What is Corrosion?
Corrosion can be defined as the gradual decay of metals and masonry due to electrochemical reactions caused by the surrounding environment. Rust (or oxidation) is a common type of corrosion. Rust occurs when iron or steel is exposed to oxygen and moisture for a long period of time. Is rust dangerous? Yes, if left unchecked, rust can destroy most metals through corrosion. Metal undergoes a visible change during corrosion. It can change color, flake, crack, splinter, and ultimately break.
Why is Corrosion Dangerous?
Corrosion causes structural damage to buildings, bridges, and other types of infrastructure. When the integrity of a building or large structure deteriorates due to corrosion, it could result in a partial or complete collapse of a building.
Metal pipes or storage tanks that suffer from corrosion could begin leaking, allowing hazardous materials to seep down into the soil or out into the workplace. Metal components inside powerful industrial machinery can become rusted and fail, breaking the machine and potentially harming nearby employees.
Because corrosion can cause metal support beams, pipes, and machinery to fail, corrosion is extremely dangerous in an industrial setting.
What Causes Corrosion?
Corrosion occurs when metal has a chemical or electrochemical reaction to environmental factors that include: moisture, oxygen, climate, hydrogen, salt, bacteria, electrical current, or pollutants.
There are several different types of corrosion each with their own unique causes and behavior. Across all forms of corrosion, environmental factors have a significant influence. Temperature, pollutants, microbes, chlorides, humidity, and pH levels all contribute to the development of corrosion.
The composition of materials being used can also influence corrosion. Some metals are more likely to corrode than others, and metals that are too far apart on the galvanic scale will corrode when situated next to each other.
When metals are involved in a chemical reaction they gain electrons. That means the materials around them must lose electrons. After an atom or ion has lost electrons, it has become oxidized. It’s through this electrochemical process that metals suffer corrosion.
What are the Main Types of Corrosion?
There are several distinct types of corrosion: uniform corrosion, aqueous corrosion, galvanic corrosion, pitting corrosion, and stress corrosion cracking. Different chemical reactions and circumstances result in different types of corrosion.
Uniform Corrosion
Uniform corrosion is the most common type of corrosion. It results in a uniform thinning over time across the exposed surface of the corroded metal. Because it’s easy to spot, the progress of uniform corrosion can be predicted and tracked, which makes failure avoidable. Examples of uniform corrosion include the reddish brown of exposed steel, and the tarnishing of silverware.
Aqueous Corrosion
Aqueous Corrosion is a type of corrosion that occurs when metal is exposed to water or moist environments at a low temperature. When this happens an electrochemical process known as oxidation occurs, where the metal exposed to water begins to rust. A common example of aqueous corrosion is an old bicycle that’s been left out in the rain.
Galvanic Corrosion
Galvanic corrosion occurs when two or more dissimilar metals are brought into electrical contact where moisture is present. When a steel screw is drilled into a piece of copper, two different types of metal are in contact. When you add moisture to this situation, one metal will begin losing electrons faster (due to salt or minerals in the water) and begin to corrode. The other metal will gain electrons and avoid corrosion. The end result is one piece of metal that’s corroded while the other is unaffected. Galvanic corrosion can be avoided by using metals that are close to each other in the galvanic series and ensuring one metal is not far more reactive than the other.
Pitting Corrosion
Pitting corrosion is a type of metal decay where small holes or “pits” develop on a metal’s surface. Pitting is a dangerous type of corrosion because it can be difficult to detect, while the metal structure continues to deteriorate. Pitting can be caused by a combination of high temperatures, low pH, and oxidizing agents like chlorine or fluorine. An example of pitting corrosion are the small holes you see in rusty old cars.
Stress Corrosion Cracking
Stress corrosion cracking is the combination of both tensile stress and corrosion. Tensile stress is the amount of pressure metal can withstand before it begins to crack. A dangerous aspect of stress corrosion cracking is that its failure is sudden, and with little warning or visible deformation. Natural gas pipes are susceptible to stress corrosion cracking due to the high pressure of gas being forced through the pipe along with caustic elements like chloride or ammonia.
Structural Damage
While corrosion may seem like a cosmetic issue, it can actually lead to serious problems. For example, rust can weaken the structural integrity of buildings, making them more susceptible to collapse. In addition, corrosion can cause pipes to leak, leading to water damage and mold growth. If corrosion gets bad enough, it can actually cause a structure to collapse completely. This could lead to serious injuries or even death.
Fire Hazard
Corrosion can also create a fire hazard. When metal corrodes, it can create sparks that can ignite flammable materials nearby. In addition, corrosion can weaken electrical wires, increasing the risk of an electrical fire. These fires are extremely dangerous and can cause significant damage to property, not to mention putting the lives of your workers at risk.
Environmental Contamination
Corrosion can also cause environmental contamination. When metals corrode, they release toxins into the air and water, which can pollute the environment and pose a health risk to humans and animals. In addition, corrosion can damage buildings and infrastructure, which can lead to costly repairs or replacement.
Safety Hazards
Corrosion can also create safety hazards. For example, rusted pipes can leak flammable or toxic gasses, which can pose a fire or health risk. Corrosion can cause electrical components to fail, which can lead to fires or explosions. If the corrosion has produced rust, these particles can be harmful to humans if they are inhaled. Inhalation of rust has the potential to lead to respiratory disorders.
Dangers of Corrosion to Equipment and Employees
In an industrial setting, corrosion represents a major safety hazard to both equipment and employees. Corrosion can result in a building collapse, or breakdown of high-powered industrial machinery both of which can result in severe injuries to workers. Additionally, corrosion can simply slow down machinery, reducing efficiency. Preventing metal corrosion is critical to help companies avoid reduced productivity and dangerous accidents
Benefits of Corrosion Prevention and Control in Industrial Settings
There are several benefits of preventing corrosion in an industrial workplace. Avoiding damage to buildings and injuries to employees are the most critical benefits, but there are a handful of others. Preventing and controlling corrosion can increase the lifespan of equipment. Avoiding corrosion helps you protect your company’s valuable assets. When equipment and facilities are free from corrosion, they’re easier to clean, maintain, and repair.
The Cost of Not Implementing Corrosion Prevention and Control Measures
When machinery like cranes, storage tanks and heavy machinery fails, it can be extremely costly. Insurance, liability, and downtime are all factors. Ignoring corrosion can result in loss of productivity and increased maintenance for structures and machinery that’s beginning to corrode. Preventing corrosion is a smart investment to protect and preserve your assets.
How to Prevent Corrosion
At Alpine Painting & Restoration, we offer a variety of corrosion control services to help prevent the deterioration of your property. Our services include painting, sealing, and waterproofing, which can help protect your property from the elements. We also offer cleaning and repair services to remove existing corrosion and repair any damage that has been caused. Our specialty coatings will also help to prevent future corrosion.
If you’re concerned about the condition of your property, contact us today to schedule a consultation. We will assess the condition of your property and recommend the best course of action to protect it from further damage.
Contact Us for Corrosion Control in Philadelphia
Corrosion is a serious problem that can cause structural damage, environmental contamination, and safety hazards. If you suspect that your property has been affected by corrosion, it’s important to contact a professional for corrosion control in Philadelphia. At Alpine Painting & Restoration, we offer a variety of services to help prevent and repair corrosion damage. Contact us today to learn more about our services or to schedule a consultation.
Last Updated: September 17th, 2024
