Lecture 6 - Cve 309

CIVIL ENGINEERING MATERIALS CVE309)
Dr. Ifeyinwa Ijeoma Obianyo

Ifeyinwa.Obianyo@nileuniversity.edu.ng 11/6/2023 1
COURSE OUTLINE
❖ CONCRETE TECHNOLOGY –
▪ Types of cements,
▪ Aggregates and their properties;

▪ Concrete mix design, properties and their determination.
❖ STEEL TECHNOLOGY –
▪ Production, fabrication and properties,

▪ Corrosion and its prevention.
▪ Tests on steel and quality control.
❖ TIMBER TECHNOLOGY –
▪ Types of wood, properties, defects, stress grading,
▪ Preservation and fire protection,
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▪ Timber products. Rubber, plastics, asphalt, tar, glass, lime, bricks and applications to buildings, roads and
bridges.
STEEL TECHNOLOGY – CORROSION AND ITS PREVENTION
LEARNING OBJECTIVES:
At the end of the class, students will be able to:
1. Define corrosion
2. Explain why metals corrodes
3. Discuss the consequences of corrosion
4. Mention at least three used to protect metals against
corrosion.
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What is corrosion?
▪ Webster’s Dictionary - corrode (v.) To eat away or be
eaten away gradually, especially by chemical action.
▪ NACE Corrosion Basics - corrosion may be defined as
the deterioration of a material (usually a metal) because
of a reaction with the environment.
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Why do metals corrode?

▪ Most metals are found in nature as ores. The manufacturing process of
converting these ores into metals involves the input of energy.
▪ During the corrosion reaction the energy added in manufacturing is released,
and the metal is returned to its oxide state.
▪ In the marine environment, the corrosion process generally takes place in

aqueous solutions and is therefore electrochemical in nature.
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CORROSION CONSEQUENCES
(A) Economic consequences - Corrosion results in the loss of $8 - $126
billion annually in the U.S. alone. This impact is primarily the result of:
1. Downtime
2. Product Loss
3. Efficiency Loss
4. Contamination
5. Overdesign
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(B) Safety / Loss of Life

▪ Corrosion can lead to catastrophic system failures which endanger
human life and health.
▪ Examples include a 1967 bridge collapse in West Virginia which killed
46. The collapse was attributed to stress corrosion cracking (SCC).
▪ In another example, the fuselage of an airliner in Hawaii ripped open
due to the combined action of stress and atmospheric corrosion.
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STEEL TECHNOLOGY – CORROSION CONTROL
The following methods are used to protect metals against corrosion:

I. Selection of the right material of construction
II. Surface coating.
III. Inhibitors
IV. Proper equipment design
V. Electrical protection
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I. SELECTION OF THE RIGHT MATERIAL OF CONSTRUCTION

The right material of construction should have the following
properties:
(1) High mechanical strength
(2) High corrosion resistance
(3) Low cost
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I. SELECTION OF THE RIGHT MATERIAL OF CONSTRUCTION

The material selection is carried out through the following steps:
1. Preliminary selection: Based on experience, availability and safety aspects
2. Laboratory testing: Reevaluation of apparently suitable materials under process
conditions
3. Interpretation of laboratory results and other data: Effect of possible impurities, excess
temperature, excess pressure, agitation, and presence of air in equipment
4. Economic comparison of apparently suitable materials: Material and maintenance cost,
probable life, cost of product degradation, and liability to special hazards
5. Final selection
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II. SURFACE COATING

There are two types of surface coating:
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II. SURFACE COATING

Factors that must be considered in selection of a coating metal:
1. The coating should be able to resist direct attack of the
environment.
2. The coating should be nonporous and continuous (no cracks)
to a void acceleration of corrosion especially in case of a more
noble metal (ex: coating of Fe by Cu).
3. The coating should be hard.
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II. SURFACE COATING

In case of coating the structure with a less noble metal the presence of pores
and cracks in the coat is not dangerous because in this case the less noble
metal will corrode by the formation of dissimilar metal cells while the
structure will remain protected.
In practice metallic coating is carried out by different methods such:
(1) Electroplating
(2) Hot dipping of the work piece in molten metal covered with a flux
(3) Spraying of the molten metal on the work piece.
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CLASS ACTIVITY I
It is preferred to coat steel with Zn rather than with Cu. Discuss

with reasons.
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II. SURFACE COATING
There are two types of nonmetallic coating:
A. Inorganic coating
B. Organic coating
Methods of inorganic coating:
i. Oxidation (passivation): Steel can be coated with an oxide film by:
a). Heating at high temperature,
b). Chemical oxidation by treating steel with hot alkaline nitrate, or persulphate or
perchlorate
c). Anodic oxidation by making the steel structure an anode in electrolytic cell
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II. SURFACE COATING

ii. Phosphating: Steel is coated with a layer of iron phosphate by dipping in
a solution containing phosphoric acid and zinc phosphate.
▪ The iron phosphate film is not highly protective because it is porous so it
usually covered with paint.
▪ The phosphate film improves the bond between the metal and the paint.
i.e. Phosphating is a pre-painting step.
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II. SURFACE COATING

iii. Enamels: Enamels are glassy layer applied to the metal by dipping
it in a suspension of powdered glass, and then the metal is heated in a
stove (furnace) at high temperature where the glass powder melts and
coat the metal.
iv. Cement coating: It is used to coat the inner side of steel pipelines
carrying water or wastewater.
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II. SURFACE COATING
B. Organic coating such as the following:
i. Paints: Before applying paint to a steel surface, the metal surface should be
cleaned of oxides by sand blasting or acid pickling. After cleaning, the metal
surface is coated with a thin layer of primer.
What is primer?
A primer is a paint containing a pigment such as lead oxide (Pb3O4 red lead) or
zinc chromate which oxidizes the steel surface and inhibits its corrosion. Besides,
the primer film increases the strength of the bond between steel and final paint
film. When the primer film dries a thick film of the required paint is applied over
the primer.
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II. SURFACE COATING
B. Organic coating such as the following:
ii. Lacquers: A lacquer consists of a thermoplastic polymer dissolved in an organic
solvent. Lacquers can be used to line steel tanks holding corrosive chemicals such
as acids.
iii. Coal tar: Coal tar is a brown or black liquid of extremely high viscosity. Coal tar
is among the by-products when coal is carbonized to make coke or gasified to
make coal gas.
iv. Temporary coating: It is used to protect metallic structures during shipping and
storage by coating the structure with layer of lubricating oil which can be removed
by an organic solvent when the structure is put to service.
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III. CORROSION INHIBITORS

➢Corrosion inhibitors are substances that are added in small amount (e.g
0.1%) to the corrosive medium stop or slow down electrochemical
corrosion reactions on a metal surface.
➢Mechanism: Corrosion inhibitors work by one or more of the following
mechanisms.
▪ They adsorb on metal surfaces to form protective films.
▪ They combine with corrosion product films to protect metal surfaces.
▪ They form precipitates, which visibly coat and protect metal surfaces.
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III. CORROSION INHIBITORS
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IV. ELECTRICAL PROTECTION
(A) Cathodic protection - Technique to reduce corrosion of a metal surface by making
that surface the cathode of an electrochemical cell.
▪ Cathodic protection is a method to reduce corrosion by minimizing the difference
in potential between anode and cathode.
▪ This is achieved by applying a current to the structure to be protected (such as a
pipeline) from some outside source.
▪ When enough current is applied, the whole structure will be at one potential; thus,
anode and cathode sites will not exist.
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Types of cathodic protection systems - There are two main types

of cathodic protection systems:
a) Galvanic system (sacrificial anode method)
b) Impressed current method
▪ Cathodic protection is commonly used on many types of
structures, such as pipelines, underground storage tanks and
ship hulls.
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CLASS ACTIVITY II
What is primer? Discuss how primer controls corrosion.
11/6/2023 24

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CIVIL ENGINEERING MATERIALS CVE309)

Dr. Ifeyinwa Ijeoma Obianyo

▪ Aggregates and their properties;

▪ Production, fabrication and properties,

Why do metals corrode?

▪ In the marine environment, the corrosion process generally takes place in

(B) Safety / Loss of Life

The following methods are used to protect metals against corrosion:

I. SELECTION OF THE RIGHT MATERIAL OF CONSTRUCTION

I. SELECTION OF THE RIGHT MATERIAL OF CONSTRUCTION

II. SURFACE COATING

II. SURFACE COATING

II. SURFACE COATING

It is preferred to coat steel with Zn rather than with Cu. Discuss

II. SURFACE COATING

II. SURFACE COATING

III. CORROSION INHIBITORS

III. CORROSION INHIBITORS

Types of cathodic protection systems - There are two main types

What is primer? Discuss how primer controls corrosion.

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