A leading manufacturer of construction and transportation equipment was facing a growing problem—corrosion was cutting into their bottom line. Their heavy-duty cranes, trucks, and offshore support vehicles were built to withstand tough conditions, but premature rusting was leading to unexpected breakdowns, costly repairs, and frustrated customers.
These machines operated in coastal construction sites, industrial shipping yards, and offshore energy projects, where exposure to salt, moisture, and extreme weather was unavoidable. The company had always tested its materials before production, yet corrosion-related failures kept appearing. They needed to figure out why—and fast.
Challenge
The company had been relying on standard salt spray tests to check for corrosion resistance. This test continuously sprayed a fine mist of saltwater onto metal surfaces, but it wasn’t replicating real-world conditions accurately.
In the field, these machines experienced cyclic exposure to harsh elements—rainstorms followed by dry heat, cold nights followed by humid mornings. Components were wet, then dry, then exposed to extreme temperature swings, all of which accelerated rust formation in ways that simple salt spray tests couldn’t predict.
The result? Materials that passed lab tests were still failing in the real world. Coatings peeled, bolts weakened, and structural parts corroded faster than expected. The company had to deal with expensive warranty claims, delayed projects, and dissatisfied customers who couldn’t afford unexpected downtime.
Beyond that, their testing process was slow and unreliable. Engineers often had to wait months or even years for field results before they could make improvements. They needed a faster, more accurate way to predict corrosion—one that matched the real-world conditions their machines faced every day.
Solution
The company adopted the Q-Fog CRH cyclic corrosion test chamber, a breakthrough in accelerated corrosion testing. Unlike the outdated salt spray method, the Q-Fog CRH accurately simulated the full range of environmental conditions these machines endured in the field.
This new system allowed engineers to test parts under precisely controlled cycles of salt exposure, drying, humidity, and temperature changes—mimicking the actual conditions in coastal shipping terminals or offshore construction sites. Instead of relying on outdated, one-dimensional tests, they could now see exactly how their materials and coatings would perform over time.
With automated and repeatable test sequences, they eliminated guesswork and inconsistencies. Engineers could now compare different metal treatments, fine-tune coatings, and spot weaknesses in days instead of months.
Results and Impact
The impact was immediate. By shifting to Q-Fog CRH testing, the company cut its product validation time by 40%, allowing engineers to make improvements faster than ever before. This led to more than 50% reduction in corrosion-related warranty claims, saving them millions in replacement and repair costs.
With a better understanding of how rust formed on their equipment, they made targeted improvements to materials and coatings, extending the lifespan of critical components like hydraulic cylinders, steel frames, and fasteners. Their machines now lasted longer in the harshest environments, reducing downtime for customers and increasing brand trust.
In fact, the improvement in durability helped them secure new contracts with major construction and transportation firms, who were looking for equipment that could withstand extreme weather and rough operating conditions.
Conclusion
Corrosion is a silent profit killer. It weakens equipment, increases maintenance costs, and damages customer relationships. But with the right testing methods, it can be controlled before it becomes a costly problem.
For this manufacturer, the switch to realistic cyclic corrosion testing didn’t just solve their immediate failures—it transformed their entire product development process. They now produce tougher, more reliable equipment that customers trust to perform in the most extreme environments.
Contact us today to learn how the Q-Fog CRH can help you optimise your testing process and deliver more resilient products to the market.
