Technology of Durability: How Protective Coatings for uST Complex Components Are Created

The components of uST transport and infrastructure complexes are subjected to intense exposure to temperature fluctuations, solar radiation, and chemically active environments. To ensure transport withstands these challenges, engineers at Unitsky String Technologies Inc. test protective systems designed to function for decades.

Years of Operation Simulated in Just 24 Hours

At the company’s testing laboratory, the climatic conditions of all the regions where uST systems are planned to be deployed are recreated. In just one day, materials go through what they will experience in reality over years of operation.

More than 200 different samples have already been tested. The technique is based on cyclic loads.

• Greenhouse Effect. A chamber set at 55°C and 97% humidity replicates tropical conditions, with water vapor literally attacking the material.
• Marine Aggression. Concentrated salt-laden air impacts test plates for four hours, simulating years of exposure in coastal ocean zones.
• Siberian Shock. A rapid transition to Arctic cold reveals weak points in coatings for uST vehicles. Even microscopic defects can lead to major failures.
• Desert Sun. The final stage involves ten hours of intense irradiation under powerful lamps, simulating operation in high-altitude and desert regions.

A Complex Multi-Layer System

Each material undergoes twenty full testing cycles while technologists meticulously record color changes, cracks, and adhesion loss.

Critical zones include welded joints and surfaces with different pre-treatment methods. The tests include galvanized steel samples, sandblasted components, and elements with arc metallization, covering the full range of surface treatment technologies applied in the construction of uST transport complexes.

Currently, coating systems with primers from six different manufacturers, including promising Belarusian innovations, are undergoing testing. Each system is a complex multi-layer structure, consisting of: specialized primers to enhance adhesion, intermediate anti-corrosion layers, final coatings with decorative and protective properties. The combination of these layers is designed to ensure at least 15–20 years of maintenance-free operation of transport infrastructure elements.

Guaranteeing the Reliability of uST Complexes

The data obtained during testing plays a key role in economic project analysis. A transport system with a planned lifespan of half a century requires precise forecasts for operational costs and maintenance expenses.