an7r020 Corrosion of structural soe! - Stee!Constucton info
Corrosion of structural steel
‘The corrosion of structural steel is an electrochemical process that requires the simultaneous presence of moisture and
‘oxygen. Essentially, the iron in the stec] is oxidised to produce rust, which occupies approximately six times the volume of
the original material. The rate at which the corrosion process progresses depends on a number of factors, but principally
the 'micro-climate’ immediately surrounding the structure,
Contents oT —
‘The corrosion process
Localised corrosion
Bimetallic corrosion
General galvanic series
Pitting corrosion
Crevice corrosion
Corrosion rates
Time of wetness
Atmospheric pollution
i
sulphates
0 + | = Se
chides | sede |” ee
References at cathode 02 + 2H20 + 4e + 40H
Further reading
See also ‘Schematic representation of the corrosion
mechanism for steel
cpp
The corrosion process
‘The corrosion of steel can be considered as an electrochemical process that occurs in stages. Initial attack occurs at anodic
areas on the surface, where ferrous ions go into solution. Electrons are released from the anode and move through the
metallic structure to the adjacent cathodic sites on the surface, where they combine with oxygen and water to form
hydroxyl ions. These react with the ferrous ions from the anode to produce ferrous hydroxide, which itself is further
oxidised in air to produce hydrated ferric oxide (1. red rust.) The sum of these reactions can be represented by the
following equation:
Fe +30 + 2H,0 = 2Fe,05H20
(Steel) + (Oxygen) + (Water) = Hydrated ferric oxide (Rust)
However, after a period of time, polarisation effects such as the growth of corrosion produets on the surface cause the
corrosion process to be stifled. New, reactive anodic sites may be formed thereby allowing further corrosion. In this case,
over long periods, the loss of metal is reasonably uniform over the surface, and this is usually described as ‘general
corrosion’. A schematic representation of the corrosion mechanism is shown (above right).
hitpssiwww.steelconstruction info/Corosion_of_structural_stesl 16an7r020 Corrosion of structural soe! - Stee!Constucton info
The corrosion process requires the simultaneous presence of water and oxygen. In the absence of either, corrosion does
not occur.
Localised corrosion
Various types of localised corrosion can also occur but these tend not to be significant for structural steelwork.
Bimetallic corrosion
When two dissimilar metals are joined together and in contact with an electrolyte, an electrical current passes between
them and corrosion occurs on the anodic metal. Some metals (e.g. stainless steel) cause low alloy structural steel to
corrode preferentially whereas other metals (e.g, zine) corrode preferentially themselves, thereby protecting the low alloy
structural steel. The tendency of dissimilar metals to bimetallic corrosion is partly dependent upon their respective
positions in the galvanic series. The further apart the two metals in the series the greater the tendency.
Another aspect that influences bimetallic corrosion is the nature of the electrolyte. Bimetallic corrosion is most serious for
immersed or buried structures, but in less aggressive environments e.g. stainless steel brick support angles attached to
mild steel structural sections, the effect on the steel sections is minimal. No special precautions are required in most
practical building or bridge situations. For greater risk situations, gaskets, sleeves and similar electrically insulating
‘materials should be used. Alternatively the application ofa suitable paint system over the assembled joint is also effective.
‘The tendency for bimetallic corrosion is also influenced by the relative surface areas of the cathodic and anodic metals
(Ac/Aa). In simple terms, the greater the A./A, ratio, the greater the tendency for bimetallic corrosion.
General galvanic series
Anodic end (More prone to corrosion)
Magnesium
Zine
‘Aluminium
Carbon & Low Alloy (Structural) Steels
Cast Iron
Lead
Tin
Copper, Brass, Bronze
Nickel (Passive)
Titanium
Stainless Steels 430/304/316 (In the passive state)
Cathodic end (Less prone to corrosion)
Pitting corrosion
In some circumstances the attack on the original anodic area is not stifled and continues deep into the metal, forming a
corrosion pit. Pitting more often occurs with low alloy structural steels in continually wet conditions or buried in soil
rather than those exposed in air. Hence, pitting corrosion is rarely encountered on typical modern steel buildings or
hitpssiwww.steelconstruction info/Corosion_of_structural_stesl 218an7r020 Corrosion of structural soe! - Stee!Constucton info
Crevice corrosion
Crevices can be formed by design detailing, welding, surface
debris, ete. Available oxygen in the crevice is quickly used by the
corrosion process and, because of limited access, cannot be
replaced. The entrance to the crevice becomes cathodie, since it
can satisfy the oxygen-demanding cathode reaction. The tip of the
crevice becomes a localised anode and high corrosion rates occur
at this point.
Pitted steel surface
Corrosion rates
‘The principle factors that determine the rate of corrosion of steel in air are:
Time of wetness
‘Atmospheric pollution
Time of wetness
‘This is the proportion of total time during which the surface is wet, due to rainfall, condensation ete. It follows, therefore,
that for unprotected steel in dry environments e.g, inside heated buildings, corrosion will be minimal due to the low
availability of water. The requirement for the application of paints or coatings becomes unnecessary other than for
appearance or fire protection purposes.
Atmospheric pollution
‘The type and amount of atmospheric pollution and contaminants (e.g, sulphates, chlorides, dust ete.)
Sulphates
‘These originate from sulphur dioxide gas produced during the combustion of fossil fuels, e.g. sulphur bearing oils and
coal. The sulphur dioxide gas reacts with water or moisture in the atmosphere to form sulphurous and sulphuric acids.
Industrial environments are a prime source of sulphur dioxide.
Chlorides
‘These are mainly present in marine environments. The highest concentration of chlorides is to be found in coastal regions
and there is a rapid reduction moving inland. In the UK there is evidence to suggest that a 2 kilometre strip around the
coast can be considered as being in a marine environment.
Both sulphates and chlorides increase corrosion rates. They react with the surface of the steel to produce soluble salts of
iron, which can concentrate in pits and are themselves corrosive.
hitpsiwww.stesleanstructioninfo/Caresion_of struct
eal as«411712020 Corason of structural sie! - StelConstcton nfo
Within a given local environment, corrosion rates can vary markedly, due to effects of sheltering and prevailing winds ete.
Itis therefore the ‘micro-climate' immediately surrounding the structure, which determines corrosion rates for practical
purposes. Because of variations in atmospheric environments, corrosion rate data cannot be generalised. However,
environments can be broadly classified, and corresponding measured steel corrosion rates provide a useful indication of
likely corrosion rates. More information can be found in BS EN ISO 12944-211 and BS EN 180 92292,
Atmospheric corrosivity categories and examples of typical environments (BS EN ISO 12944-2(")
Corrosivity | _Low-carbon steal Examples of typical environments (informative only)
categor jickness loss (um)*
‘gory Thiekt loss (um) Exterior Interior
ct 513 - Heated buildings with clean atm
very low 2.4 flees, shops, schools, hot
c2 > 1.3025 ‘Atmospheres with low evel of pollution: | Unheated bullings where conde
low mostly rural areas can occur, 6.9. depots, sports he
3 > 261050 Urban and industrial atmospheres, Production rooms with high hur
medium moderate sulphur dioxide pollulion; coastal__| some air pollution, e.food-pro
area with low salinity plants, laundries, breweries, dai
ca > 50 to 80 Industrial areas and coastal areas with | Chemical plants, swimming pool
high moderate salinity ship and boatyards
cs > 80 to 200 Industrial areas with high humidity and Buildings or areas with almost p
very high aggressive atmosphere and coastal areas | condensation and high pollution
with high salinity
ox > 20010700 | Offshore areas with high salinity and Industrial areas with extreme hu
extreme industrial areas with extreme humidity and | aggressive atmosphere
aggressive atmosphere and sub-tropical
and tropical atmospheres
Notes:
‘jum (1 mioron) = 0.00%mm
* The thickness loss values are after the first year of exposure. Losses may reduce over subsequent years.
‘The loss values used for the corrosivity categories are identical to those given in BS EN ISO 9223!
References
1. BS EN ISO 12944-2: 2017, Paints and vamishes ~ Corrosion protection of steel structures by protective paint systems
—Part 2: Classification of environments, BSI
2. BS EN ISO 9223: 2012, Corrosion of metals and alloys — Corrosivity of atmospheres — Classification, determination
and estimation. BS]
Resources
Stee! Buildings, 2003, The British Constructional Steelwork Association Ltd.
Chapter 12 — Corrosion Protection
Further reading
D.Deacon & R.Hudson (2012), Stee! Designer’s Manual (7th Edition), Chapter 36 - Corrosion and corrosion
prevention, The Steel Construction Institute.
D.A. Bayliss & D.H.Deacon (2002), Steelwork Corrosion Control (2nd edition), Spon Press.
hitpeiwuwcstesleonstructioninfo/Corosion_of_structural_ steal 46an7r020 Corrosion of structural soe! - Stee!Constucton info
PD 6484:1979, Commentary on corrosion at bimetallic contacts and its alleviation, British Standards Institution.
See also
Influence of design on corrosion
Surface preparation
Paint coatings
Standard corrosion protection systems for buildings
Metallic coatings
Appropriate specifications
Inspection and quality control
CPD
Corrosion protection
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