Bodhi Tree_August 10:Bodhitree 15/09/10 12:07 PM Page 1

Metallic
Corrosion
the bodhi tree
S E P T E M B E R 2 0 1 0

Project Name – ICI Vietnam, Location – Vietnam

All materials have an expected life and its replacement over a period of time is inevitable. In general, any material would
perform to its expected lifespan only when the conditions it is exposed to, are favourable, else it would corrode. It may be therefore
safely assumed that all materials will eventually suffer from some form of deterioration or the other.
Reasons for material deterioration may vary; however, the most common reason for a metal failure is its eventual corrosion.
Corrosion may be defined as destruction or deterioration of a material due its reaction with the surrounding environment, which
to some degree is always corrosive.
In order to understand the potential causes of unsatisfactory material performance, one should have a high degree of awareness
regarding the material design, specification and installation combinations. Also, along with these aspects, awareness regarding
corrosion is also important.
This issue of “Bodhi Tree”, therefore, is an attempt to understand the basics of the metallic corrosion.

S h a r i n g K n o w l e d g e
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Corrosion is usually defined as the loss of a metal or its properties, caused due to a
reaction with its surrounding environment. In other words, corrosion is the wearing
out of the metal due to a chemical reaction. Corrosion occurs in various forms
ranging from a generalised attack over the entire surface to a localised one. Corrosion
in case of materials other than metals, such as ceramics or polymers, may be termed
as degradation.

Metallic Corrosion
Most metals occur naturally in chemical combination with other Time of Wetness
elements and are usually chemically stable but may not be
suitable for commercial usages. Extracted metal/alloy, when
exposed to oxygen and other oxidizing agents, try to revert to
SO2 Corrosion Rate Airborne Salinity
their natural state. This natural reversal is Metallic Corrosion.
Man made materials change into its constituents due to chemical
or electrochemical reactions with its surroundings, starting at its
surface. Many structural alloys corrode merely from exposure to Special Factors
moisture in the air, but the corrosion rate (Fig. 1) is strongly
Fig.1-Factors influencing corrosion rate.
affected by certain factors/substances in the environment.
All metals exhibit a tendency to corrosion; some corrode more Corrosion Types
easily than others. A tabulation of the relative strength of this Galvanic/Bi-metallic Corrosion : Galvanic Corrosion is of
tendency is called the Galvanic Series (Please refer Table 1). major interest where water is in contact with metal. For Galvanic
The position of a metal in the series also suggests its potential Corrosion, an electrically conductive path (two metals in
usefulness for structural and other applications. electrical contact) and a path for movement of ions (immersion
Table 1: Galvanic Series of Metals (and Alloys) in Sea Water in an electrolyte) are required. As the name “Bi-metallic”
suggests, this type of corrosion will always involve 2 dissimilar
NOBLE (CATHODIC) non-compatible metals. In the process, more active metal (as in
Gold Galvanic Series) corrodes at higher rate than the noble metal.
Platinum Galvanic corrosion is often utilised in sacrificial anodes e.g.
Titanium
Graphite
Silver
Stainless steel*
Copper-Nickel*
Bronzes*
Copper
Brasses* Active discharge from Copper tube Stainless steel screw causing
causing rusting of coated steel sheet. corrosion of metallic coated steel
Tin
Lead usage of Zinc as a sacrificial anode for steel structures (pipelines
Cast Iron or docked naval ships).
Carbon Steel
Pitting Corrosion : Pitting corrosion is usually found where
Cadmium
Aluminium resistance against general corrosion is present, except at the
Zinc rusting points. Pitting corrosion occurs due to localised
Magnesium Alloys conditions such as high concentrations of salt/ localised
Magnesium breaking of passive film, which are favourable for corrosion e.g.
chlorides in contact with stainless steel/aluminised steel. These
ACTIVE (ANODIC)
tiny local fluctuations may degrade the protective oxide film.
*- Different alloy chemistry may result in different position in the Corrosion at these points gets greatly enhanced and holes are
Galvanic Series table. developed. It may be noted that, although pitting occurs due to
severe local conditions, it may continue, even after these
conditions are not there.
Bodhi Tree_August 10:Bodhitree 15/09/10 12:07 PM Page 3
Crevice Corrosion : Crevice corrosion is another localised form
of corrosion. It occurs in spaces where the access of the working
fluid from the environment is limited and varying oxygen
concentration is present. These spaces are generally called
crevices. Examples of crevices are gaps and contact areas
Crevice corrosion at lock seam
between parts, under gaskets or seals, seams/lap joints etc.
Aluminised steel/Aluminium is prone to ‘Crevice Corrosion’ in
marine atmosphere.
Microbial Corrosion : Microbial corrosion or bacterial corrosion
is caused or promoted by microorganism. It can happen to both
metallic and non-metallic materials, irrespective of the presence
or lack of oxygen. In the presence of oxygen, some bacteria
directly oxidize iron to iron oxides and hydroxides, while other
bacteria oxidises Sulphur and produces Sulphuric Acid, causing
corrosion. Non-metals, nylon etc. are degraded by plastic eating
bacteria.
High Temperature Corrosion : This non-galvanic form of
corrosion can occur when a metal is subjected to a high
temperature atmosphere that contains oxygen, sulphur or other
gases. For example, materials used in Aerospace, Power
Generation and even in car engines get exposed to an
atmosphere containing corrosive products of combustion at high
temperature.
At times, the by-products of high temperature corrosion can also
prove to be advantageous. The formation of oxides on stainless
steels/carbon steel for example, provides a protective layer that
prevents further atmospheric attack at both room and high
temperature.
Intergranular Corrosion : Metal is made up of a large number
of "crystal grains" with regularity in atoms. Between the two
grains lies the grain boundary. Misalignment amongst atoms of
one grain to other may occur at these grain boundaries.
Intergranular corrosion
Intergranular corrosion is a form of corrosion that occurs at the
grain boundaries. It occurs due to thermal processes causing
change in constituents at grain boundaries within the
microstructure of the metal. For example: depletion of Chromium
at grain boundaries in stainless steel during welding/ improper
heat treatment, renders it less resistant to corrosion at these
points.
Rusting : Rusting is the most common form of corrosion. Metals
may undergo corrosion, but the resulting oxides are not
commonly referred to as rust. This is because, rusting is a term
used for corrosion of iron and steel products only. Iron/steel
products react with oxygen in the presence of water or air
moisture and form hydrated iron oxides, commonly known as
rust. There are also other forms of rust, such as the green rust
which is a result of the reaction of iron with chlorine. White rust
is corrosion of zinc in the coating on steel. Generally rust has a
White rust Red rust
much higher volume than that of the original mass of metal, and
its build-up may also cause failures.
Steel is relatively unaffected by pure water or by dry oxygen
alone. As in case of hot rolled/blued steel, a tightly adhering
oxide coating- passivation layer, protects the bulk steel from
further oxidation. However, when in contact with water and
oxygen, or other strong oxidants and/or acids, steel will rust.
Similarly in the presence of salt, for example, near sea, it tends
to rust more quickly due to the electro-chemical reactions. Other
degrading solutions are sulphur dioxide / carbon dioxide in
water. Under these corrosive conditions, hydrated oxides are
formed. And these oxides (rust) are not passivating because
these do not adhere to the bulk metal. Rust is permeable to air
and water, therefore, the interior iron/steel continues to corrode
until all of the steel or oxygen or water in the system is removed
or consumed.
Project Name – Inter Auto, Location – India
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Corrosion Resistance / Prevention / Protection

Materials most resistant to corrosion are those for which
O2 O2
corrosion is unfavourable. Any corrosion products of gold &
platinum tend to decompose spontaneously into pure metal, Paint
which is why these elements can be found in metallic form.
Some metals have naturally slow reaction kinetics, even though
Base Metal (Fe)
their corrosion is thermodynamically favourable. These include
metals such as Zinc, Magnesium and Cadmium. While corrosion Mechanical Barrier between
of these metals is continuous and ongoing, it happens at an steel and atmosphere
acceptably slow rate. Paint
O2
More common metals or alloys such as steel need to be
protected. In most cases, it is impossible or economically Base Metal (Fe)
impractical to completely arrest the corrosion process. However,
it is usually possible to control the process to acceptable levels. Rust
Breaks in coating result
This can be achieved by various ways for different material with in corrosion to base steel
different results in different environments.
Fig.2-Barrier protection mechanism
Barrier Protection : Corrosion can be controlled with the help of
passivation, a thin film of external solution passivates the
impervious coatings e.g. coatings produced by painting/plating/
material e.g. chrome passivation of metallic coated steel.
anodising/ bluing, etc. These coatings isolate the metal from the
environment. They work by providing a barrier of corrosion- Dehumidification : Another method to avoid corrosion is by
resistant material between the damaging environment and the controlling the environment. Controlling the humidity, if possible,
material (Fig.2). At places that are not covered or with damaged below a certain threshold level can help reduce the rate of
coating, corrosion may set in. corrosion process.

Passivation : Passivation is another type of barrier protection
provided by a very thin film. It could be achieved by self
passivation of material or by an externally applied solution. In
self passivation, a thin film of corrosion products on a metal
surface acts as a barrier to prevent further corrosion. When this
thin film stops growing at less than a micrometre in thickness,
the phenomenon is known as passivation. In case of external
Design Considerations : Corrosion can also be controlled by
proper design. Some points for consideration towards the same
are:
Unwashed Areas : In a building design, there may be certain
areas which will not be exposed to general rain washing. These
unwashed areas have a build up of dust and dirt, which
increases the “time of wetness” on the material surface. The

Project Name - Sungai Buloh Hospital, Location – Malaysia

Bodhi Tree_August 10:Bodhitree 15/09/10 12:07 PM Page 5
“time of wetness” is an important factor governing the rate of
corrosion. An increase in the “time of wetness” will increase the
rate of corrosion. In case there is a presence of salts/SO2 in
these deposits, the corrosion will worsen. The underside of
eaves, fascia linings, vertical walls protected by overhanging
sections, the top sections of garage doors, etc. are all typical
examples of such unwashed areas. Minimisation of these areas
will lead to increased life.
End Lapping : Metal sheets are manufactured by a continuous
process. Therefore, it is possible to have sheet lengths
manufactured (at the building site) such that there is no end lap.
Improper end lapping
However, when shorter sheet lengths are to be used, certain
precautions are required to prevent the early deterioration at the
lapped joint. This potential problem can be avoided by
appropriate use of neutral cure silicone rubber sealant.
Slip Sheets : Sometimes slip sheets may be used at the point
of corroded old roof. However, it must be noted that coated steel
slip sheets will corrode when in contact with rusted or bare steel.
Pitch Transition Flashing : In all instances where a change of
pitch occurs, the appropriate change of pitch flashing should be
chosen in order to correctly flash the joint. Care should be taken
that while waterproofing a transition joint, the overlapping sheet
should not be simply fastened firmly down onto the underlying
sheet. If it is done so, thermally induced stresses will remove the
coating on the underlying sheet at the point of contact and will
result in rapid corrosion due to the loss of sacrificial metallic
coating.
Low Pitched Roofing : Laying of sheet at a pitch lower than
required for the respective profile type causes a possibility of
water movement through capillary action, penetrating the side
laps. This not only results in damage of the ceiling structure due
to water but also corrosion of the roof sheets.
Expansion Joints : Expansion joints are provided in order to
overcome longitudinal thermal movement encountered on a long
roof, in order to avoid structural damage to the roof sheeting.
Care must be taken while designing and installing the expansion
joint, so as to adequately flash it and prevent water and dirt from
entering into the lapped joint.
Supporting Steel Structure : Coated (both pre-painted &
metallic coated) steel roofing and walling must be installed on
structure coated with an appropriate compatible material. This is
essential since, the corrosion of uncoated steel will also cause
corrosion of the coated steel in contact.
Ponding : “Ponding” causes deterioration of the sheet coating
and leads to perforation. Care must be taken not to block any
valleys or trays that would prevent the water from draining.
Gutters are most affected due to “ponding” of water.
Use Of Compatible Materials : Bi-metallic corrosion is
observed when non-compatible materials come in “direct
contact” or when overflow of water (e.g. from Copper to Zn
containing coating) occurs.
In case of corrosion due to overflow, the noble metal corrodes
slightly and dissolves in water which subsequently flows over a
less noble material and may then deposit on it forming a bi-
metallic contact. A typical example of this can also be seen with
stainless steel screws causing corrosion of metallic (bare/pre-
painted) coated steel around the screw. This is further enhanced
if the washer contains carbon black (highly conductive) even in
the absence of a noble or cathodic screw. Thus, use of washers
free of carbon black, is advised.
Sacrificial /Cathodic/Galvanic Protection
This is the most commonly used method of corrosion protection.
It is achieved by placing the metal in contact with another, more
easily corroding metal (Fig.3).
This leads to increased corrosion of the more active metal and
decreased corrosion of the more noble metal. Cathodic
protection continues till the sacrificing metal is present. The
biggest advantage of sacrificial protection is the protection of
areas which are not directly covered e.g. scratches/cut
Anodic Reaction Cathodic Reaction
2M M2+ + 2e- O2+ 2H2O+ 4e- 4OH-
M2+ OH-
e-
Metal
Zn Zn2+ + 2e-
Steel
Fig.3-Sacrificial protection mechanism
ends/piercings. Sacrificial anodes are made from material with a
more negative electrode potential than the cathode (e.g. zinc
acts as anode to iron/steel).
Bodhi Tree_August 10:Bodhitree 15/09/10 12:07 PM Page 6

Rust protection
In order to protect steel from corrosion, metallic coatings are said to be sacrificially or galvanically protected. The corrosion
applied to it. There are two types of metallic coatings; “active” (or rate of zinc depends on the relative humidity, rainfall,
sacrificial) coatings and “noble” (or cathodic) coatings. The terms temperature and nature of pollutants (industrial or marine).
“active” and “noble”, indicate whether the metallic coatings are
For providing corrosion protection, there are two ways by which,
active (will corrode) or noble (will not corrode). Zinc and Zinc
metallic coatings are commonly applied to steel:
containing coatings are “active” for steel, while, hot dipped
lead/tin coatings are “noble”. However, tin coatings constitute a 1. Hot dipped
special case, it is cathodic to steel on the outside of a tin plated 2. Electro deposited
steel container but usually “active” to steel on the inside.
Hot dipped and electrodeposited coatings, both, protect steel in
Two important qualities of an “active” metal coating are: a similar manner, difference being: hot dipped coatings are
a) They provide essential corrosion resistance usually thicker and therefore offer a longer life under the same
exposure conditions. The protective life of a metallic coating is
b) Their ability to corrode in a controlled manner, so as to
essentially a function of the coating thickness.
sacrificially protect the steel base
The principles of galvanic corrosion are used for protecting steel
with the help of a metallic coating that contains zinc. Steel is then

Project Name - Sabeco Vietnam, Location – Vietnam

Bodhi Tree_August 10:Bodhitree 15/09/10 12:08 PM Page 7

Conclusion
It may be concluded that corrosion reactions are generally
governed by the available moisture and oxygen in the
environment. It may be delayed but cannot be avoided. While
design and installation practices play an important role in the
process of corrosion, the use of compatible materials helps
reduce corrosion. Metallic corrosion and its rate is influenced by
properties of metal, “time of wetness” and the constituents of
environment it is exposed to. Further contamination of the
environment by corrosive products (may exist or be derived
from industrial or marine condition), accelerate corrosion of the
material. Galvanic series is a tool to select the sacrificial
protecting metal/alloy. For steel, corrosion is due to iron trying to
return to the original hydrated iron oxide or iron oxide state.
Although many other metals form their oxides when corrosion
occurs, “rusting” is a term reserved only for the corrosion of Iron
and Steel. Zinc & Zinc containing e.g. 55% Al-Zn alloy coating
protects steel by way of barrier as well as sacrificial protection.
The 55% Al-Zn alloy coating provides up to 4 times more
corrosion protection to the steel as compared to Zinc coating of
equal thickness, in a near neutral environment.

Project Name – BSC Suzhou Factory, Location – China

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