At present, domestic construction machinery equipment, whether from manufacturers or users, generally lacks rust prevention awareness, let alone mastering correct rust prevention methods. Machines are generally placed on open factory grounds or construction sites, directly exposed to harsh environments, wind and sun, rain and dew erosion, and various corrosions quickly appear inside and outside the machine.

　　A domestic construction machinery enterprise often received feedback from customers that many places were rusty as soon as the machine was received, and they suspected it was a second-hand machine. In fact, these were new products that had just come off the production line not long ago. Why did they become "old machines" before use? The enterprise invited the most professional corrosion solution institution in China—the Metal Rust Prevention Technology Public Service Platform—to help find the problem. After a comprehensive inspection by platform experts, it was found that most of the products produced by the enterprise were stored in open-air factories or ordinary warehouses without any protective measures. Not only did the appearance show corrosion, but internal components were also corroded. In particular, the machine's boom and connections also showed corrosion. These places are the load-bearing points of the machine, and corrosion will reduce service life. After finding the cause of the problem, platform experts gave the enterprise a "prescription": isolate the easily corroded parts of the machine from the air. First, remove impurities, apply rust preventive oil, and then wrap with rust preventive packaging paper or film. The results proved that the rust prevention effect was very good. For complete machines stored for a long time, overall packaging with rust preventive film and adding vapor phase corrosion inhibitors can ensure that the machine remains in its original condition for one to two years. Not only is the cost low, negligible compared to the overall value of the machine, but the operation is simple, and ordinary machine operators can operate it after simple training.

　　Transportation Rust Prevention

　　After leaving the factory, construction machinery needs to be transported to all parts of the country for sale, and this transportation process is a link prone to corrosion. A brand-new machine at departure, upon arrival at the destination, is covered with dirt and rust, which will leave a very bad impression on customers. Therefore, it is particularly important to take suitable rust preventive packaging measures during transportation. At present, most construction machinery enterprises in China do not use any packaging, a small number use cover-type packaging, and very few take rust preventive packaging measures.

　　A leading construction machinery enterprise exported a batch of machines to a Southeast Asian country, requiring the vehicles to be driven directly to the destination. Because of the long distance, complex traffic, and frequent rainy weather along the way, there had been cases where machines became "second-hand" products upon arrival, causing losses to the enterprise. In order to ensure that the machines arrive looking brand new, the enterprise sought help from Shenyang Rust Prevention, the most advanced rust preventive packaging company in China, to design a solution. Shenyang Rust Prevention sent an expert team, and after on-site investigation and in-depth research, finally designed a heat-shrink film packaging vapor phase rust prevention solution. After many strict experiments, the rust prevention and protection effects were very good, fully meeting customer needs. This is a packaging film specially developed by Shenyang Rust Prevention for large construction machinery. It has excellent flexibility and airtightness, shrinks when heated to make the packaging tighter, and has functions such as waterproof, dustproof, rust prevention, and collision prevention. More importantly, the cost is low, making it very suitable for packaging large construction machinery.

　　In 2013, a batch of pump trucks traveled long distances to a Southeast Asian country, crossing mountains and rivers and encountering many harsh weather conditions. Upon arrival at the destination, after opening the packaging, the contents were exactly the same as when they left the factory, without any corrosion or bumps. At present, construction machinery enterprises that value quality have successively adopted this most advanced packaging method. Zhonggong Lianchuang predicts that heat-shrink film packaging will become the main form of rust preventive packaging for large equipment.

　　Rust Prevention for Components Can Learn from Automobiles

　　Although there is less experience in rust prevention for construction machinery components, it can learn from the experience of automotive component rust prevention. The automotive industry has a long development history, large market demand, and has entered a mature stage of refinement and standardization. The automotive industry places rust prevention in a very important position and has accumulated rich experience in rust prevention. Construction machinery has a short development history and small scale in China, and is still in the extensive development stage. In the future, it will gradually begin to pay attention to rust prevention work.

　　Rust prevention for construction machinery components mainly includes rust prevention for the entire engine system and components (cylinder block, cylinder liner, cylinder head, etc.), rust prevention for various stamped parts, and rust prevention for key components (gears, universal joints, transmission shafts, hydraulic parts), etc. All of these can learn from automotive component rust prevention. Major domestic enterprises producing construction machinery engines have accepted Shenyang Rust Prevention's "full-process rust prevention" concept and adopted systematic solutions from production line to storage and packaging, and corrosion problems have been well solved.

　　According to a survey by the Zhonggong Lianchuang International Equipment Manufacturing Research Center, although rust prevention and protective packaging for construction machinery in China is in its infancy, with only a few leading enterprises passively trying it after suffering losses, China's rust prevention and packaging technology for construction machinery has tended to mature. With the transformation and upgrading of construction machinery enterprises and the implementation of cost reduction and efficiency enhancement measures, and the gradual enhancement of rust prevention awareness, China's construction machinery products will receive more rust prevention care, and product quality will reach a new level.