BEYOND

THE SURFACE
DIVING DEEP INTO STEEL PROTECTION
SURFACE PREPARATION
EIGHT KEY STEPS TO AVOID CORROSION FAILURE
When it comes to corrosion, structural steel is widely used across various industries such as
concrete, building, construction, architecture, and infrastructure. It's a major concern
because corrosion can lead to instability, safety issues, and potential dangers. Did you know
that the annual global cost of corrosion is a staggering US$2.5 trillion, which is approximately
3.4% of the world's gross domestic product? That's why it's crucial to take preventive
measures to avoid corrosion failures.

In this article, we will delve into eight key steps that can help you prevent corrosion failures
and ensure the durability and safety of your structures. But first, let's take a moment to reflect
on the tragic collapse of the Champlain Tower Condominiums in Surfside, Miami, which
claimed the lives of 98 people. One of the contributing factors to this catastrophic event was
the long-term degradation of a reinforced concrete structural support caused by water
penetration and corrosion of the reinforced steel. This incident serves as a stark reminder of
the importance of addressing corrosion issues promptly and effectively.

Now, let's dive into the eight key steps we'll be exploring to avoid corrosion failure.

WHAT IS CORROSION AND

HOW DOES IT AFFECT STEEL STRUCTURES?
Corrosion, a chemical process that requires the simultaneous presence of moisture and
oxygen, causes refined metals to revert to their more natural and stable oxidized state. Steel
is one of the most corrosion-resistant materials; however, corrosion can still affect steel
structures over extended periods of time due to environmental factors like exposure to
seawater, hydrocarbons, or saltwater fog. When corrosion happens the steel structure is
weakened, the iron in the steel oxidizes causing the loss of steel material, producing red rust
which occupies approximately four to seven times the volume of the steel. The increase in
volume creates stresses in concrete to an extent that it can crack, resulting in delamination in
concrete bridge decks or parking garage slabs, and loss of concrete cover in beams, girders,
and columns as well as shortening the lifespan of any steel structure. To reduce corrosion,
preventive maintenance measures should be employed such as frequent painting and
rustproofing, along with regular inspections for signs of corrosion.

STEEL STRUCTURES AND TYPES OF CORROSION

Steel structures are among the most popularly used materials in construction due to their
strength, durability, and relatively low cost. However, corrosion can still pose a threat to steel
installations if not prevented by taking the appropriate measures. There are several types of
corrosion that damage steel structures. These include uniform corrosion, general corrosion,
pitting corrosion, galvanic corrosion, stress corrosion cracking and crevice corrosion. Each of
these corrosion types has different effects and needs unique preventive measures for
maximum effectiveness. Understanding the various corrosion processes on steel is important
to establish good maintenance practices and protect your investment in structural steel.
 STRUCTURAL EFFECTS OF CORROSION
Corrosion has several different effects on structures, which are:

LOSS OF STRENGTH When steel corrodes, the products of corrosion expand. This will leave a
poor-quality steel layer over the surface of the reinforcement. This layer has a poor bond with
surrounding concrete; therefore, it will reduce the capacity of the section.

FATIGUE Development of pitting corrosion introduces additional points of stress

concentration at which cracking may develop, which will reduce the fatigue strength.

REDUCED STEEL Concrete Bond - When steel corrodes, the products of corrosion expand. This
will leave a poor-quality steel layer over the surface of the reinforcement. This layer has a poor
bond with surrounding concrete.

LIMITED DUCTILITY Corroded sections have lower ductility, which means their plastic deforma-
tion is limited. This will affect the seismic response of the elements.

KEY STEPS IN CORROSION MITIGATION AND PREVENTION

While steel is one of the most durable metals available, it is still susceptible to corrosive
elements that reduce its lifetime. Steel is a common material used to build structures, but if
preventive measures are not taken, it can be susceptible to corrosion. There are several
preventive steps that can be taken to prevent or mitigate corrosion damage on steel
structures. Rust inhibitors, such as coatings and sacrificial anodes, create a barrier on the
metal structure that prevents oxygen and moisture from reaching the metal surface.
Galvanizing is another measure which involves applying a zinc coating to prevent oxidation
and rusting of the metal. Surface treatments and proper maintenance can also reduce the
likelihood of corrosion occurring. Cleaning clogged gutters, repairing broken seals, and
painting over peeled off paint helps prevent oxygen and water access to the metal surface
potentially leading to corrosion damage. Regular inspections of steel structures can often
alert you to signs of developing corrosion early so any preventative steps can be taken
promptly.

To ensure that your structural steel retains its durability, the following measures should be
considered:

1
CONSIDER STEEL SELECTION & DESIGN Start with quality materials and choose the right steel.
The quality of the steel alone can play a role in preventing corrosion. Poor-quality steel or low
alloy steel is prone to weaken with rust. Using corrosion-resistant alloys such as stainless steel,
aluminum or copper can help prevent corrosion. Additionally, selecting the right design and
engineering to reduce any risk factors is essential when designing structural steel
installations. The structure should be designed to reduce exposure to the atmosphere,
prevent water from building up, avoid surface irregularities and the use of dissimilar metals.
This could include selecting thicker sections of metal which are more resistant to corrosion,
using a coating system that will resist oxidation and reduce air access to the metal surface, or
ensuring the steel is not in contact with aggressive chemicals. Taking these steps will help
protect your investment in structural steel and ensure a safer and more durable structure for
years to come.
2
CONSIDER THE IMPACT OF LOCATION The location of a steel structure can play a significant role
in the risk of corrosion. The environment in which it is situated, such as proximity to water, air
pollution, industrial activities and salt spray can all influence the rate at which rust forms on
steel. Structures built in coastal areas are more susceptible to corrosion such as rust because
of the high concentration of salt in the air. This also applies for areas that have a high degree
of environmental pollutants because toxins escalate the rate at which corrosion occurs.
Regular inspections should be conducted so any signs or potential sources of corrosion
damage can be detected and rectified as necessary. Taking measures to protect steel
structures in high-risk areas such as coastal regions is essential, with a combination of
galvanizing and other coatings recommended for maximum protection. Ensuring adequate
ventilation around the structure can also reduce humidity levels and help slow down
corrosion processes.

3
TEST YOUR SURFACE The biggest cause of corrosion is due to not testing and preparing the
surface correctly. First test your steel before surface preparation for surface contamination.
Any steel structures should be cleaned and prepared thoroughly before paint, or any other
coating is applied. Testing for surface salts, surface roughness and surface profile can
determine the level of surface preparation needed to prevent issues with coating adhesion
and quality. The surface should also be tested with a galvanometer to ensure the right
level of adhesion between the metal and paint exists. At Gardco, we have a variety of
surface profile testers, thickness gauges, and conductivity meters and refractometers.

4
PREPARE YOUR SURFACE Surface preparation can run from simple chemical pre-cleaning to
abrasion methods such as grinding and abrasive blasting. Steel surface preparation removes
the physical defects and loose or soluble contaminants before coatings are applied. For
cleaning relatively smaller surface areas, chemical stripping may be cost-effective but, if there
are several thousand square feet of surface to be prepared, pickling or abrasive blasting
would be more cost-effective. After cleaning and removing rust that developed on the
structure, proceed to add the protective coating that is imperative for the long-term
well-being of your steel structure.

5
APPLY PROTECTIVE COATINGS The most effective line of defense in preventing corrosion on
structural steel is the application of protective, barrier coatings. By applying protective
coatings, the life of a steel structure can be extended significantly. There are many different
types of coatings that can be used, including zinc-rich primer, epoxy coating, and
acrylic-based paints. These coatings create a barrier between the metal surface and oxygen
and moisture, which helps to prevent corrosion. It is also important to ensure that any
coatings are applied correctly and checked regularly to ensure they remain in good
condition. The value of applying multiple layers of rust-inhibiting primer is well known in the
industry as the most important measure that can be taken.

6
INSTALL QUALITY INSULATION AND VENTILATION Quality insulation and ventilation prevents
excess moisture from escaping from the insulation, which in combination with oxygen,
accelerates the corrosion process. The better the insulation and ventilation, the less moisture
to create problems.
7
CHOOSE A HIGHLY QUALIFIED, PROFESSIONAL BUILDING COMPANY Like they say, “You get what
you pay for”. This is not a place to save money. When choosing a building partner for your
construction project, always ensure you select a company that is experienced in steel
fabrication and knowledgeable about corrosion prevention. A quality building company will
have professionals that understand the science behind corrosion and can provide guidance
about the materials you should employ, the location you should opt for, and the design that
is suitable to prevent corrosion. This will help to reduce the risk of corrosion on your metal
structure and give you peace of mind knowing it has been built correctly to last for
many years.

8
ONGOING PROTECTIVE COATINGS TESTING By testing the protective coatings regularly, you can
help identify any areas that need attention and repair. Testing the coating thickness,
adhesion to the metal surface, and visual inspection of any defects can all be done regularly
to ensure that a steel structure remains corrosion-free. Additionally, keeping an eye on
environmental factors such as temperature, humidity and air pollution can help protect your
structural steel from developing long-term damage due to corrosion.

CASE STUDIES OF CORROSION CONCERNS WITH STEEL STRUCTURES

Steel is an essential material used in many building projects, but when exposed to
environmental factors such as sea air and wet climates, it can experience rapid corrosion. This
threatens structural integrity, making it critical for engineers and architects to be diligent in
implementing preventative measures to protect steel structures. Fortunately, there have
been numerous successful case studies documenting how effective anti-corrosive strategies
can help mitigate the effects of corrosion on steel structures. For example, one study
analyzed a highly polluted industrial environment which demonstrated that pre-fabricated
stainless steel coating systems can drastically reduce maintenance costs while increasing the
service life of a structure by five times or more. Other examples highlight the effectiveness of
linseed oil which was applied on visually corroded items or employing kinetic protection
techniques such as thermal spray aluminum coatings. By studying cases of successfully
treated corrosion concerns on steel structures, professionals can stay informed about the
best practices for shielding these structures against corrosion for longer-lasting results.

In one such study published on IOPScience, researchers rolled up their sleeves and delved
deep into two types of corrosion damage in steels: corrosion fatigue and stress corrosion
cracking. Picture these as the villainous duo in our story, plotting and scheming to bring our
steel heroes down.

The researchers prepared test specimens and used special devices and loading frames to
conduct their experiments. Think of these as our detectives' toolkit, helping them gather the
evidence they needed. They found that three different chemical solutions had a significant
impact on the fatigue life of specimens taken from an L485MB steel crude oil pipeline IKL.

In the second part of the study, the researchers turned their attention to the negative effects
of stress corrosion cracking on structural steel CSN411353. This is akin to studying how stress
impacts human health. And just like how stress can make us more susceptible to illness,
stress corrosion cracking was found to significantly reduce the fracture toughness
of the steel.
Recently, another study published on ScienceDirect took a deep dive into this issue, focusing
on steel frame structures and how they fare under the relentless attack of corrosion. The
researchers also considered a phenomenon called lateral torsional buckling - imagine a long
ruler being twisted and bent until it buckles under the pressure.

The study's results were enlightening, to say the least. They found that when both corrosion
and lateral torsional buckling were considered, the load-carrying capacity of the structures
significantly decreased. It's akin to a weightlifter suddenly finding themselves unable to lift
the weights they once could with ease.

This study underscores the importance of considering corrosion in structural analysis and
design. It's a clarion call for engineers and architects to ensure that steel structures can
withstand the corrosive onslaught and continue to perform at desired levels throughout their
service life.

Another great article is from AMPP on Protecting Steel-Reinforced Concrete Marine

Structures from Corrosion. This talks about the major cause of deterioration on
steel-reinforced concrete structures is the corrosion of reinforced steel.

Recently, a study published on MDPI tackled this tricky issue head-on, reviewing existing
corrosion models and evaluating their effectiveness under different corrosivity classes, as per
the ISO standard. Think of these models as secret decoder rings, helping us predict how
much damage corrosion can do over time.

The researchers also delved into a real-world case study, using a technique called the finite
element method (FEM) to examine how corrosion affected the structure's dynamic
characteristics over its lifetime. It's a bit like running a marathon - the further you go, the
more your body starts to feel the strain.

The findings were quite eye-opening. Corrosion was found to significantly affect the dynamic
characteristics of the structure. For instance, the vibration period increased by up to 15% for
high corrosivity class structures with a 100-year lifespan. The corroded structure also showed
higher acceleration and drift demand, while the base reaction forces were reduced by up to
60% for the same class and time period.

From stainless steel coatings to linseed oil applications, from kinetic protection techniques to
the innovative use of corrosion models - we've seen how proactive measures can turn the tide
against corrosion. Each case study serves as a beacon, illuminating the path for engineers
and architects, guiding them towards best practices for long-lasting, corrosion-resistant
structures.
THE FUTURE OF CORROSION PREVENTION ON STEEL STRUCTURES
The most effective way of preventing corrosion on steel structures is to prevent the
condensation of moisture on the surface through advanced coatings. Products like
polyurethane-based products, epoxy additivated polysiloxane polymer or water-based acrylic
formulations are designed to provide strong protection against corrosive environments.
These coatings provide superior performance when used in coastal, industrial, and other
environments prone to exposure from saltwater, chemical pollutants, and humidity.
Additionally, these coatings would be regularly tested and checked for recurring wear and
tear. An integrated approach combining galvanizing, painting, and routine monitoring for
any signs of corrosion should ensure that steel structures can meet their expected lifecycles
even in harsh environments.

Corrosion is one of the highest concerns for the industrial sector. It affects steel as well as
concrete surfaces under the aggressive conditions of acids, alkalis, chemicals, solvents, etc.
With the above steps followed, it is possible to substantially reduce the risks of structural steel
corrosion and ensure a long-lasting and safe installation. Taking steps to protect metal
structures from the outset is essential, but regular inspection and maintenance of steel
installations can also reduce the risk of corrosion damage. Understanding the cause and
magnitude of deterioration will aid in the implementation of repair and protection strategies
that can extend the life and preserve structures for years to come, even under aggressive
exposure conditions. Having a good corrosion prevention system in place requires an entire
system that will protect the substrate for many years. A good system balances the
environment, design, and coating systems to obtain the desired performance and the service
life cycle at the least expensive cost. By following these tips, you can benefit from a
longer-lasting structure with minimal disruption down the line. Protecting structural steel is
essential to maintaining asset integrity.

ABOUT GARDCO
Since 1936, the Paul N Gardner Company (Gardco) has provided quality control and testing
solutions for a variety of industries. From paints and coatings to plastics, chemicals, powders,
paper, packaging and food, their comprehensive services ensure that products meet or
exceed the highest standards of precision and quality.

What sets Gardco apart is the commitment to providing not only exceptional service and
value but also a personalized experience for each client. With specialized experts in a wide
range of fields, our customers are assured of the right solution for their specific needs.
Offering the most advanced tools and technologies available, Gardco provides accurate test
and measurement solutions to help organizations make informed decisions.

The team at Gardco strives to maintain excellent customer service while delivering
unsurpassed test and measurement solutions on time and on budget. With decades of
experience in providing top-tier products for an impressive array of industries, Gardco stands
out as an industry leader dedicated to excellence in quality control and inspection products.

Today the company is in Columbia, Maryland and forms a part of the ALTANA Group.