DEPARTMENT OF CIVIL ENGINEERING

STRUCTURAL STEEL AND TIMBER DESIGN III

Corrosion Protection of Steel Structures

NAME: BM PHUNGULA STUDENT NO: 22117161

TABLE OF CONTENT:

Introduction…………………………………………
Summary/Abstract………………………………….
Research…………………………………...
Methodology………………………………………….
Result…………………………………………………
Conclusion…………………………………………….
References……………………………………………..
 INTRODUCTION

Background:

If left unprotected in corrosive environments, steel structures are liable to

corrosion that can be costly and put lives in danger. One way to control
corrosion is to use paints and coatings. ISO 12944 and other design standards
(SANS, BS, ACI, etc….) are the internationally recognized standards that
provides instruction and guidance to those working with steel structure design,
including planners, painters, maintenance and coatings manufactures.
Therefore, corrosion must be considered early in the design of steel structures.

SUMMARY:

Corrosion is a serious problem that can affect the performance, safety, and
durability of steel structures. Corrosion can cause material loss, structural
damage, aesthetic degradation, and functional impairment of steel components.
Corrosion can also lead to increased maintenance costs, reduced service life,
and potential failures that can endanger lives and property.
Therefore, it is important to protect steel structures from corrosion by using
appropriate corrosion protection systems, such as protective coatings, cathodic
protection, or corrosion inhibitors. These systems can prevent or reduce the
corrosion process by creating a barrier, an inhibitor, or a sacrificial anode
between the steel and the corrosive environment. These systems can also extend
the service life, improve the appearance, and enhance the performance of steel
structures.
However, choosing the right corrosion protection system for a specific steel
structure is not a simple task. It requires a careful analysis of various factors,
such as the type and grade of steel, the design and size of the structure, the
environmental conditions, the expected service life, and the maintenance
requirements. It also requires a comparison of the initial and life-cycle costs, the
effectiveness and reliability, and the environmental and health impacts of
different corrosion protection systems.
 RESEARCH:

Working with steel can cause numerous challenges including corrosion,

depending on the type, grade, and application of steel. These are some of the
common problems that you may encounter when working with steel are:

 Welding difficulties: Steel is not easy to weld, especially if it has a high

carbon content or alloying elements. Welding can cause distortion,
cracking, or weakening of the steel joints. To avoid these problems, you
need to choose the right welding method, filler material, and preheating
and post-welding treatment.
 Corrosion issues: Steel is prone to corrosion and rust when exposed to
moisture, oxygen, or chemicals. Corrosion can reduce the strength,
durability, and appearance of steel structures. To prevent corrosion, you
need to apply protective coatings, such as paint, zinc, or stainless steel.
 Surface contamination: Steel can be contaminated by dirt, oil, grease,
iron filings, or other foreign materials that can affect its quality and
performance. Surface contamination can cause poor adhesion of coatings,
reduced corrosion resistance, or increased wear and tear. To avoid surface
contamination, you need to clean the steel surface thoroughly before
applying any treatment or fabrication.

Steel corrosion is a serious problem that affects the performance and durability
of many structures and devices made of steel. Steel corrosion occurs when steel
reacts with the environment, such as air, water, or chemicals, and forms rust or
other products that weaken the steel and make it susceptible to further damage.
Some of the issues related to steel corrosion are:

 Steel is not naturally corrosion resistant. Steel is an alloy of iron and

carbon, and iron is very prone to corrosion. When exposed to the
atmosphere, iron reacts with oxygen and water to form rust, which is a
brittle and porous material that does not protect the steel from further
corrosion.
 Steel can be alloyed with other metals to improve its corrosion resistance.
One example is stainless steel, which contains chromium and other
elements that form a thin oxide film on the surface of the steel. This film
acts as a barrier that prevents the steel from reacting with the
environment. However, stainless steel can still corrode under certain
conditions, such as high temperatures, low pH, or exposure to chloride
ions.
 Corrosion mechanisms are complex and depend on many factors.
Corrosion involves chemical, electrochemical, and mechanical aspects
that interact at different levels of scale. Understanding the corrosion
 mechanisms at macroscopic, microscopic, and atomic levels is essential
for designing alloys, coatings, inhibitors, and other methods to prevent or
mitigate corrosion.
 Corrosion has economic and environmental impacts. Corrosion causes
losses in terms of material wastage, maintenance costs, reduced
efficiency, and shortened service life of steel structures and devices.
Corrosion also poses environmental risks, such as pollution,
contamination, and resource depletion.
 Corrosion can affect safety and reliability. Corrosion can lead to failures
of critical components in various sectors, such as transportation, energy,
construction, and health. Corrosion can cause accidents, injuries,
fatalities, and damage to property and infrastructure.

Some common types of corrosion that affect metals are:

Galvanic corrosion: This occurs when two different metals are in contact with
each other and an electrolyte, such as water or salt. The more reactive metal acts
as an anode and corrodes faster, while the less reactive metal acts as a cathode
and corrodes slower. For example, iron nails can rust faster when in contact
with copper wires.

Uniform corrosion: This occurs when a metal is exposed to a corrosive

environment uniformly over its entire surface. The metal loses its thickness and
strength gradually and evenly. For example, steel pipes can corrode uniformly
when exposed to acidic soil or water.

Stress corrosion cracking: This occurs when a metal is subjected to both

tensile stress and a corrosive environment. The metal develops cracks that
propagate and cause failure. For example, brass fittings can crack when exposed
to ammonia or mercury.

Crevice corrosion: This occurs when a metal has a narrow gap or crevice
where stagnant water or other corrosive substances can accumulate. The crevice
creates a localised environment that is more corrosive than the surrounding
area. For example, stainless steel bolts can corrode in the crevices between the
bolt head and the washer.

Pitting corrosion: This occurs when a metal develops small holes or pits on its
surface due to localised attack by corrosive agents. The pits can penetrate deep
into the metal and cause structural damage. For example, aluminium alloys can
pit when exposed to chloride ions.
 METHODOLOGY

Steel is resistant to corrosion and rust caused by exposure to water and air. The
corrosion resistance of steel depends on the composition, surface treatment,
and environment. Generally, adding chromium, nickel, or other elements make
steel more corrosion-resistant, but also more expensive.

These are some of the main corrosion protection systems that are available for
different applications and environments. Each system has its own advantages
and disadvantages that need to be considered before choosing the most suitable
one for a specific situation. There are different types of corrosion protection
systems that can be applied to metal structures to prevent or reduce corrosion.
Some of the common corrosion protection systems are:

 Protective coatings: These are layers of materials that cover the metal
surface and act as a barrier, an inhibitor, or a sacrificial anode. Protective
coatings can be paints, zinc, stainless steel, or other metals or polymers.
Protective coatings have the advantages of being easy to apply, cost-
effective, and versatile. However, they also have some disadvantages,
such as requiring proper surface preparation, being prone to damage or
degradation, and needing regular maintenance.
 Cathodic protection: This is a technique that uses an external direct
current (DC) source or a sacrificial anode to make the metal structure act
as a cathode. Cathodic protection prevents the metal from corroding by
reducing the potential difference between the anode and the cathode.
Cathodic protection is commonly used for pipelines, ships, tanks, and
offshore oil platforms. Cathodic protection has the advantages of being
effective, reliable, and durable. However, it also has some disadvantages,
such as requiring a power source or a sacrificial anode, being complex to
design and install, and needing regular monitoring.
 Corrosion inhibitors: These are chemicals that are added to the
environment or the metal surface to slow down or stop the corrosion
process. Corrosion inhibitors can work by forming a protective film,
reducing the aggressiveness of the environment, or interfering with the
electrochemical reactions. Corrosion inhibitors are widely used for oil
and gas production, water treatment, and industrial processes. Corrosion
inhibitors have the advantages of being simple to use, economical, and
adaptable. However, they also have some disadvantages, such as
requiring continuous dosing, being sensitive to environmental changes,
and having potential environmental or health impacts.
 RESULT:

Corrosion in steel structures:

Steel corrosion treatment:

CONCLUSION:

Steel corrosion is a serious problem that affects the durability, safety, and
appearance of steel structures. It is caused by the interaction of steel surfaces
with various environmental factors, such as moisture, oxygen, electrolytes, and
corrosive agents. The corrosion of steel can be general or localised and can be
influenced by the properties of the steel, the corrosive environment, and the
protective measures. Different methods can be used to characterise and prevent
steel corrosion, depending on the specific application and service conditions of
the steel structures.
REFERENCE:
https://www.icorr.org/iso12944-steel-structure-design-corrosion/

Anti-Corrosion Methods and Materials, Volume 50, Issue 2 (2006-09-19)

https://www.corrosionpedia.com/2/1368/prevention/cathodic-protection/cathodic-
protection-101