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STEEL CONSTRUCTION:
PROTECTION: CORROSION
1. PRACTICAL DESIGN
General considerations, the benefits of designing to allow the effective use of protective
coatings and, making a conscious decision as to where they should be applied are dealt
with in Section 2 of Lecture 4A.2. The requirements of Eurocode 3 [1] are described in
Appendix 1.
Corrosion prevention truly starts on the drawing board. Design details which avoid water
traps, ensure adequate drainage and promote air circulation restrict corrosion. Avoiding
contact between dissimilar metals, removing sharp edges and corners are all important.
Supremely important, but frequently overlooked or ignored in design is access for
6. SPECIAL CASES
6.1 Steel in Concrete
For many years it was held that steel in concrete required no protection. Provided that the
compaction of the concrete was adequate, it was uncontaminated with salt, and remained
crack-free, this view was true due to the high pH value of concrete. However the concrete
thickness needs to be above 40 mm for protection to remain effective for the life of most
structures.
A particular problem is the spalling or cracking of concrete associated with the corrosion
of reinforcing bars (rebars) in concrete. External chlorides from de-icing salts, marine
environments or internal sources, e.g. from saline aggregate, can alter the electrochemical
environment locally causing the reinforcing steel in reinforced concrete structures to
become non-passive.
If corrosion is remotely possible, then protection of the steel by fusion bonded epoxy
coatings should be considered.
6.3 Cladding
Prefinished cladding for roofing and walls is lightweight and its use allows cost savings to
be made in the overall building frame. A variety of profiles is available with the basic
material being either steel or aluminium. If steel, it is hot dip zinc or zinc/aluminium
coated for protection against corrosion.
Choice of substrate
Choice of coating
On aluminium, the coating is generally 30 m or below. This coating does not give a good
performance externally.
On galvanized steel cladding both 'thin' and 'thick' coating systems are available. As noted
above, 'thin' coatings of 30 m or below behave poorly outside. 'Thick' coatings (200 m)
are mainly plastisols. 'Thin' coatings are commonly PVF2, Acrylic or Polyester.
Manufacturers' descriptions
One must be cautious of manufacturers' descriptions. Many thin coatings are claimed to
have excellent colour retention; no reference is made to the ease of site damage during
storage, installation or, life of the building.
"Plastiscol" is a generic term applied to formulae whose performances vary dramatically.
Be specific regarding performance pollution. Assess internal environments equally
carefully.
The period to first maintenance is generally defined as the time after which the protective
system no longer protects the surface. It can also be the point in time when the cladding's
appearance becomes aesthetically unacceptable. It is important to specify which definition
is being used.
Influence of aspect
When appearance is important, it should be noted that the same product weathers
differently on north- and south-facing elevations or roofs. Data from manufacturers
requires careful study.
Modern coated cladding may well have a life to first maintenance of twenty five years.
Eventually however the coating will need refurbishing.
Deterioration of coatings has four phases:
1. The coating chalks, i.e. its surface weathers into a chalk-like layer which is
unsightly but can be removed leaving the surface beneath unaffected, reducing its
thickness. Planned maintenance is of greatest value at this stage.
2. The coating develops a very fine crazing which, if left, penetrates to the metal
substrate. Maintenance systems must be able to deal with this condition.
3. With the coating system crazing and finally cracking, the substrate begins to
corrode. The specialist maintenance processes available today can be used
effectively, but the original coats must be stripped off. The cost of maintenance is
therefore increased.
4. The substrate perforates, when there is no alternative but to reclad.
Overpainting prepainted cladding is a major undertaking. The cladding may have been
finished in one of seven generic types, all of which pose different problems. It is essential
to involve a specialist contractor to apply the maintenance system. The system in turn
must be supplied by one of a small number of European paint manufacturers producing
paints specifically designed to maintain cladding.
7. CONCLUDING SUMMARY
Good design of the members and the joints in the steel framework is the key to
corrosion prevention.
The quality of the coatings on fasteners and welds is as important as that on the
main framework.
The macro- and micro-environments both inside and outside of the building have
to be considered.
Particular care must be taken when designing steelwork that will be inaccessible on
completion of execution. Allowances for construction tolerances should be made.
Steelwork surrounded with concrete having a low pH value, poor compaction and
placed in thin layers will not protect the steel from corrosion.
Cladding is not only a weather-proof covering to the structure. It may also provide
insulation and strength and thus require a sophisticated protective coating.
When writing a corrosion prevention specification for the first time advice should
be taken from an experienced practitioner.
8. REFERENCES
[1] Eurocode 3: "Design of Steel Structures": ENV1993-1-1: Part 1.1: General rules and
rules for buildings. CEN, 1992.
[2] pr EN 1029: Specification for hot dip galvanised coatings on iron and steel articles.
[3] BS 4221: Specification for sheradised coatings in iron and steel articles.
[4] BS 3382: Specification for electroplated coatings on threaded components.
[5] ISO 3269: Fasteners - Acceptance Inspection.
APPENDIX 1
Eurocode 3 Requirements
Eurocode 3 "Design of Steel Structures - Part 1 General Rules and Rules for Buildings"
[1] sets out certain general requirements with regard to durability as follows:
1. To ensure an adequately durable structure, the following inter-related factors shall
be considered:
the use of the structure
the required performance criteria
the expected environmental conditions
the composition, properties and performance of the materials
the shape of members and the structural detailing
the quality of workmanship and level of control
the particular protective measures
the likely maintenance during the intended life.
APPENDIX 2
A.2.1 Faying Surfaces of Friction Grip Joints
These surfaces are those which, when in contact with one another, transmit a load across
the interface by friction.
Faying surfaces require special attention. If left bare all moisture access points must be
effectively sealed. The alternative is to protect the faying surfaces, but the effect of the
protective treatments on the slip-factor should first be closely investigated: their behaviour
under static, dynamic and sustained loading should be considered.
Faying surfaces are usually blast-cleaned at the same time as the general surfaces of the
steelwork. It may be advantageous to specify masking and that the masking should be
retained as a temporary protection, being removed before assembly. The type of masking
should be specified to ensure minimum contamination by adhesives. The method of
preparing surfaces after stripping the masking should also be specified.
Where paint over sprayed metal is the specified protective system, masking may be used
to prevent paint being applied to the faying surfaces of connections. If galvanizing is the
protection, roughening can take place immediately before assembly. When galvanizing is
to be overpainted, the roughening should be carried out before the masking is applied.
A.2.2 Fasteners
Where steelwork is to be manually cleaned after weathering, the fasteners may be
prepared and treated in the same manner as the general surfaces. The specified primer
must be suitable for site application to manually prepared steelwork.
Where the overall surface preparation is by blasting after bolting-up, the exposed surfaces
of the bolts, nuts and washers should be blast-cleaned at the same time as the general
surfaces. Such blast cleaning should also be used if high-strength friction-grip bolts are
used in similar circumstances.
If surfaces are blast-cleaned prior to bolting-up and it is impractical to utilize the same
preparation method for the connector surfaces, then pickling of the bolts may be specified
to remove scale and assist in manual preparation of the exposed surfaces for coating.
Pickling may not be suitable for high-strength friction-grip bolts. On site, after erection,
fasteners must be treated with a corrosion inhibiting primer suitable for application to
manually prepared steelwork under site conditions.