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Tag: Corrosion

  • Securing the AI Boom in the Americas

    Securing the AI Boom in the Americas

    The data center market in the Americas is no longer just growing. The AI boom is surging at a pace that is fundamentally altering the global digital landscape. According to recent industry analysis from Business Facilities, the Americas have solidified their lead as global data center capacity explodes. This lead is largely driven by the unrelenting demand for Artificial Intelligence (AI) and high-performance computing (HPC).

    As of 2025, the U.S. remains the epicenter of this expansion. Northern Virginia, the world’s largest data center market, saw under-construction capacity jump by 80% in the first half of 2025 alone (CBRE). However, this rapid growth brings two critical challenges that threaten to stall the AI revolution. Unprecedented energy demand and the silent degradation of cooling infrastructure.

    At Coat Zone, we believe that the key to sustaining the AI boom isn’t just about building more. It’s about protecting and optimizing what we already have.

    The Energy Paradox: AI’s Massive Cooling Appetite

    Data centers are among the most energy-intensive facilities on Earth. In 2024, data centers consumed approximately 183 terawatt-hours (TWh) in the U.S. alone—roughly 4% of the country’s total electricity (Pew Research). By 2030, this demand is projected to grow by 133% to 426 TWh.

    The “energy hog” in the room is cooling.

    • The Cooling Tax: Cooling systems are the second-largest energy consumer in a data center. They account for 30% to 50% of total energy use in less-efficient enterprise facilities (IEA/Coat Zone).
    • The AI Multiplier: AI-focused servers generate significantly more heat than traditional servers, requiring 2 to 4 times the power and, consequently, a massive increase in cooling capacity to prevent catastrophic hardware failure.

    When cooling efficiency drops even by a small percentage, the Power Usage Effectiveness (PUE) of a data center skyrockets. This drop leads to millions of dollars in wasted operational expenditure (OpEx).

    The Corrosion Threat: A Silent Saboteur of Uptime

    While power grids struggle to keep up with demand, environmental factors are attacking the very machines designed to provide relief. Corrosion is a primary cause of HVAC failure, responsible for nearly 40% of equipment failures in industrial settings (CED Engineering).

    In data center hubs—ranging from the humid corridors of the East Coast to industrial zones in the Midwest—cooling coils are under constant attack from:

    • Salt Air & Humidity: Accelerating the oxidation of aluminum and copper.
    • Pollutants & “Electrolytes”: Gaseous contaminants that cause pitting and “formicary” corrosion, which can lead to refrigerant leaks and total system failure in less than a year.
    • Thermal Stress: Constant 24/7 operation at high loads accelerates the mechanical degradation of the bond between HVAC fins and tubes, reducing heat transfer by 15–20% over just five years (IRE Journals).

    Re-Engineering Resilience for the AI Boom

    To meet the goals of the “Americas-first” data center expansion, facilities must shift from a “replace-on-failure” mindset to a “protect-and-optimize” strategy. Coat Zone’s dual-coating approach provides a high-impact, low-cost shield for the infrastructure powering the AI boom:

    1. CoilSafe® & CoilSafe Plus® (Internal Protection): These ultra-thin (8–10 micron) inorganic coatings bond covalently to HVAC coils. Unlike traditional thick coatings, they do not impede heat exchange. By preventing corrosion and “fouling” (the buildup of dirt and microbes), CoilSafe can improve HVAC efficiency by up to 10% and maintain near-factory performance for the life of the unit.
    2. ThermalBlock™ (External Defense): Applied to exterior cabinets and rooftop ductwork, ThermalBlock acts as a radiant barrier that blocks up to 93% of solar heat. By keeping the unit’s cabinet temperature within 10°F of ambient air, it drastically reduces the “thermal load,” allowing the system to run less frequently and consuming significantly less kWh during peak demand.

    Sustaining the AI Boom with ROI

    As Business Facilities highlights, the Americas are leading the charge in capacity, but that leadership requires a foundation of efficiency. Integrating Coat Zone’s coatings can:

    • Reduce cooling energy consumption by 15–30%.
    • Extend the useful life of assets by 50% or more, deferring massive capital expenditures.
    • Deliver a rapid ROI, typically within 12 to 36 months.

    The future of AI is being built today. By protecting the cooling infrastructure that keeps these digital brains alive, Coat Zone is helping ensure that the surge in capacity is matched by a surge in resilience.

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  • Go Beyond the Lab with ASTM G50

    Go Beyond the Lab with ASTM G50

    Why ASTM G50 Should Be the Gold Standard for Atmospheric Corrosion Testing

    When evaluating how metals and alloys will perform in real-world conditions, choosing the right test method is crucial. While accelerated laboratory tests have their place, the superior method for determining true, long-term atmospheric corrosion resistance is ASTM G50: Standard Practice for Conducting Atmospheric Corrosion Tests on Metals.

    This testing helps product manufacturers, metallurgical companies, and end users understand the wear and corrosion behavior of specified materials.

    What is ASTM G50?

    ASTM G50 is a comprehensive standard that outlines the general procedures and conditions for exposing metal panels and alloys to real-world weather and atmospheric conditions.

    • Objective: To evaluate the corrosion resistance of metals when exposed to the weather and to assess the relative corrosivity of the atmosphere at specific testing locations.
    • Methodology: It involves placing test panels in defined outdoor exposure sites to accumulate data for comparison purposes.
    • Key Consideration: Recognizing the highly variable and complex nature of the atmosphere (weather effects, industrial factors, natural elements), the standard recommends a multi-year exposure period to minimize the influence of short-term variations and provide a reliable assessment.
    • Quality Control: It mandates the use of control specimens—materials with established weathering characteristics—to ensure the test results are meaningful and comparable.

    The Real-World Relevance of ASTM G50

    The most significant advantage of ASTM G50 is its direct correlation to how a material will actually perform in service.

    • True Corrosivity Data: By exposing materials to actual rain, humidity, temperature cycles, UV light, pollution, and natural salt deposits, the test captures the synergistic effect of these variables. This provides data that is inherently more relevant than data from conditions simulated in a controlled environment.
    • Long-Term Performance: The test accounts for seasonal variability and requires multi-year exposure. The results are highly reliable for predicting a material’s long-term durability and lifespan in a specific atmospheric environment.
    • Material Selection and Site Evaluation:
      • It helps determine the most suitable metal or protective coating for products used outdoors (e.g., in construction, automotive, or infrastructure).
      • It can also be used to evaluate and compare the inherent corrosivity of different geographical locations before large-scale projects are built.

    Why ASTM G50 is Superior to ASTM B117 (Salt Spray)

    When the goal is to predict real-world atmospheric performance, ASTM G50 offers a level of fidelity that the commonly used ASTM B117, Standard Practice for Operating Salt Spray (Fog) Apparatus, cannot match.

    While ASTM B117 (often called the salt fog or salt spray test) is a valuable tool for quality control and detecting gross material defects, it is fundamentally an accelerated laboratory test with severe limitations for performance prediction.

    FeatureASTM G50 (Atmospheric Corrosion)ASTM B117 (Salt Spray/Fog)
    Test EnvironmentReal-world weather (rain, sun, temperature cycles, natural contaminants).Controlled, high-humidity fog of 5% neutral salt solution at constant temperature.
    RelevanceHighly correlated with real-world, long-term outdoor performance.Seldom correlated with performance in natural environments when used as stand-alone data.
    Test DurationTypically multi-year (e.g., 1, 3, 5 years).Typically measured in hours or days (e.g., 24, 100, 1000 hours).
    PurposeEvaluates true corrosion resistance and atmospheric corrosivity.Provides relative corrosion resistance information for comparison in a given test chamber.
    LimitationHigh variability if exposure time is too short.Poor predictability for long-term outdoor use without corroborating field data.

    As the ASTM B117 significance section notes, “Prediction of performance in natural environments has seldom been correlated with salt spray results when used as stand-alone data.” Furthermore, correlation should be considered “only in cases where appropriate corroborating long-term atmospheric exposures have been conducted.”

    The ultimate “corroborating long-term atmospheric exposure” is, in essence, an ASTM G50-style test. The salt spray test simply does not replicate the complex, cyclic drying/wetting, UV exposure, and contamination effects that occur naturally. It creates a highly specific, controlled environment, which is why its results often fail to translate to the real-world performance engineers truly need to know.

    Coat Zone and ASTM G50

    Despite completing 6,000 hours of B117 testing, we believe the G50 evaluation provides a stronger case for the efficacy of CoilSafe®, which is why we conducted an ASTM G50-style marine exposure evaluation. This evaluation included 25,000 hours of natural marine exposure on Galveston Island, one of the harshest coastal environments. Third-party reporting showed that CoilSafe® exhibited complete corrosion resistance, whereas the uncoated coil on the same rooftop showed extensive deterioration consistent with chloride-driven corrosion. Learn more about the results of this evaluation here.

    Final Thoughts

    For any material designed to withstand the elements, relying solely on an accelerated lab test such as ASTM B117 is a risk. ASTM G50 provides the necessary rigor and realism by testing materials in their actual operating environment: the open atmosphere. By adhering to its procedures—including using controls and committing to multi-year exposures—companies can gain confidence that their material’s performance data is not only fast but also accurate.

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  • Beyond the Algorithm: Protecting Your HVAC Investment from the Unseen Threats

    Beyond the Algorithm: Protecting Your HVAC Investment from the Unseen Threats

    In an era defined by artificial intelligence and interconnected systems, the promise of a smart HVAC system often takes center stage. We hear about predictive maintenance, optimized energy consumption, and seamless climate control, all powered by sophisticated algorithms and real-time data. Indeed, these advancements represent a monumental leap forward in facility management. However, even the most advanced automated HVAC solutions, while brilliant at detection, have limitations when it comes to the physical threats that quietly degrade your equipment: corrosion, unchecked thermal load, and insidious microbial growth.

    Your substantial investment in HVAC infrastructure is the lifeblood of your operations, directly impacting everything from product quality and data center stability to patient care and grid reliability. While a smart HVAC system can expertly identify a problem, it cannot fix or prevent the root causes of physical deterioration.

    The Blind Spots of Smart HVAC: Where Data Meets Deterioration

    Think of your smart HVAC system as a highly intelligent diagnostic tool. It can tell you when a coil is losing efficiency, when airflow is restricted, or when a temperature differential suggests a problem. These systems excel at alerting you to anomalies that might indicate:

    • Increased Thermal Load: A rise in temperature or unexpected energy consumption may signal that your HVAC unit is struggling against external heat, possibly due to compromised insulation or an overloaded system. Your smart system identifies the symptom but doesn’t inherently reduce the heat transfer at the component level.
    • Corrosion: Over time, particularly in harsh environments prone to salt air, humidity, or industrial pollutants, metal components within your HVAC system are susceptible to corrosion. A smart system might detect a drop in performance or a change in pressure that results from corrosion-induced leaks or blockages, but it doesn’t apply a protective barrier against the corrosive elements themselves.
    • Microbial Growth: The damp, dark interiors of HVAC coils and drain pans are ideal breeding grounds for bacteria, mold, and other microbes. A smart HVAC system might flag compromised indoor air quality or reduced airflow, which are consequences of microbial buildup, but it cannot actively inhibit the growth of these organisms on surfaces.

    In essence, while your intelligent system flags the “what” and sometimes the “when,” the “how to fix” and “how to prevent” often extend beyond its digital capabilities, requiring tangible, physical solutions.

    The Human Element: Recognizing and Solving Tangible Problems

    This is where proactive, physical protection becomes indispensable. Smart systems are invaluable for monitoring, but true resilience and longevity for your HVAC assets come from addressing these silent, destructive forces head-on. Without effective countermeasures, early detection by a smart HVAC system merely becomes an early warning of inevitable, costly repairs or premature system replacement.

    Consider the implications:

    • Corrosion leads to a loss of structural integrity, refrigerant leaks, reduced efficiency, and can even compromise indoor air quality by serving as a haven for harmful pathogens.
    • Unmitigated Thermal Load forces your system to work harder, leading to increased energy bills, premature wear and tear on components, and potential system failure.
    • Microbial Growth not only reduces system efficiency but also contaminates indoor air, posing health risks to occupants and exacerbating allergies and respiratory conditions.

    These are not problems that software updates can resolve. They require a physical shield, a robust defense engineered to withstand the very environmental stressors that smart systems can only report.

    Coat Zone: The Proactive Solution Your Smart HVAC System Needs

    At Coat Zone, we understand that true HVAC optimization means combining intelligent monitoring with superior physical protection. Our advanced coatings are specifically designed to address the challenges that even the most sophisticated smart HVAC system cannot:

    • CoilSafe and CoilSafe Plus: These interior coil coatings offer entry-level and enhanced protection against microbial buildup and corrosion, thereby maintaining coil efficiency and airflow. CoilSafe Plus®, with its antimicrobial properties, actively prevents coil fouling, ensuring cleaner air and optimal performance where bacteria and viruses might otherwise thrive.
    • ThermalBlock: Our comprehensive exterior and rooftop defense solution protects cabinets, ductwork, and rooftop units, providing a robust defense against thermal stress. This UV-resistant, waterproof coating significantly reduces thermal load, keeping your systems cooler, reducing energy consumption, and extending the lifespan of your valuable equipment.
    • The Dual Approach: For total system performance and unparalleled durability, Coat Zone advocates a “Dual Approach,” combining interior coil protection with exterior surface defense. This strategy creates a holistic shield, allowing your smart HVAC system to focus on optimizing performance while our coatings safeguard your equipment from the physical threats it faces daily.

    While your automated HVAC system provides invaluable insights for diagnosis, Coat Zone and its approved dealers offer enduring solutions for prevention and protection. We own the cutting-edge coatings, and our network of certified dealers ensures their expert application, providing a seamless solution from assessment to implementation.

    Don’t let the silent threats of corrosion, thermal load, and microbial growth compromise your critical HVAC investments. Empower your smart HVAC system with the physical resilience it needs to truly thrive.

    Act Now for Lasting Protection

    Ready to move beyond mere detection and embrace comprehensive protection for your HVAC infrastructure? Schedule a consultation with Coat Zone today. Our experts and approved dealers are ready to provide tailored solutions that extend equipment life, enhance efficiency, improve indoor air quality, and secure your operations against the unseen, physical threats.

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