Case Studies

Case Study - Type 4 Rail Car Rust Proofing

The maintenance of high speed railway rolling stock is something that requires expert engineering know how. Wabtec of Doncaster are one such company trusted with the maintenance of East Coast Railways Type 4 Railcars. Rustbuster where consulted by Interfleet Technologies now SNC Lavilan to advise them on the best way of applying rust proofing to cavity areas between a double skinned floor. The only access would be via 20mm holes drilled into the under body.

Rustbuster proposed the use of Fe-123 rust converter followed by Rustbuster Mil-Spec cavity wax.

Tests where carried out to ensure that Fe-123 was not only capable to convert the rust within the cavities, but also its abilities to travel into the damp areas that existed with hidden seams. It was clearly shown that Rustbuster Fe-123 was able to penetrate the damp substrate and migrate through to the steel. Rustbuster Fe-123 was also sublected to Fire propogation testing and was passed on the grounds that it will not add to fire propogation or create additional smoke.

Rustbuster Mil-Spec cavity wax was also subjeted to the same fire propogation testing and was duly approved for use on the refurbishment and maintenance of these type four Rail cars.

Both the Rustbuster Fe-123 and the Mil-Spec rust proofing wax where injected using a Lemmer 460 HD injection system supplied by Rustbuster Ltd

Rail car Injection Drawing

´╗┐Full Interfleet Spec

Rust remover

Rust treatment

Case Study - Protecting Sea Tractors

When approached by the RNLI in Poole Dorset requiring a system specification for a coating that could withstand immersion in salt water and being hit by sand and stones at the same time we had no hesistation in recomending our Rustbuster Epoxy Mastic 121 system.

Click hetre to view work we copmpleted in October 2016 for the FORD motor company blue light division. We recieved a brand new Ford Ranger truck with instructions from the RNLI for Ford to have it coated in Rustbuster EM121 Epoxy Mastic to protect it from the rigours of use as a coast guard vehicle having to withstand being driven in sea water containing moving pebbles and sand. No tougher test we'd say,

Prior to using the system tests where made by the RNLI for salt water immersion and gravelometre testing for resistance to stone and chip abrasion. The Epoxy Mastic 121 passed the test and was specified for use on there tractor refurbs. For the last 8 years Rustbuster has been supplying the RNLI with its Epoxy mastic 121 product. The results have been so succesfull that new tractors are also upgraded to the Rustbuster Epoxy 121 system.

System specification.

Blast clean to SA 2.5 or MBX Bristle blast prior to application of two coats Rustbuster Epoxy Mastic 121.

Royal National Lifeboat Institution

epoxy mastic 121

epoxy mastic

Cast Study - Salt Contaminated Electric Fence

Here is one to watch for the future, Nuclear power stations are positioned next to the sea for lots of good reasons. Due to the controversial nature of Nuclear power they have to be protected. The perimeters are often protected by an electric fence. Steel, wire and the insulators exposed in an extremely salty atmosphere soon build up huge amount of salt. Salt being the conductor it is kindly sets off the intruder alarms when it reaches a certain level and bridges the insulators.

At Rustbuster we have recently developed a unique salt removing surfactant Rustbuster Chlor-X that gets right underneath the salt crystals and lifts them from the surface of the steel, wire and insulators. With a regular cleaning regime of power washing with Rustbuster Chlor-X salt remover at a dilution of 100:1 the problem will soon be solved.

Rustbuster Chlor-X will remove salt from vehicles, trains, bridges, fences and buildings in fact any structure where salt causes damage will benefit from regular washing down with Rustbuster Chlor-X salt remover. The above case study prooves the point excellently

No salt no conductivity

No salt reduces corrosion.

chlor X salt remover



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Rustbuster Ltd
Welland House
Cradge Bank
South Linconshire
PE11 3AN

01775 761 222

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Rustbuster is a registered trade mark of Rustbuster Ltd, registered in the UK Trademark number 2211446 Class 02 & 37.
Any unlawful use of the Rustbuster name or logo or passing off will result in legal proceedings. Rustbuster Ltd UK registerered 3639350.