Page 343 - Challenges in Corrosion Costs Causes Consequences and Control(2015)

CORROSION STUDIES 321

TABLE 5.3 Costs of Corrosion Protection Methods in Japan
Corrosion Protection Method Cost (Yen × Billion)
Paints and protective coatings 1595
Surface treatment 648
Corrosion-resistant materials 239
Rust-preventive oils 16
Corrosion inhibitors 16
Cathodic protection 16
Research and development 22
Total 2551

total costs amounted to approximately 2.5 trillion yen (US $9.2 billion). Paints and
coatings amounted to nearly $3.1 billion. Surface treatments and corrosion-resistant
materials accounted for nearly one-quarter and one-tenth of the costs, respectively.
All other corrosion control methods accounted for less than 5% of the costs. The costs
to prevent or control corrosion by Uhlig’s methodology yielded the data provided in
Table 5.3 with respect to the Japanese context.
The Hoar method applied to determine the cost of corrosion in the Japanese indus-
trial sector resulted in the data mentioned in Table 5.4.
The disparity between the two estimates is large. The Uhlig method’s estimate is
1.5 trillion yen higher than the value obtained by the Hoar method. The difference in
the two estimates is in part because of omission of some costs by the Hoar method.
In the normal course, the Hoar method is expected to give a higher value than the
value estimated by Uhlig’s methodology. The differences between the two methods
may be attributed to the difficulties and uncertainties in the investigation of the costs
of corrosion.
The Japanese report recommended to: (i) establish corrosion prevention service
center of technical experts; (ii) increase two-way communications between academic
institutions and industry and (iii) enhance training of engineers; (iv) increase aware-
ness from elementary school to university level for saving material resources and
conservation of the environment; (v) monitor and inspect, in terms of research and
development, equipment and machines for corrosion prevention control.

TABLE 5.4 Cost of Corrosion in the Japanese Industrial Sector (Hoar Method)
Industry Sector Corrosion Cost (Yen × Billion) Percent of Total
Energy 60 6
Transportation 195 19
Building 175 17
Chemical industry 154 15
Metal production 27 3
Machinery and manufacturing 433 42
Total 1043 100%