Purchasing a heavy-duty vehicle is a long-term investment that should offer a reasonable return over time. In the case of trailers and body systems, each additional year of use significantly increases cost-efficiency. This is why both manufacturers and transport company owners pay close attention to vehicle lifespan and the additional costs associated with inspections, repairs, and refurbishments.
When estimating the total cost of ownership, it’s crucial to consider every detail. The best approach is to verify the manufacturer’s claims—examining how their vehicles and superstructures are built, and more importantly,
how they are protected against damage, wear, and above all, corrosion.
Factors contributing to corrosion
Corrosion can arise from a variety of causes and develop in different ways. It typically begins with mechanical damage to steel components, which increases their exposure to the atmosphere. The process accelerates when aggressive chemical compounds are present, or when the environment becomes highly acidic or alkaline. Electrochemical reactions can also be triggered by contact with dissimilar materials.
Heavy-duty vehicles – especially those used in off-road or construction environments – are exposed to a wide range of corrosive factors, including chemically active construction materials and salt-laden slush from winter roads. High temperatures (e.g., when transporting asphalt or bitumen), humidity, mechanical impacts, and abrasion during loading/unloading further exacerbate the issue. Under such harsh conditions, even the most robust factory coatings may fail to prevent corrosion within the first few years of operation.
Traditional protection methods
Traditional corrosion protection consists of multilayer paint systems – starting with a strong anti-corrosive primer, followed by intermediate coatings, and a hardened, impact-resistant topcoat. An additional level of protection can be achieved using galvanized components.
However, maintaining these systems in good condition is complex and costly. Structural elements must be regularly inspected to detect early signs of damage: cracks in the coating, initial corrosion, or delamination. Any identified issues require immediate repair. The vehicle must be taken out of service, cleaned, and prepared for workshop treatment, which may involve the disassembly of certain components – a time-consuming and expensive process. If corrosion is left unaddressed, it may eventually lead to the vehicle’s premature withdrawal from service, even if the overall mechanical condition remains acceptable.
Have you known?
In winter, water in lakes near Norwegian roads can be up to ten times saltier than seawater, creating extreme corrosion conditions. That’s why ISTRAIL is the only manufacturer to offer metallization of dump truck and trailer body components as standard—backed by a 3-year warranty on metallized surfaces.
www.istrail.com
Metallization – proven corrosion protection
One of the most effective methods of protecting steel or other metal components from corrosion is metallization, which involves applying a metallic coating that adheres tightly to the substrate
and provides excellent resistance to rust.
Several methods and coating materials are used in practice, including:
- APS – Atmospheric Plasma Spraying: coatings of chromium oxide, aluminum oxide, zirconium dioxide, tungsten carbide,
- HVOF – High-Velocity Oxygen Fuel Spraying: tungsten carbide and chromium carbide coatings; known for high-speed application and oxide-free layers,
- AWS – Arc Welding Spraying: zinc and aluminum coatings, carbon and alloy steels, bronze, brass, etc.,
- FWS/FPS – Flame and Powder Wire Spraying: zinc and aluminum, molybdenum, carbon and alloy steels, bronze, brass, and copper.
Every truck operator knows how quickly rust becomes a cosmetic and financial problem. ISTRAIL has addressed this with metallization, offering long-term, rust-free durability. ISTRAIL is the first company in Norway to implement this solution as standard, ensuring peace of mind for our customers. ISTRAIL – as the first company in Norway – offers this solution and provides a three-year warranty on metallized parts. The anti-corrosion treatment extends the life of parts and increases their value in use. The metallization is a standard feature of ISTRAIL products and is available at
no extra charge.www.istrail.com
Metallization at ISTRAIL
At ISTRAIL’s production plant in Golub–Dobrzyń, metallization is used to protect structural elements of truck bodies, trailers, and semi-trailers. The effectiveness of this method has been confirmed by long-term field performance, especially under harsh environmental conditions.
Metallized surfaces can be left uncoated or finished with traditional paint systems. ISTRAIL’s extensive experience in truck body metallization shows that this process significantly increases component durability – and, by extension, the operational life of the vehicle itself.
Metallization of structural components is a standard feature in ISTRAIL products and is included at no extra cost. Additionally, all metallized components are covered by a 3-year warranty, demonstrating ISTRAIL’s commitment to quality and longevity.