2.

After completing this chapter, the student should be able to:

2.1. Describe the various factors controlling atmospheric corrosion
2.2. Explain the importance of relative humidity in the atmosphere
2.3. Differentiate between relative humidity and 'time of wetness'.
2.4. Discuss the effects of atmospheric pollution and atmospheric
contaminants (salts) and their effect on corrosion and their inter-
relationship with relative humidity.
2.5. Indicate how you would pick up the effects of prevailing winds on
structures.
2.6. Differentiate between the good and bad effects of sunshine on the
corrosion control measures.
2.7. Differentiate between micro and macro climates and their respective
effects.
2.8. On what basis they would differentiate between different corrosion
zones in South Africa
 CLIMATIC FACTORS

1. FACTORS CONTROLLING ATMOSPHERIC CORROSION

1.1. Rain
1.2. Relative Humidity and 'Time of Wetness'
1.3. Atmospheric Pollution
1.4. Atmospheric Contaminants or- salts
1.5. Winds
1.6. Effect of Sunshine
1.7. Micro versus Macro Climates
1.8. Atmospheric Corrosion Zones of South Africa
2. AN OVERVIEW OF GENERAL ENVIRONMENTAL CONDITIONS IN
SOUTH AFRICA
3. REFERENCES
 Climatic factors affect the durability of long-term corrosion control measures
and also play an important role in ensuring the correct surface preparation
prior to applying protective coatings. Climatic factors are also important
during the coating process. It is therefore important to have a good
understanding of the role of these various factors and to apply this knowledge
specifically to South African conditions to achieve the maximum benefit from
the money spent on corrosion control.

1. Factors Controlling Atmospheric Corrosion

Atmospheric corrosion may be described as the reaction of a metal to its

environment. The environment can vary considerably with respect to
moisture content, temperature variations and the amount of pollution and/or
other contaminants present in the atmosphere. Usually it is convenient to
classify particular environments according to whether conditions are rural,
urban, industrial or marine, with combinations of these factors as necessary.
Whatever type of atmosphere is prevalent in a particular area, it is important
to realise that changes will always occur with time. Meteorological and
pollution factors can vary from year to year ~ population densities will change
etc. We will consider some of the more important variables and how these
affect, corrosion control.

1.1. Rain

Rain may reduce corrosion by washing away harmful products or deposits

such as soot or salts that would otherwise accelerate the corrosion process.
 Sometimes, however, the rain may be so light as to merely wet the surface,
thereby promote corrosion. On balance, rain is thought to be more beneficial
than harmful in South Africa.

1.2. Relative Humidity and Time of Wetness

The wetting of a metal surface, for example by morning dew or from settled
fog or mist is important as this is likely to promote corrosion. Thus the dew
point, relative humidity of the atmosphere and the hygroscopic (i. e. moisture
absorption) nature of settled dust are important. What really is important is
the length of time a metal remains wet - often referred to as the 'time of
wetness' as this is important to a coating's life and to the conditions
applicable at the time of surface preparation and applying the coating.

It has been demonstrated that in absence of rain, gaseous or solid pollutants

in the atmosphere, serious corrosion of steel does not occur when the relative
humidity of the atmosphere is below about 70%. (See Figure 1.) Although
there may be no apparent moisture on the metal's surface, at about 70%
relative humidity, an invisible layer of moisture begins to form an electrolyte
and corrosion initiates more readily. Humidity isographs showing relative
humidity patterns throughout the day throughout the year are useful for
assessing the likelihood of condensation and corrosion. (Fig. 2-6.)

1.3. Atmospheric Pollution

Vernon, an English Corrosion Scientist, was the first to describe the

accelerating effect of SO2, on corrosion as a function of humidity. Other
contaminants also play a role, but SO2, (usually associated with the waste
products of burning coal, fuel and petrol) has been more closely linked to
 higher corrosion rates and the breakdown of protective coatings.

1.4. Atmospheric Contaminants or Salts

Proximity to the coast plays an important role in atmospheric corrosion. Wind

carries sea-salt nuclei Car inland and the hygroscopic nature and penetration
of sea salt into structures causes severe corrosion. Surface preparation and
coating procedures must take notice of the effect of settled salt from the sea.
Industrial areas suffer similar problems in that industrial pollution can have
the same affect as sea salt. Distance from the sea or from a source of
industrial pollution can be an important factor in determining the efficiency of
corrosion control.

1.5. Wind

Wind plays an important role in that they affect the distribution of corrosive
constituents as a result of marine or industrial atmospheres. Our coasts are
subject to heavy surf action and often very directional on-shore winds are
prevalent. Directional effects are particularly noticeable in the Cape
peninsula and Port Elizabeth areas. Wind borne sea salt has been carried
over 30 km inland in the South Western Cape.

1.6. Effect of Sunshine

Radiation from the sun shows seasonal variations and its effect can vary. For
example radiation raises the temperature of the metal's surface reducing the
'time of wetness'. On the other hand intensive UV radiation is particularly
damaging to organic coatings.
1.7. Micro versus Macro Climates

It is important to distinguish between micro and macro climates. For

example, the general Durban environment can be described as a severe
corrosive industrial marine or urban marine climate, but the corrosion rate
may vary considerably depending on where the structure is exposed. On the
Bluff the corrosion rate is extremely high – over 200 micrometers of steel will
be lost from a structure annually. The corrosion rate drops significantly to 35
to 40 micrometers/year at Salisbury Island in the Bay as a result of direct
protection by the Bluff from the prevailing winds. Similarly tall buildings can
cause significant protection to lower buildings situated behind them.

1.8. Atmospheric Corrosion Zones of South Africa

In 1992 for convenience, the C.S.I.R. published a booklet containing

Meteorological, Pollution and Corrosion data for South Africa where all this
information was collated and was used to draw up an 'Atmospheric Corrosion
Map of Southern Africa'. The meteorological data includes aspects such as
rainfall (broken down to each month), temperature and relative humidity data
at 08h00, 14h00 and 20h00, also on a monthly basis. Also included are the
SO2 pollution data together with trends, indicating the degree of pollution
control, being achieved in the various regions. Corrosion rates are then
correlated to the morphology of the country and climatic factors to produce a
corrosion map suitable for use by all contractors, applicators and specifiers
who wish to know likely conditions at various sites in South Africa.

2. An Overview of General Environmental Conditions in South Africa

As corrosion is the reaction of a metal with its environment, obviously the

nature of the metal and the environment to which it is subjected are
important in determining the type of corrosion that will occur and the rate of
corrosion. Under some circumstances, metals will pit and cause failure (e.g.
pipes in building services) in a relatively short time. In general the rate of
corrosion of metals varies according to the particular metal and the climatic
conditions to which it is exposed. Similarly, the performance of paint and
metal coatings varies according to the substrate below the coating and
environmental factors.

As a general guide to environmental conditions and the expected degree of

severity in terms of corrosion, the following types of environmental zones are
considered important for designers.

Indoor – Dry

Conditions are normally dry and the relative humidity is generally below 60
percent. Very little corrosion is anticipated and corrosion protective
measures required are minimal. Coatings are often applied for aesthetic
reasons only.

Indoor Under Cover– Wet

Although indoors, the location is such that the metal's surface is wetted at
regular intervals and cannot dry rapidly. Typical examples are ablution
blocks, kitchens and other areas of high water vapour and/or splashing. Areas
of particular concern are those surfaces that cool at night resulting in
condensation, such as metal roofs and cladding systems. Localized corrosion
can be severe and accessibility limited, thus these areas must be adequately
protected initially.
 Exterior Inland – Low Pollution

Those areas of South Africa that are over 30 km inland or sheltered by high
mountains from the coastal areas, fall into this zone. The relative humidity is
generally below 70 percent for most of the day or night. Corrosion is not
particularly severe.

Exterior Coastal - Mild to Medium

This zone covers those areas of South Africa between 5 and 30 km from the
coast. The relative humidity may exceed 70 percent for the greater part of
the day and night, but the incidence of air-borne salt is relatively low.
Corrosion problems become significant and adequate protective measures
are important.

Exterior Coastal – Severe

The area of the country covered by the inter-tidal zone to about 5 km inland
can be considered as extremely aggressive to most metals and corrosion
protection systems. High humidity and high temperatures also play an
important role. The application of protective measures under these
aggressive conditions is difficult and many failures may be attributed to
application problems rather than faults in the coating itself.
 Industrial - Coastal or Inland

A high incidence of industrial pollution will lead to serious corrosion problems.

Obviously coastal conditions and high relative humidity will aggravate the
problem, but confined spaces indoors should also be considered where
industrial processes create chemical vapours or fall out.

Besides the rather generalized environmental areas described above, it is

equally important to consider localized effects, generally termed micro-
climates. For example fumes from chimneys and excess moisture from
baking processes in food factories could cause corrosion in a particular
locality. The shielding effects of sand dunes may alter the corrosion pattern
significantly. Prevailing winds may play an important role in a micro- climate,
for example a strong directional wind off the sea channelled up a valley may
induce severe corrosion up to 30 km inland.

In the light of criteria discussed the following points are considered important
in selecting a material or protective system for a particular site.

Examine all structures, poles, pylons and fencing in the area to assess
directional effects; consider the success of other protective systems and
general corrosivity of the area. This on-site information may prove very
effective as a guideline to choice of protective system, and actual siting of a
structure in relation to protective dunes or other landscape features.

The functional requirements may also narrow the selection of materials.

Hygiene may dictate the use of stainless steels, colour coding may be
 important as may be resistance to mechanical damage during handling and
shipping to site. Aspects such as compatibility of component to the
protective scheme may also dictate choice. The size of a galvanised bath
could preclude this type of protection or necessitate different fastening
procedures or drilling of holes into hollow sections to allow access of zinc and
escape of gasses without causing explosions.

Another important criterion in selecting materials or protective systems

would be the decision as to where fabrication and/or coating application will
be carried out. Transport over long distances, delays and characteristics of
the coating (for example time intervals between paint coatings ) may play an
important role in choosing protective systems. Certain coating systems such
as galvanising or the inorganic zinc coatings are suitable for transport,
whereas some soft coatings are
easily damaged. Specific advantages of some soft coatings may necessitate
surface preparation (such as abrasive blasting) and application on site before,
during or after erection.

3. References

Atmospheric Corrosion Testing in southern Africa -

Results of a Twenty Year National Exposure Programnie. By
B G Callaghan, Scientia Publishers, Pretoria 1992.
Fig 1. Schematic diagram illustrating effect of relative
humidity on the corrosion of steel (Pollutants absent)
Fig 5 Relative Humidity Isogram for East London
Fig 6 Relative Humidity Isogram for Durban
Fig 3
Relative Humidity Isogram for Cape Town

PIGUE4
Relative Humidity Isogram" for Port Elizabeth