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Standard corrosion protection systems for buildings

From Steelconstruction.info
This article is designed to assist those responsible for either drafting corrosion protection specifications, or as contractors with a
requirement to meet that which is specified. The information provided is based upon industrial experience, and is in the form of
current practice tables of standard corrosion protection systems for steelwork in a range of environments.

Contents
1 Introduction
2 Interior environments
2.1 Hidden steelwork
2.2 Visible steelwork
2.3 Swimming pools
3 Exterior environments
4 Perimeter walls
4.1 Steelwork in clear separation from outer leaf
4.2 Steelwork in contact with outer leaf
5 References
6 Resources
7 Further reading
8 See also
9 External links
10 CPD

Coating application in the fabrication factory

(Image courtesy of Hempel UK Ltd.)

Introduction
The tables of standard systems for steelwork presented in this article relate to environment categories which are based upon those
given BS EN ISO 12944-2[1] and BS EN ISO 9223[2], which are described in the table below.
Atmospheric corrosivity categories and examples of typical environments (BS EN ISO 12944-2[1])
Corrosivity
Examples of typical environments in a temperate climate (informative only)
Low-carbon steel
category
Thickness loss (m)a
Exterior
Interior
and risk
C1
very low

1.3

C2
low

> 1.3 to 25

C3
medium

> 25 to 50

C4
high

> 50 to 80

C5-I
very high
(industrial)
C5-M
very high
(marine)

Heated buildings with clean atmospheres, e.g.

offices, shops, schools, hotels

Atmospheres with low level of pollution

Mostly rural areas

Unheated buildings where condensation may

occur, e.g. depots, sports halls

Urban and industrial atmospheres,

moderate sulphur dioxide pollution
Coastal area with low salinity
Industrial areas and coastal areas with
moderate salinity

Production rooms with high humidity and

some air pollution e.g. food-processing
plants, laundries, breweries, dairies
Chemical plants, swimming pools, coastal,
ship and boatyards

> 80 to 200

Industrial areas with high humidity and

aggressive atmosphere

Buildings or areas with almost permanent

condensation and high pollution

> 80 to 200

Coastal and offshore areas with high salinity

Buildings or areas with almost permanent

condensation and high pollution

Notes:
1m (1 micron) = 0.001mm
a The thickness loss values are after the first year of exposure. Losses may reduce over subsequent years.
The loss values used for the corrosivity categories are identical to those given in BS EN ISO 9223[2].
In coastal areas in hot, humid zones, the mass or thickness losses can exceed the limits of category C5-M. Special precautions
must therefore be taken when selecting protective paint systems for structures in such areas.
In many instances, steelwork will be in a warm dry interior where it will not corrode, and the structural stability of the building will not
be threatened during its design life (generally taken as 50 years). In such conditions (classified as C1) no corrosion coating is
required. Examples include steelwork inside dry buildings with neutral atmospheres such as multi-storey office buildings, shops,
schools, hotels, residential buildings, airport terminals, and hospitals, etc.
However, when steelwork is exposed to moisture, corrosion will occur at a rate depending on the severity of the environment. In
such cases, a coating system appropriate to the environment category should be provided. Note that some buildings may contain
areas where different environment conditions apply e.g. hospitals would normally be C1, but may contain kitchens and laundry areas
that would normally be C3. Some types of buildings, such as car parks may fall into any of the above categories or combinations of
them depending upon their location, design and construction. Higher risk categories for interior environments (e.g. C4 and C5) are
not covered in this article and users are advised to seek specialist advice if their project involves such situations.
The protective systems in the tables have unique identities. The film thicknesses given in the tables are nominal dry film values (m =
micron = 0.001mm). The tables also identify the nearest equivalent system in BS EN ISO 12944-5[3] , and the required surface
preparation to BS EN ISO 8501-1[4]

Interior environments

In deriving the protection systems described on these pages, the design life of building structures has been taken as 50 years. The
tables give two figures for durability:
Structure life The period of reasonable freedom from severe corrosion of the steelwork that might lead to weakening of the structure.
This figure assumes no mechanical damage in service that no maintenance is carried out and that up to 1mm of steel may be lost from
the surface at the corrosion rate for each environment given in BS EN ISO 12944-2[1]. Visible steelwork will normally be accessible
for maintenance and if repainting is carried out the quoted structure life will be extended.
Coating life The expected period to maintenance of the protective coating. More frequent re-coating may often be preferred for
decorative reasons because of fading, contamination, wear and tear, etc. Hidden steelwork is assumed to be not accessible for
maintenance, thus a figure for coating life of hidden steelwork systems is not applicable.

Hidden steelwork

Standard systems for C2 low risk environment category

Standard systems for C3 medium risk environment category

Notes to tables:
1. The thickness values given for primers are the total thickness used and may include a prefabrication primer. For example,
80m can be in one coat or as 20m prefabrication primer plus 60m post-fabrication primer.
2. For steel profiles over 6mm thick the minimum average thickness of galvanized coatings to BS EN ISO 1461[5] is 85m
3. MIO - micaceous iron oxide.

Visible steelwork

Standard systems for C2 low risk environment category

Standard systems for C3 medium risk environment category

Notes to tables:

1. The thickness values given for primers are the total thickness used and may include a prefabrication primer. For example,
80m can be in one coat or as 20m prefabrication primer plus 60m post fabrication primer.
2. A wetting low viscosity primer is recommended to obtain satisfactory performance.
3. For steel profiles over 6mm thick the minimum average thickness of galvanized coatings to BS EN ISO 1461[5] is 85m.
4. To enhance durability and improve the aesthetic appearance, the hot-dip galvanized coating can be treated with a mordant
wash or T wash followed by a vinyl primer at 40m and a vinyl finish at 60m.
5. MIO - micaceous iron oxide.

Swimming pools

Standard systems for C4 high risk environment category

Notes to table:
1. The Coating Life is estimated for the paint system only and does not include the hot-dip galvanized coating. The life of the total
protection system without maintenance should exceed 25 years, however, it is anticipated that for aesthetic reasons
maintenance will be carried out at periods of 10 years or less.
2. For steel profiles over 6mm thick the minimum average thickness of galvanized coatings to BS EN ISO 1461[5] is 85m. For
hidden steelwork, e.g. behind a suspended ceiling, no further treatment is required. For steelwork that is visible, the galvanized
coating should be surface treated and coated as shown.
3. Methods of preparing hot-dip galvanized coatings need to ensure that a satisfactory condition is achieved to accept a paint
coating system. It is important that the steelwork is thoroughly degreased and free from any contamination. Several methods
can be considered including:
1. Mordant wash or 'T' wash, which is the brush application of a chemical solution that reacts with the galvanized
surface. The effectiveness of the solution is readily visible and untreated areas are self evident. After treatment, the
solution should be rinsed off with clean water and then the treated surface dried ready for painting. It is important that
the manufacturers' instructions are carefully followed to ensure successful results.
2. Etch primers, which can be either single or two pack materials and they are applied as thin film coatings to around

10m to 25m in thickness. The two pack versions tend to provide an improved surface compared with the single pack
3. Sweep blasting, which is the use of low pressure fine grade non-metallic abrasive which can be very effective but
requires care and expertise. The treatment should slightly roughen the galvanized surface without removing the coating.
4. MIO - micaceous iron oxide.

Exterior environments
Coating system durability given in the following tables is based on practical experience. It is the expected life, in years, before first
major maintenance. This is taken as degradation level Ri3 from BS EN ISO 4628-3[6] (1% of surface area rusted). It should be
noted that this does not imply a guarantee of life expectancy. The durability of galvanized steelwork is derived from the figures in BS
EN ISO 14713[7].

Standard systems for C3 medium risk environment category

Standard systems for C4 high risk environment category

Standard systems for C5 very high risk environment category

Notes to tables:
1. For steel profiles over 6mm thick the minimum average thickness of galvanized coatings to BS EN ISO 1461[5] is 85m.
2. Where painting of galvanized steelwork is required for aesthetic or other reasons; suitable systems from BS EN ISO 129445[3] may be used.
3. The thickness values given for primers are the total thickness used and may include a prefabrication primer. For example,
80m can be in one coat or as 20m prefabrication primer plus 60m post fabrication primer.
4. MIO - micaceous iron oxide.
5. It should be noted that the colour range of MIO is limited.
6. The zinc rich primer applied at 80m would increase the durability of the system by approximately 5 years.
7. The primer coat may be omitted providing the build/intermediate coat is applied directly to a clean steel substrate of suitable
surface profile.
8. With time, elastomeric urethanes may suffer from superficial degradation known as chalking which changes the visual
appearance but does not affect the over all durability of the system. Where colour stabilization is required for appearance
purposes, this can be achieved by the application of the finish coat in this system.
9. The protection of structural steelwork against atmospheric corrosion by thermal sprayed aluminium or zinc coatings is covered
in BS EN ISO 2063[8].

Perimeter walls
Steelwork in clear separation from outer leaf
For wall cavities in which steel will remain
dry, either by use of an impermeable outer
leaf or where there is physical separation of
the steel from the outer leaf, a system from
the Hidden steelwork section for

environment categories C1, C2 or C3 may

be appropriate. The treatment specified for
cavity wall condition should also be suitable
for the interior environment of the building.
Should the internal environment be more
aggressive, additional protection will be
required.

Notes to table
1. The thickness values given for primers are the total thickness used and may include a prefabrication primer. For example,
80m can be in one coat or as 20m prefabrication primer plus 60m post-fabrication primer.
2. The environment within a normal cavity wall construction is categorised as being C2. The system PW-C2-S is considered
appropriate for such conditions. However, where steelwork within the cavity is deemed to be in a more aggressive
environment category, the application of a high build bitumen coating at 150m to the faces of the steelwork within the cavity
may be applied before or during construction.

Steelwork in contact with outer leaf

Brickwork cladding or other masonry, can develop cracks and leakage over time. When steelwork is in contact with, or embedded
in a brick/masonry outer leaf, one of the following systems should be used. In some regions, stainless steel may be required for
embedded members by local regulations or be deemed necessary to provide adequate durability. Specialist advice should be sought.

References
1. ^ 1.0 1.1 1.2 BS EN ISO 12944-2: 1998, Paints and
varnishes Corrosion protection of steel structures by
protective paint systems Part 2: Classification of
environments, BSI
2. ^ 2.0 2.1 BS EN ISO 9223: 2012, Corrosion of metals and
alloys Corrosivity of atmospheres Classification, BSI
3. ^ 3.0 3.1 BS EN ISO 12944-5: 2007, Paints and varnishes
Corrosion protection of steel structures by protective paint
systems Part 5: Protective paint systems, BSI
4. ^ BS EN ISO 8501-1: 2007, Preparation of steel
substrates before application of paints and related products.
Visual assessment of surface cleanliness. Rust grades and
preparation grades of uncoated steel substrates and of
substrates after overall removal of previous coatings, BSI
5. ^ 5.0 5.1 5.2 5.3 BS EN ISO 1461: 2009, Hot dip galvanized
coatings on fabricated iron and steel articles. Specifications and test methods. BSI
6. ^ BS EN ISO 4628-3: 2003 Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity and size of
defects, and of intensity of uniform changes in appearance - Part 3: Assessment of degree of rusting. BSI
7. ^ BS EN ISO 14713-1: 2009 Zinc coatings. Guidelines and recommendations for the protection against corrosion of iron and
steel in structures. General principles of design and corrosion resistance. BSI
8. ^ BS EN ISO 2063: 2005, Thermal spraying - Metallic and other inorganic coatings - Zinc, aluminium and their alloys, BSI

Resources
Hendy, C.R.; Iles, D.C. (2010) Steel Bridge Group: Guidance Notes on best practice in steel bridge construction (5th Issue).
(P185). SCI
Guidance Note 8.01 Preparing for effective corrosion protection
Guidance Note 8.03 Hot dip galvanizing
Guidance Note 8.04 Thermally sprayed metal coatings
Guidance Note 8.05 High performance paint coatings
Steel Buildings, 2003, The British Constructional Steelwork Association Ltd.

Chapter 12 Corrosion Protection

Further reading
D.Deacon & R.Hudson (2012), Steel Designers Manual (7th Edition), Chapter 36 - Corrosion and corrosion prevention, The
Steel Construction Institute.
D.A. Bayliss & D.H.Deacon (2002), Steelwork Corrosion Control (2nd edition), Spon Press.

See also
Corrosion of structural steel
Influence of design on corrosion
Surface preparation
Paint coatings
Metallic coatings
Appropriate specifications
Inspection and quality control

External links
British Coatings Federation (http://www.coatings.org.uk)
Galvanizers Association (http://www.galvanizing.org.uk)
Paint Research Association (http://www.pra-world.com)
The Thermal Spraying and Surface Engineering Association (http://www.tssea.co.uk)

CPD
Corrosion protection
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Category: Corrosion protection
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