ECONOMICS OF CORROSION CONTROL

Module 5

OVERVIEW
Materials selection Design Coatings Engineering disasters

MATERIALS SELECTION
Carbon Steel is a cheap material (~$900/ tonne). If properly used, good life can be had
Corrosion allowance Uniform corrosion Maintenance and inspection program Planned replacement Coatings, CP, Inhibitor

Stainless grades of steel can out perform CS, but:

More expensive (x6 cost) Difficulties with fabrication
Some grades can be welded, some cannot

Problems with chlorides, temperature Corrosion control mechanism is different to CS, therefore may perform differently. Can suffer from SCC, IGC, deep pitting

POLYMERS AND COMPOSITES

Can achieve good per formance. Not much experience therefore many unsure of per formance. Conservative engineers means resistance to adoption. New materials all the time.

DESIGN

ANGLE SECTIONS

AVOID WATER RETENTION

ALLOW COMPLETE DRAINAGE

AVOID WET INSULATION

ASSET LIFE

COATINGS

COATINGS
Cost benefit analysis between design life and
coating system used
Preparation standard Primer Resin Film thickness

Repair strategy
Inspection protocol Repair/ recoat

Case histor y: For th Rail Bridge, opened 1890

Previous to 2004, was painted on a 4 year cycle, permanent repair crew employed 2004 was painted with a coating with a 25-40 year life. Bridge still has an estimated 100 year life.

CONSEQUENCES OF CORROSION FAILURE

FORTH RAIL BRIDGE

Opened 1890
Previous to 2004, was painted on a 4 year cycle, permanent repair crew employed 2004 was painted with a coating with a 25 -40 year life. Reducing the need for regular repainting. Bridge still has an estimated 100 year life.

FORTH ROAD BRIDGE

And yet, the For th road bridge, opened in 1964 with a 120 year design life, a cable suspension bridge. Will require replacement by 2020 due to corrosion. The suspension cable contains 13,000 high tensile steel wires. Water ingress into the cable has caused corrosion of the cables with resultant loss of strength.

CORROSION FATIGUE CRACKING

CFC

EROSION CORROSION DUE TO ROUGH WELD

MIC

MIC

CONCRETE CORROSION

PARKING STRUCTURE

WATER TOWER ABU DHABI