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DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OFSTEEL STRUCTURES
Hugo Perneta, Maria João Correia and Manuela Salta
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 2
Scheme of presentation Introduction
Corrosion protection systems:Cathodic protectionPaint systemsMetallic coatings
Surface preparation Conclusion
EN 12473:2000, General principles of cathodic protection in sea water.EN 14505:2005, Cathodic protection of complex structures.EN 13174:2001, Cathodic protection for harbour installations.Several parts of EN ISO 12944, Paints and varnishes – Corrosion protection of steel structures by protective paint systems.Several parts of EN ISO 14713, Zinc coatings – Guidelines and recommendations for the protection against corrosion of iron andsteel structures.Several parts of EN ISO 8504, Preparation of steel substrates before application of paints and related products – Surfacepreparation methods.
ObjectivePresentation of the most commonly used corrosion protection systems, identifying the most importantfactors for an effective protection of steel structures
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
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![Page 2: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/2.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 3
IntroductionMain deterioration mechanisms of steel structures: Corrosion Fatigue
Corrosion may be prevented by: Steel isolation from the surrounding environment Design of the structure Action on the steel
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 4
Introduction
Corrosion performance depends on: Type of metal or alloy and its microstructure Exposure conditions
Corrosivity categories (ISO 9223 and EN ISO 12944-2):
AtmosphericC1 – very lowC2 – lowC3 – averageC4 – highC5 – very high (marine and industrial)
Im1 – fresh waterIm2 – sea or brackish waterIm3 – soils
MatosinhosC4
Viana do CasteloC3
Macedo de Cavaleiros
C2
Alto RabagãoC2
Maia>C5
Leixões>C5
SeiaC2
LavosC4
Vila Velha de RódãoC2/C3
PegoC2/C3
LumiarC3
LisboaC3
BarreiroC3/C4
Reguengos de Monsaraz
C2
Sines>C5
AlfazinaC3
Water and soil
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
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![Page 3: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/3.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 5
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 6
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
Applicable standards
EN 12954:2001, Cathodic protection of buried or immersed metallic structures. General principles and application forpipelines
EN 14505:2005, Cathodic protection of complex structures.
EN 12473:2000, General principles of cathodic protection in sea water
EN 13174:2001, Cathodic protection for harbour installations
EN 13509:2003, Cathodic protection measurement techniques
EN 50162:2004, Protection against corrosion by stray current from direct current systems.
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
2
![Page 4: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/4.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 7
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
[1] Aapted from: http://www.voestalpine.com/stahl/en/op2/press/pictures.ContentPar.3300.File.tmp/hot_dip_galvanizing_inspection.jpg (Viewed in 07/10/2011)
[1]
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 8
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
Applicable standardsEN ISO 12944, Paints and varnishes – Corrosion protection of steel structures by protective paint systems: Part 1: General introduction Part 2: Classification of environments Part 3: Design considerations Part 4: Types of surface and surface preparation Part 5: Protective systems. Part 6: Laboratory performance test methods. Part 7: Execution and supervision of paint work. Part 8: Development of specifications for new work and maintenance.
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
2
![Page 5: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/5.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 9
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
Applicable standards
Several parts of EN ISO 14713, Zinc coatings – Guidelines and recommendations for the protection against corrosion of iron and steelstructures
EN 14616:2004, Thermal spraying – Recommendations for thermal spraying
EN ISO 2063:2005, Thermal spraying – Metallic and other inorganic coatings – Zinc, aluminium and their alloys
Several parts of EN ISO 14922, Thermal spraying – Quality requirements of thermally sprayed structures
EN 1403:1998, Corrosion protection of metals – Electrodeposited coatings – Methods of specifying general requirements
EN ISO 4042:1999, Fasteners – Electroplated coatings.
Hot dip galvanization Thermal spraying
Sherardizing Electrodeposition
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 10
Protection systems
Cathodic protection Sacrificial anodes Impressed current
Coating systems Paint systems Metallic coatings Duplex systems
Applicable standardsSeveral parts of EN ISO 12944, Paints and varnishes – Corrosion protection of steel structures by protective paint systems.
Several parts of EN ISO 14713, Zinc coatings – Guidelines and recommendations for the protection against corrosion of iron and steelstructures
EN 14616:2004, Thermal spraying – Recommendations for thermal spraying
EN ISO 2063:2005, Thermal spraying – Metallic and other inorganic coatings – Zinc, aluminium and their alloys
Several parts of EN ISO 14922, Thermal spraying – Quality requirements of thermally sprayed structures
EN 1403:1998, Corrosion protection of metals – Electrodeposited coatings – Methods of specifying general requirements
EN ISO 4042:1999, Fasteners – Electroplated coatings
Paint systems
Metallic coating
Duplex system
Sinergic effect on durability
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
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![Page 6: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/6.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 11
Surface preparation
Water, solvent and chemical cleaning
Mechanical cleaning Hand-tool and power-tool cleaning Blast cleaning
Flame cleaning
Applicable standards
EN ISO 12944-4:1998, Paints and varnishes – Corrosion protection of steel structures – Part 4: Types of surface and surface preparation.EN ISO 8504:2001, Preparation of steel substrates before application of paints and related products – Surface preparation methods: Part 1: General principles Part 2: Abrasive cleaning Part 3: Hand and power-tool cleaning
.
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 12
Surface preparation
Water, solvent and chemical cleaning
Mechanical cleaning Hand-tool and power-tool cleaning Blast cleaning
Flame cleaning
Applicable standards
EN ISO 12944-4:1998, Paints and varnishes – Corrosion protection of steel structures – Part 4: Types of surface and surface preparation.EN ISO 8504:2001, Preparation of steel substrates before application of paints and related products – Surface preparation methods: Part 1: General principles Part 2: Abrasive cleaning Part 3: Hand and power-tool cleaning
.
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
2
![Page 7: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/7.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 13
Surface preparation
Water, solvent and chemical cleaning
Mechanical cleaning Hand-tool and power-tool cleaning Blast cleaning
Flame cleaning
Applicable standards
EN ISO 12944-4:1998, Paints and varnishes – Corrosion protection of steel structures – Part 4: Types of surface and surface preparation.EN ISO 8504:2001, Preparation of steel substrates before application of paints and related products – Surface preparation methods: Part 1: General principles Part 2: Abrasive cleaning Part 3: Hand and power-tool cleaning
.
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 14
Surface preparation
Water, solvent and chemical cleaning
Mechanical cleaning Hand-tool and power-tool cleaning Blast cleaning
Flame cleaning
Applicable standards
EN ISO 12944-4:1998, Paints and varnishes – Corrosion protection of steel structures – Part 4: Types of surface and surface preparation.EN ISO 8504:2001, Preparation of steel substrates before application of paints and related products – Surface preparation methods: Part 1: General principles Part 2: Abrasive cleaning Part 3: Hand and power-tool cleaning
.
Blast cleaning
Dry abrasive
Centrifugal
Compressed-air
Vaccum or suction-head
Wet abrasive
Moisture-injection
Compressed-air
Slurry
Pressurized-liquid
Other application
Sweep
Spot
Water
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
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• ICDS1
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![Page 8: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/8.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 15
Surface preparation
Water, solvent and chemical cleaning
Mechanical cleaning Hand-tool and power-tool cleaning Blast cleaning
Flame cleaning
Applicable standards
EN ISO 12944-4:1998, Paints and varnishes – Corrosion protection of steel structures – Part 4: Types of surface and surface preparation.EN ISO 8504:2001, Preparation of steel substrates before application of paints and related products – Surface preparation methods: Part 1: General principles Part 2: Abrasive cleaning Part 3: Hand and power-tool cleaning
.
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 16
Conclusion
Main causes of corrosion: Design and construction errors Inadequate maintenance of the protection system Resulting from other deterioration processes
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
LNEC
• ICDS1
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![Page 9: 3 HPerneta [Modo de Compatibilidade]durati.lnec.pt/pdf/ICDS12_Presentations/A1_3_HPerneta.pdf · Several parts of EN ISO 8504, Preparation of steel substrates before application of](https://reader031.pdfslide.net/reader031/viewer/2022013006/5b80c90c7f8b9af0088e1a4c/html5/thumbnails/9.jpg)
DURABLE STRUCTURESLNEC Lisbon 31 May - 1June 2012
CORROSION PROTECTION OF STEEL STRUCTURES 17
Acknowledgments
The information included in this presentation is developed in Duratinet Technical Guide –Maintenance and Repair of Transport Infrastructure, Part III, Vol. 5, prepared within the ambit of project No. 049/2009 DURATINET - Durable Transport Infrastructures in the Atlantic Area Network, approved by the Atlantic Area Transnational Programme, co-financing by the ERDF.
A summarized web version of Duratinet Technical Guide may also be found in the following address:
http://durati.lnec.pt/techguide/
ICDS12 International Conference DURABLE STRUCTURES: from construction to rehabilitation LNEC • Lisbon • Portugal • 31 May - 1 June 2012
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