UNIVERSITY OF CEBU

Maritime Education Program

SEAMANSHIP
1
Course: BSMT Topic:
Period: 1st sem SY 2023- • Causes of Corrosion and its prevention
2024
Week: Week 13 methods
• Procedures how to safely de-rust and prepare
 Overvie
• Definition of Corrosion
•wTypes of Corrosion
• Effects of Corrosion
• Methods in preventing corrosion
• Procedures how to safely de-rust and prepare steel surface for
painting
Learning
• LO 4.9: Explain the causes of corrosion and the corresponding
Outcomes
methods of its prevention
• LO4.10: Determine the procedures and how to safely de-rust and
prepare steel surface for painting
What is corrosion?

• is the gradual deterioration

of metals caused by chemical
and electrochemical
reactions.
TYPES OF CORROSION

• Uniform Corrosion
• Galvanic Corrosion
• Pitting Corrosion
• Crevice Corrosion
• Stress Corrosion
TYPES OF CORROSION
• Uniform Corrosion
-the entire exposed surface of a metal corrodes uniformly
• Galvanic Corrosion
-when to different metals are in electrical contact with each other and exposed
to a electrolyte (like water)
• Pitting Corrosion
-a localized form of corrosion that leads to the formation of small, deep pits or
holes in the metal
• Crevice Corrosion
-occurs in confined spaces or where the metal surface is shielded from the
surrounding environment
• Stress Corrosion
-the growth of cracks in a material caused by the combined effects of tensile
stress and a corrosive environment
CAUSES OF CORROSION

• Environmental Factors
• Material Factors
• Operational Factors
CAUSES OF CORROSION
• Environmental Factors
-also known as Atmospheric corrosion
-external conditions that accelerate corrosion processes
*Exposure to Oxygen
*Exposure to Moisture
*Exposure to Acids and Alkalis
*Exposure to Gases
*Exposure to Electrolytes
--Microbial Corrosion
*caused by bacteria that bring about corrosion
CAUSES OF CORROSION
• Material Factors
-involves Galvanic corrosion
-properties of the metal itself that can influence its susceptibility
to corrosion
*Metal Purity
*Metal Composition
*Metal Surface Condition
CAUSES OF CORROSION

• Operational Factors
-related to how a metal is handled that influences
corrosion rate
*Temperature
*Stress (Fretting Corrosion)
*Cleaning Agents
PREVENTION METHODS

I. Protective Coatings:

Paints and Polymers - Applying paint, enamel, or plastic

coatings can protect metals from direct exposure to air and
moisture.

Galvanization - This involves coating iron or steel with a layer

of zinc. The zinc layer corrodes preferentially, protecting the
underlying metal.

Anodizing - Commonly used for aluminum, this electrochemical

PREVENTION METHODS

II. Cathodic Protection

Sacrificial Anodes - In this method, a more reactive metal (like

magnesium or zinc) is attached to the structure. This metal
corrodes instead of the protected metal.

Impressed Current - An external current source is used to make

the metal surface cathodic, thereby reducing corrosion.
PREVENTION METHODS

III. Material Selection

Alloys - Some metals are more corrosion-resistant due to their

chemical composition. For example, stainless steel resists rust
because of its chromium content, which forms a protective
oxide layer.

Non-Metallic Materials - For certain applications, non-metallic

materials like plastics or composites are used, as they are
inherently resistant to corrosion.
PREVENTION METHODS

IV. Environmental Control

Dehumidification - Reducing humidity around the metal

surface can prevent corrosion, especially in storage
environments.

Inhibitors - Adding chemical inhibitors to the environment can

slow the corrosion reaction. For example, corrosion inhibitors
are added to cooling systems and pipelines to protect metals.
PREVENTION METHODS

V. Regular Cleaning and Maintenance:

Routine cleaning removes salts and pollutants from surfaces,

reducing the chance of corrosion. Inspections allow early
detection and treatment of corrosion.
EFFECTS OF CORROSION
• Structural Damage - Weakening and failure of infrastructure
(bridges, buildings, etc.).

• Economic Costs - High costs for repairs, maintenance, and

replacement.

• Environmental Impact - Contamination due to leaking materials.

• Safety Hazards - Potential accidents from weakened structures.

SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
1. Before beginning, ensure you have the necessary safety
equipment, as chemicals and particles released during de-rusting
can be hazardous. Essential PPE includes;
-Respiratory Protection: Use appropriate respirators or dust
masks, especially when working with chemicals, solvents, or
during tasks that generate dust or fumes (e.g., sandblasting,
grinding, or solvent application).
-Eye and Face Protection: Wear goggles or face shields to
protect against particles, dust, and splashes from chemicals or
paints.
SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
-Hearing Protection: When using power tools, wear earplugs or
earmuffs to reduce exposure to noise levels that could damage
hearing.
-Protective Clothing: Wear coveralls, gloves, and steel-toe
boots. Ensure gloves are chemically resistant if handling
solvents or other hazardous substances.
-Fall Protection: For work at heights, use harnesses and other
fall arrest equipment, particularly on scaffolding or elevated
platforms.
2. Ensure Ventilation: Work in a well- ventilated space to avoid inhaling
fumes or dust.
3. Secure the Work Area: Stabilize the steel piece and ensure it’s in a safe
position for sanding or chemical application.
SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
4. Surface Inspection
-Assess the Condition: Examine the surface for rust, existing paint
degradation, oil, grease, and other contaminants.
-Identify Areas Needing Repair: Mark any areas with damage,
pitting, or structural issues that may need repair or welding before
proceeding.
5. Cleaning the Surface
-Remove Loose Paint and Debris: Use scrapers, wire brushes, or
grinders to remove loose paint, rust, and any other debris.
-Degreasing: Apply a degreasing agent to remove oils, grease, and
other contaminants. Rinse the surface thoroughly with fresh water
after degreasing to remove all traces of the cleaning agent.
SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
5. Cleaning the Surface (cont.)
-Salt Removal: For surfaces exposed to seawater, use freshwater
to wash away salts. If necessary, use a salt remover or detergent to
ensure no salt residue remains, as it can affect adhesion.

6. Rust and Corrosion Removal: Select a de-rusting method based on

the extent of corrosion. Chemical rust removers, like phosphoric
acid-based products, dissolve rust effectively but must be handled
with caution.
-Assess Rust Level: Determine if rust is light, moderate, or
severe.
SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
6. Rust and Corrosion Removal: Select a de-rusting method based on the extent of
corrosion. Chemical rust removers, like phosphoric acid-based products, dissolve
rust effectively but must be handled with caution. (cont.)
-Assess Rust Level: Determine if rust is light, moderate, or severe.
*Mechanical Cleaning: For extensive rust, use mechanical tools such as
grinders, rotary brushes, or needle guns to remove corrosion. This is
particularly useful for smaller areas or places where sandblasting may be
difficult.
*Abrasive Blasting: Use abrasive blasting (e.g., sandblasting or grit
blasting) to remove heavy rust, mill scale, and old coatings. This is the
preferred method for large areas as it provides a clean, rough surface that
promotes paint adhesion.
 SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
7. Drying the Surface
-Dry Completely: Ensure that the surface is completely dry before applying
any paint or primer, as moisture can cause poor adhesion and lead to blistering or
corrosion under the paint layer.

8. Final Surface Preparation Check

-Inspect Surface: Check that the surface is clean, dry, and free from
contaminants. It should be at the specified surface profile and ready for painting.
-Check Environmental Conditions: Ensure the temperature and humidity levels
are within the recommended range for the paint or primer to be applied. Avoid
surface preparation in high humidity or during rain to prevent flash rusting.
SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
9. Primer Application
-Apply Primer Immediately: To prevent flash rust, apply the
primer as soon as possible after surface preparation, especially in
humid environments or on surfaces prone to rapid rusting.
-Ensure Even Coating: Apply an even layer of primer according
to the manufacturer's specifications, which will serve as a base
for the paint and improve adhesion.
 SAFETY PROCEDURES BEFORE AND DURING SURFACE
PREPATION
10. Quality Control and Inspection
-Visual Inspection: Check that the primer covers all areas uniformly and
adheres well to the prepared surface.
-Coating Thickness Check: Use a dry film thickness gauge to measure that the
primer is at the required thickness, ensuring optimal protection.

11. Ready for Painting

-Allow Primer to Cure: Let the primer dry and cure fully according to the
manufacturer’s instructions before applying any topcoats.
-Begin Painting: Apply the topcoat(s) according to the specific paint system
requirements, typically in multiple layers with drying time between coats.
Q&A Session
Thank you for listening!
Lesson
Completed