Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                

DR Rao Corrosion Management Presentation

Download as pptx, pdf, or txt
Download as pptx, pdf, or txt
You are on page 1of 82

CORROSION

9th and 10th MAY 2016

By

Dr Renga Rao Krishnamoorthy


Faculty Of Civil Engineering
Universiti Teknologi MARA, Shah Alam
1.0
INTRODUCTION
TO
CORROSION
1.1 What is Corrosion?
Corrosion is the oxidation of a metal due to an
ELECTROCHEMICAL reaction. The oxidizing agent is
most often O2 (atmospheric corrosion) or H+ (chemical
corrosion) or both.
A natural process, which converts a refined metal to a
more stable form, such as its oxide, hydroxide, or
sulfide.

Why is it a problem?
Recipe for corrosion
Active metal

Water

Oxygen
(atmospheric corrosion)

Acid
(chemical corrosion)

Salt

High temperature
1.1 Basic corrosion

Figure 2. Corrosion on exposed metal


1.2 Basic Concepts in Corrosion

Figure 3. The corrosion cycle of steel (ASMI, 2000)


1.3 Corrosion Terminologies
• Electrochemical corrosion of iron (Figure 4)
– Corrosion starts at location (1) as shown in figure
below. At this location, the metal is under stress.
– Then, the metal ions diffuse in the moisture layer
and the electrons move to another location (2).
– Oxygen (a depolarizer) taken up the electrons
which produce hydroxide ions. These ions will
reacts with the Fe2+ to form a mixture of hydrous
iron oxides called as rust.
1.3 Corrosion Terminologies

Figure 4. Corrosion therminologies


1.3 Corrosion Terminologies

Figure 5. Schematic diagram of corrosion cells on iron


1.4 Types of Environment-Corrosion

• General Attack Corrosion


– caused by a chemical or electrochemical reaction that results in the
deterioration of the entire exposed surface of a metal
• Localized Corrosion
– specifically targets one area of the metal structure
– Three types, namely pitting, crevice corrosion and filiform corrosion.
• Galvanic Corrosion
– occurs when two different metals are located together in a corrosive 
electrolyte
– A galvanic couple forms between the two metals, where one metal
becomes the anode and the other the cathode
1.4 Types of Environment-Corrosion
• Environmental Cracking
– a corrosion process that can result from a combination of
environmental conditions affecting the metal
•  Flow-Assisted Corrosion (FAC)
– A protective layer of oxide on a metal surface is dissolved or
removed by wind or water, exposing the underlying metal to further
corrode and deteriorate
• Intergranular corrosion
– a chemical or electrochemical attack on the grain boundaries of a
metal.
• DeAlloying
– selective corrosion of a specific element in an alloy
1.4 Types of Environment-Corrosion
• Fretting corrosion
– occurs as a result of repeated wearing, weight and/or vibration
on an uneven, rough surface.
– often found in rotation and impact machinery, bolted assemblies
and bearings, as well as to surfaces exposed to vibration during
transportation.
• High Temperature Corrosion
– Fuels used in gas turbines, diesel engines and other machinery,
which contain vanadium or sulfates can, during combustion, form
compounds with a low melting point
– caused by high temperature oxidization, sulfidation and
carbonization.
1.5 Corrosion preventive measures
• Rust-resistant alloys
– Stainless steel forms a passivation layer of
chromium(III) oxide.
• Galvanization
– Galvanization consists of an application on the object
to be protected of a layer of metallic zinc by either hot-
dip galvanizing or electroplating.
– Zinc is traditionally used because it is cheap, adheres
well to steel, and provides cathodic protection to the
steel surface in case of damage of the zinc layer.
1.5 Corrosion preventive measures
• Cathodic protection
– A technique used to inhibit corrosion on buried or
immersed structures by supplying an electrical charge
that suppresses the electro-chemical reaction.
– It is achieved by attaching a sacrificial anode, thereby
making the iron or steel the cathode in the cell
formed.
– Cathodic protection can also be provided by using a
special-purpose electrical device to appropriately
induce an electric charge.
1.5 Corrosion preventive measures
• Coatings and painting
– Paint, lacquer or varnish (types of coating) that
isolate the iron from the environment can prevent
rust formation.
• Bluing
– A technique that can provide limited resistance to
rusting for small steel items, such as firearms; for
it to be successful, a water-displacing oil is rubbed
onto the blued steel and other steel.
1.5 Corrosion preventive measures
• Inhibitors
– To prevent corrosion inside sealed systems.
– They are not effective when air circulation disperses
them, and brings in fresh oxygen and moisture.
• Humidity control
– Rust can be avoided by controlling the moisture in
the atmosphere.
– An example of this is the use of silica gel packets to
control humidity in equipment shipped by sea.
1.6 Economic effect due to corrosion
• Replacement of corroded equipment
• Overdesign to allow for corrosion
• Preventive maintenance, for example, painting
• Shutdown of equipment due to corrosion failure
• Contamination of a product
• Loss of efficiency—such as when overdesign and corrosion products
• decrease the heat-transfer rate in heat exchangers
• Loss of valuable product, for example, from a container that has cor
• roded
• through
• Inability to use otherwise desirable materials
• Damage of equipment adjacent to that in which corrosion failure occurs
1.6 Economic effect due to corrosion
• Replacement of corroded equipment
• Overdesign to allow for corrosion
• Preventive maintenance, for example, painting
• Shutdown of equipment due to corrosion failure
• Contamination of a product
• Loss of efficiency—such as when overdesign and
corrosion products decrease the heat-transfer
rate in heat exchangers.
1.6 Economic effect due to corrosion

• Loss of valuable product, for example, from a


container that has corroded through
• Inability to use otherwise desirable materials
• Damage of equipment adjacent to that in
which corrosion failure occurs
1.6 Social effect due to corrosion
• Safety, for example, sudden failure can cause fire,
explosion, release of toxic product, and construction
collapse.
• Health, for example, pollution due to escaping product
from corroded equipment or due to a corrosion
product itself.
• Depletion of natural resources, including metals and
the fuels used to manufacture them.
• Appearance as when corroded material is unpleasing
to the eye.
1.7 Form of corrosion
• Corrosion occurs in several widely differing forms.
• Classification is usually based on one of three factors:
– Nature of the corrodent
Corrosion can be classified as “wet” or “dry.”
A liquid or moisture is necessary for the former, and dry corrosion usually
involves reaction with high-temperature gases.
– Mechanism of corrosion
This involves either electrochemical or direct chemical reactions.
– Appearance of the corroded metal
Corrosion is either uniform and the metal corrodes at the same rate over the
entire surface, or it is localized, in which case only small areas are affected.
• Figure 7 illustrates schematically some of the most common
forms of corrosion.
1.7 Form of corrosion

Figure 7. Most common forms of corrosion.


1.7 Form of corrosion
• Forms of wet (or aqueous) corrosion can be identified based
on appearance of the corroded metal, which are:
– Uniform or general corrosion
– Pitting corrosion
– Crevice corrosion, including corrosion under tubercles or deposits,
filiform corrosion, and poultice corrosion
– Galvanic corrosion
– Erosion-corrosion, including cavitation erosion and fretting corrosion
– Intergranular corrosion, including sensitization and exfoliation
– Dealloying, including dezincification and graphitic corrosion
– Environmentally assisted cracking, including stress-corrosion
cracking, corrosion fatigue, and hydrogen damage
2.0

METALLURGY
2.1 Galvanizing fundamentals
• Galvanization, or galvanisation is the process of applying a
protective zinc coating to steel or iron, to prevent rusting.
• Hot dip galvanizing is a method of submerge steel or iron
in a bath of molten zinc.
• Galvanizing protects:
– corrosive substances from reaching the more delicate part of
the metal.
– in a way if the coating is scratched, the exposed steel will still
be protected by the remaining zinc.
– base metal by corroding before iron.
2.1 Galvanizing fundamentals

Figure 8. Model of the Hot-dip Galvanizing process


2.2 Galvanizing process
• Surface preparation
– The purpose is to obtain the cleanest possible steel surface
by removing all of the oxides and other contaminating
residues.
– Thorough surface preparation, zinc will not react with
unclean steel.
• Degreasing/Caustic Cleaning
– The steel is immersed in an acid degreasing bath or caustic
solution to remove organic contaminants such as dirt, oil,
and grease from the surface of the steel.
– After degreasing process, the steel is rinsed with water
2.2 Galvanizing process
• Pickling
– The steel is “pickled” in a dilute
solution of either hydrochloric or
sulfuric acid to removes oxides and
mill scale.
– After oxidation has been removed
from the steel, it is again rinsed
with water and sent to the final Figure 9. Pickling
process
step of the surface preparation.
2.2 Galvanizing process
• Fluxing
– The steel is dipped in the flux.
– The purpose of the flux is to clean the steel of all
oxidation developed since the pickling of the steel
and to create a protective coating to prevent any
oxidation before entering the galvanizing kettle.
2.3 Galvanized coating
• A typical galvanized coating is shown in figure
below.

Figure 10. Galvanized coating


2.3 Galvanized coating characteristic

• Typical used of galvanized iron and steel:


– Cornices and other wall ornaments
– Door and window hoods
– Decorative formed shingles and pantiles designed
to imitate other materials
– Roof ornaments such as crestings and finials
– Sheetmetal for flashing, and gutters and
downspouts.
– Hot-dipped galvanized steel nails.
2.3 Galvanized coating characteristic
• Benefits
– Lowest first cost.
Galvanizing is lower in first cost than many other commonly specified protective
coatings for steel. (The application cost of labour intensive coatings such as
painting has risen far more than the cost of factory operations such as
galvanizing.)
– Less maintenance/Lowest long term cost.
Even in cases where the initial cost of galvanizing is higher than alternative
coatings, galvanizing is almost invariably cheapest in the long term (because it
lasts longer and needs less maintenance). 
Maintenance causes problems and adds to costs when structures are located in
remote areas, and when plant shutdown or disruption to production is involved.
– Long life.
The life expectancy of galvanized coatings on typical structural members is far in
excess of 50 years in most rural environments, and 20 to 25 years plus, even in
severe urban and coastal exposure.
2.3 Galvanized coating characteristic
• Benefits
– Reliability.
Galvanizing is carried out to Australian / New Zealand Standard 4680,
and standard, minimum coating thicknesses are applied.
Coating life and performance are reliable and predictable.
– Toughest coating
A galvanized coating has a unique metallurgical structure which gives
outstanding resistance to mechanical damage in transport, erection and
service.
– Automatic protection for damaged areas.
Galvanized coatings corrode preferentially to steel, providing cathodic or
sacrificial protection to small areas of steel exposed through damage.
Unlike organic coatings, small damaged areas need no touch up.
2.3 Galvanized coating characteristic
• Benefits
– Complete protection.
Every part of a galvanized article is protected, even
recesses, sharp corners and inaccessible areas.
No coating applied to a structure or fabrication after
completion can provide the same protection.
– Ease of inspection.
Galvanized coatings are assessed readily by eye, and simple
non-destructive thickness testing methods can be used.
The galvanizing process is such that if coatings appear
sound and continuous, they are sound and continuous.
2.3 Galvanized coating characteristic
• Benefits
– Faster erection time
As galvanized steel members are received they are ready for
use.
No time is lost on-site in surface preparation, painting and
inspection.
When assembly of the structure is complete, it is
immediately ready for use, or for the next construction stage.
– A full protective coating can be applied in minutes
The galvanizing process is not dependent on weather
conditions
2.4   Factors affecting galvanizing quality and
service
• Surface Condition
Steel that is heavily rusted will be slow to pickle and result in costly
processing delays.
Badly rusted steel should be abrasive blasted prior to delivery for galvanizing.
While heavily pitted steel will galvanized satisfactorily after cleaning, the
galvanized coating will reflect the profile of the rough steel surface.
• Previously coated steel.
Steel that has been previously painted with architectural or industrial paint
systems, should be cleaned by abrasive blasting prior to delivery for
galvanizing, as these types of paints are difficult to remove in the pre-
treatment process.
A range of hollow and light structural sections are manufactures with a thin
zinc coating already applied.
These are frequently used with black steel sections in fabrications to be hot-
dip galvanized.
2.4   Factors affecting galvanizing quality and
service
• Type of product
Heritage products that are may be brazed, riveted or soldered, or
manufactured from wrought or cast iron may not be able to be
galvanized.
Riveted or brazed connection can be galvanized provided steel rivets
are used.
Aluminium pop rivets will dissolve in the pre-treatment chemicals.
Solder will melt well below the temperature of the galvanizing bath.
Old wrought of cast iron may contain voids or nonmetallic inclusions
that will trap air or pre-treatment chemicals in the surface of the
item, creating a risk of blow-outs or more serious steam explosions
that could damage or destroy the item.
2.4   Factors affecting galvanizing quality and
service
• Weld Quality
Welding slag is inert being a ceramic material, and will not be
removed during the pre-treatment process.
Welding slag left on fabrications will give rise to `misses’ in the
galvanized coating.
Weld splatter will be galvanized along with the steel to which it is
attached, creating a rough and unsightly area adjacent to the weld.
Poor quality welds with inadequate penetration will allow pre-
treatment chemicals to penetrate the joint.
The poor weld quality will be manifested after galvanizing as
staining around the weld joint occurs as these chemicals leach out
of the joint.
2.4   Factors affecting galvanizing quality and
service
• Very thick sections
Very thick cast steel sections (over 100 mm thick) such as
counterweights or bollards can cause problems in the hot-
dip galvanizing process.
This occurs because their mass of the item is such that the
zinc freezes around it, and remains frozen for several
minutes until the heat of the steel increases to over 420oC
– the melting point of zinc.
This phenomenon can result in the preflux coating on the
steel surface deteriorating and not performing effectively.
This will cause misses in the galvanized coating.
2.4   Factors affecting galvanizing quality and
service
• Vent and drain hole locations
The location of vent and drain holes on hollow or partly closed
sections, other than causing air locks or zinc puddling if poorly
located, can cause unsightly runs or blowouts on the surface of the
item if not correctly located or sized.
• Lifting points
For larger items, the provision of lifting point for transporting the work
through the galvanizing process will improve appearance and coating
quality, and minimise the risk of handling damage in the process.
If chains have to be used to support the work, ‘chain marks’ will be
unavoidable.
This is particularly undesirable on larger circular sections such as
poles, where there will be a large area of contact between the lifting
chains and the surface of the item.
2.5 Design basics of galvanizing
• Provide an additional clearance equal to 4x the coating thickness on threaded
fasteners.
• Provide about 1mm extra clearance on all matting surfaces.
• Do not attempt to galvanize low melting point soldered joints.  They will collapse.
• Do not use silicon - containing anti splatter paints.  The galvanizing will not "take"
on these paints.
• Remove moulding sand from castings by grit blasting.  Galvanizing will not "take"
to sand.
• Avoid overlapping surfaces if possible.  If you cannot avoid them, make sure you
follow the venting guidance.
• Remember the galvanizer must lift and turn your fabrication.  Make sure you
provide lifting points for them to use.
• Do not ask your galvanizer to galvanize fabrications which are very stiff in one
plane but not in another.  They will almost certainly distort.
• Avoid large unsupported areas of this gauge sheet.  They will probably distort.
2.6 Galvanizing rules to avoid distortion
• Welding plays an essential part in the fabrication of
structural steel items.
• Most structural steel items can be successfully galvanised,
some of them tend to distort when welding is followed by
the hot dip galvanizing.
• A designer should follow certain rules of:
– Avoid designs that require double-end dipping to be able to fit
into the galvanizing bath
– Use symmetrical sections e.g square or round in preference to
angle and channels
– Use sections of nearly equal thickness at joints
2.6 Galvanizing rules to avoid distortion
• For welding fabrication, welding procedures to
minimize residual stresses should be applied.
• It involves:
– Avoid over welding
– Plan and follow a balanced welding sequence
– Use as few weld passes as possible
– Use opposing weld shrinkage forces to balance each
other
– Use backstep welding or a staggered welding sequence
3.0

FAILURE ANALYSIS
3.0 Failure analysis
• There are 5 methods of corrosion mitigation:
– Materials selection
– Coatings
– Inhibators
– Cathodic protection
– Design
3.1 Material Selections
• Metal and alloy has unique and inherent
corrosion behaviour.
• The corrosion resistance of a metal depends
on the environment to which it is exposed,
that is:
– the chemical composition
– Temperature
– velocity
3.1 Material Selections
• When the corrosion resistance of the material
increases, the rate of corrosion decreases (given
corrosivity of the environment)

• It is important to consider corrosion resistance


for selection process.
• To overcome the corrosion problem by substitute
alloy with greater corrosion resistance for the
alloy that has corroded.
3.2 Coating
• Corrosion protection (coatings) can be divided
into 2 main groups:
– metallic
– nonmetallic (organic and inorganic).
• Metallic coating increase corrosive resistance
of the noble metal.
• One example of metallic coating is galvanized
steel.
3.2 Coatings
• Nonmetallic organic coatings were use to
isolate the metal from the corrosive
environment.
• It can contain corrosion inhibitors.
• Nonmetallic inorganic coatings also were use
as barrier coatings.
3.3 Inhibitors
• Examples of inhibitors are chromates, silicates,
and organic amines.
• The use of inhibitors is favoured in closed
systems where the necessary concentration of
inhibitor is more readily maintained.
• Inhibitors can be integrated in a protective
coating or in a primer for the coating.
3.4 Cathodic protection
• Cathodic protection subdue the corrosion current that
causes damage in a corrosion cell and forces the current to
flow to the metal structure to be protected.
• Cathodic protection can be achieved by two application
methods of:
– impressed-current system
– sacrificial-anode system
• An impressed-current system uses a power source to force
current from inert anodes to the structure to be protected.
• A sacrificial-anode system uses active metal anodes to
provide the cathodic-protection current.
3.5 Design
• Implementing rational design principles can
eliminate many corrosion problems and
reduce the time and cost associated with
corrosion maintenance and repair.
• Where corrosion damage is anticipated,
design can provide for maximum
interchangeability of critical components and
standardization of components
3.6 High temperature resistant coatings
• High-temperature-resistant coatings are designed to
withstand temperatures ranging from 150°C (300°F)
to over 760°C (1,400°F) while providing protection
against corrosion.
• Example of high-temperature coating resins are:
– epoxy
– epoxy phenolic
– epoxy novolac
– silicone
– a more specialized multi-polymeric matrix
3.6 High temperature resistant coatings

• High-temperature coatings can be found in the


following industries:
– Aerospace
– Power
– Manufacturing
– Petrochemical
– Military
3.6 High temperature resistant coatings

• Applications for high-temperature coatings


includes:
– Jet Engines
– Power/Chemical plants/Refineries
– Offshore assets
– OEM applications
– Corrosion Under Insulation
– Fireproofing
– Buildings and Construction
3.7 Zinc-rich coatings
• It provide sacrificial cathodic protection to the steel
substrate by using zinc particles as the pigment within
the coating.
• Zinc-rich coating were used in:
– highway and infrastructure
– industrial
– automotive applications
• It provide lesser protection than galvanizing, although
their protection is typically improved as compared to
organically coated carbon steel.
3.7 Zinc-rich coatings
• Zinc-rich coating were mostly used for repair
and touch-up operations (including
repairduring manufacturing).
4.0
LIFE PREDICTION OF
CORODIBLE STRUCTURES
AND COMPONENTS
4.1 Life Prediction
• Sevice life – the time during which the structure is able to
safely meet the user requirements
• Service life prediction
– to access long-term environmental effects
– For maintenance management of infrastructure systems
– For maintenance of building components related to material
• Therefore, a systematic methods needs to in place to access
the risk of premature deterioration of existing structures.
• The evaluation of durability using existing standards does
not give adequate service life information.
4.2 Impacts of corrosive environments

• In 2012, it is reported that direct cost of


corrosion in India was estimated Rs. 2 lakhs.
• A corrosion protection strategy is necessary to
minimize the repair and maintenance.
• Corrosion-deterioration of a metal and is
caused by the reaction of the metal with the
environment (ASMI, 2000).
4.2 Impacts of corrosive environments

• Corrosion have serious impact to economic,


especially:
– Replacement of corroded equipment
– Overdesign to allow corrosion
– Preventive maintenance, for example, painting job
– Shutdown of equipment due to corrosion failure
– Contamination of product
– Damage to equipment adjacent to that in which
corrosion failure occur
4.2 Impacts of corrosive environments

Figure 11. Corrosion cost split-up in the USA (FHWA, 1998)


4.3 Economic impact of corrosion
• Corrosion of metals costs the U.S. economy
almost $300 billion per year at current prices.
• Approximately one-third of these costs could
bereduced by broader application of corrosion-
resistant materials and the application of best
corrosion-related technical practices.
• Table 2 compares the results of the 1978 and
1995 Battelle/NIST studies.
4.3 Economic impact of corrosion
Industry Billions of U.S. dollars

1975 1995
All industries
Total 82 296
Avoidable 33 104
Motor vehicles
Total 31.4 94
Avoidable 23.1 65
Aircraft
Total 3 13
Avoidable 0.6 3
Other industries
Total 47.6 189
Avoidable 9.3 36

Table 2. The results of the 1978 and 1995 Battelle/NIST studies (Source: Economic Effects of
Metallic Corrosion in the United States, Battelle Columbus Laboratories and the National
Institute of Standards and Technology (NIST), 1978, and Battelle estimates)
4.3 Factors influencing corrosion

Figure 12. Factors that influence corrosion and its costs


4.3 Factors influencing corrosion
• Corrosion costs are reduced by the application of available
corrosion technology, which is supported by technology
transfer.
• New and improved corrosion technology results from
research and development.
• The proper application of methods to control corrosion (e.g.,
coatings, inhibitors, and cathodic protection) reduces the
cost of corrosion.
• Increased corrosion costs result from government
regulations that prohibit the use of time-honored methods
of protection because of safety or environmental damage.
4.3 Factors influencing corrosion
• The original Battelle/NIST study identified ten elements of the cost of
corrosion:
– Replacement of equipment or buildings
– Loss of product
– Maintenance and repair
– Excess capacity
– Redundant equipment
– Corrosion control
– Technical support
– Design
– Insurance
– Parts and equipment inventory
• Table 3 list examples under each of these categories.
4.3 Factors influencing corrosion
Element of cost Example

Replacement of equipment or buildings • Corroded pressure vessel

Loss of product • Corrosion leak


• Corrosion contamination of product
• Corrosion during storage

Maintenance and repair • Repair corroded corrugated metal roof


• Weld overlay of chemical reaction tank
• Repair pump handling corrosive slurry—
erosion and corrosion
• Scheduled downtime for plant in
continuous operation, for example,
petroleum refinery

Redundant equipment • Installation of three large fans where two


are required during operation

Table 3. Elements of cost of corrosion


4.3 Factors influencing corrosion
Element of cost Example
Corrosion control
Inhibators • Injection of oil wells
Organic coatings • Coal tar on exterior of underground pipeline
• Paint on wooden furniture
• Topcoat on automobile—aesthetics and
corrosion
• Zinc-rich paint on automobile
Metallic coatings • Galvanized steel siding
Cathodic protection • Chrome-plated faucets—aesthetics and
corrosion
• Cathodic protection of underground
pipelines
Technical support • Corrosion-resistant alloy development
• Materials selection
• Corrosion monitoring and control

Table 3. Elements of cost of corrosion


4.3 Factors influencing corrosion
Element of cost Example
Design
Material of construction for structural • Stainless steel for corrosive applications
integrity • Stainless steel for high-temperature
mechanical properties
Material of construction • High alloy to prevent corrosion products
contamination, for example, drug industry
Corrosion allowance • Thicker wall for corrosion
Special processing for corrosion resistance • Stress relief, shot peening, special heat
treatment (e.g., Al alloys) for corrosion
Insurance • Portion of premiums on policy to protect
against loss because of corrosion (to cover
charge of writing and administering policy,
not protection amount)
Parts and equipment inventory • Pumps kept on hand for maintenance, for
example, chemical plant inventory

Table 3. Elements of cost of corrosion


4.4 Corrosion controls
• The massive costs of corrosion provide many
opportunities to users, manufacturers, and
suppliers.
• Opportunities exist to reduce corrosion
• costs and the risks of failure, and to develop new,
expanded markets.
• Examples of these opportunities and the means
to implement a program to capitalize on the
opportunities are shown in Table 1.
4.4 Corrosion controls
Opportunity Examples Implementations

Reduce corrosion costs • Lower maintenance and repair • Identify all corrosion costs by
costs review of total processes,
• Extended useful lives of equipment, and buildings
equipment and buildings • Quantify corrosion costs
• Reduction of product loss from • Implement plan to reduce
corrosion damage costs
Lower risk of failure • Safety • Review process and products
• Product liability for exposure to risk
• Avoidance of regulation • Evaluate risk and
• Loss of goodwill consequences of failure
• Lower exposure by technology
change
Develop new and expanded • Coatings • Apply emerging technology
markets • Alloys • Develop competitive
• Inhibitors advantage by more corrosion-
• Corrosion monitors resistant product
• Transfer existing technology to
other industries

Table 1. Opportunities in corrosion control


4.5 Life prediction of reinforced concrete
structures
• Concrete cover with low permeability is
essential to achieve durability.

Figure 13. Cross section of reinforced concrete


4.5 Life prediction of reinforced concrete
structures
• Critical durability parameters
– Rate of penetration (diffusion) of
chlorides through concrete cover
w/c
SCMs
SPs
– Concrete cover depth
– Chloride threshold of steel
– Chlorides at the surface of concrete
4.6 Example structures having corrosion
issues

Figure 14. The Golden Gate Bridge, San Francisco, USA


4.6 Example structures having corrosion
issues

After 13 years of service, tendons of the bridge failed.

Figure 15. Sunshine Skyway bridge, Florida, USA


4.7 Service life
• Service life – the time during which the
structures is able to safely meet the user
requirements.
• Figure 20 shown below is the service life of
structures
4.7 Service life

Figure 16. Service life of structure

You might also like