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The Basics of Corrosion & How to Beat It

Dangle Rope Access • 26 August 2019
Oil Rig Corrosion

Understanding Corrosion: Essential Insights for Asset Owners


Corrosion is defined as wearing away or gradual destruction from the surface inward.


Something a bit lighthearted before we look at corrosion basics.



"Rust is a Must"

Mighty ships upon the ocean

Suffer from severe corrosion,

Even those that stay dockside

Are rapidly becoming oxide.

Alas, that piling in the sea

Is mostly Fe2O3.

And where the ocean meets the shore,

You'll find there's Fe3O4.

'Cause when the wind is salt and gusty,

Things are getting awful rusty. 

We can measure, we can test it,

We can halt it or arrest it.

We can gather it and weigh it,

We can coat it, we can spray it.

We examine and dissect it,

We cathodically protect it

We can pick it up and drop it.

But heaven knows we'll never stop it!

So here's to rust, no doubt about it,

Most of us would starve without it.

written by T.R.B. WATSON (DECEASED)



Unlocking the Secrets of Corrosion: How to Stop it for Good


So we all understand that corrosion can be found all around us. You never have to look far for rusty steel. In the UK it's estimated that the industry is worth upwards of £80 billion per annum. Rust can form at various levels due to location and protection from the environment i.e. paint. The closer the marine environment is, the more likely it is that rust or corrosion will form due to the salt-laden environment.

Corrosion occurs at anodic sites. Therefore, if we made steel cathodic, we could stop corrosion altogether. It is however unusual to find them uniform as various factors such as contaminants will cause different types of corrosion rates even on a single piece of metal.


The corrosion process is a complex one, and can be accelerated in general by increased humidity, higher temperatures and higher rates of pollution. It’s clear therefore that more corrosion is present near chemical plants and marine environments and why industrial painting requires a professional coating contractor who understands the industry.



Chemical Formula of Rust


Corrosion is an electrochemical process that occurs in stages, primarily on the surface: For rust to form the reaction requires Steel, Oxygen and Water, with the removal of water or oxygen, it will result in the elimination of rust as shown in this mathematical equation (4Fe+3O2+2H20= 2Fe03H20 )


Ferrous ions (Fe++) go into solution at anodic sites. Electrons (e-) are released from the anodic sites and pass through the metal to the cathodic sites.


If oxygen and water are combined, it forms hydroxyl ions. Ferrous and hydroxyl ions react to form ferrous hydroxide. Ferrous hydroxyl further oxidises to produce a hydrated ferric oxide or commonly called red rust.



Unveiling the Mysterious Rules of Corrosion's Energetic World


Corrosion has some general rules, like most things consisting of energy.



Rule 1 – Moist air is more corrosive than dry air (relative humidity).

Rule 2 – Corrosion rates increase with temperature

Rule 3 – Polluted air is more corrosive than clean air

Rule 4 – Saltwater is more corrosive than fresh water

Rule 5 – Corrosion does not occur in a vacuum



Pitting Corrosion


As previously mentioned, it is important to note that not all steel surfaces will result in uniform corrosion. Corrosion, a natural process that occurs over time, can take on various forms and manifestations, including but certainly not limited to, pitting. Pitting corrosion can be particularly detrimental, as it can lead to the formation of small holes or depressions in the steel surface. In more severe cases, this pitting can even result in perforation, creating pathways for leakage of a wide range of products, some of which may be potentially harmful or hazardous. It is therefore crucial to monitor and address any signs of pitting corrosion in steel structures or equipment to prevent the occurrence of leaks and mitigate any potential risks.



Why Does Rust Occur?


Corrosion can form in many ways depending on the storage and usage of the steel, the location, as well as the environment in which it is placed. Corrosion of an anode can be demonstrated over time using current flow between the anodic and cathodic sites when an electrolyte is introduced. The electrolyte can be water or soil. Resistivity will change between the different types of medium, dry soil for example will have a different resistivity from damp soil and sea water will have a different resistivity from fresh water.


Corrosion control is therefore more prudent in areas where corrosion is more aggressive, such as marine and offshore environments. High performance coating systems are often used here to ensure asset longevity.



Electrolytes and their Relationship with Conductivity and Coatings


Electrolytes are normally associated with a solution, which is in contact with the metal. Different electrolytes have different levels of conductivity. A example of an electrolyte is the sea water around an offshore platform, semi-sub or jack-up. This electrolyte is more conductive than other electrolytes as it contains chlorides. The level of chlorides also varies between various waters around the world, with some seas having very high concentrations of chloride salts and therefore very corrosive environments.


As we now know, chlorides can accelerate corrosion and should therefore be removed from the surface by fresh water washing. In certain environments, you may even need to wash between paint coats during painting programs. This is to ensure there will be no trapped salts which will inevitably lead to premature film breakdown.


In addition to chlorides we also have sulphates which are a bi-product of fossil fuel burning, such as coal or oil producing sulphur dioxide. Sulphur dioxide combines with water in the atmosphere to form sulphurous and sulphuric acids. These acids also increase corrosion rates and are found in many industrial locations around the world where sulphates are high.



Why Does Rust Come Through Paint?


To understand why rust comes through paint we first need to consider the driving force that causes metals to corrode is actually a natural consequence of their temporary existence in metallic form. To reach this metallic state it is necessary for them to absorb energy as different materials absorb energy at different rates. As a rule of thumb, the more energy absorption, the increased steel's reactivity.


Magnesium and potassium, for example are very reactive and therefore top the galvanic series. The galvanic series is a table used to demonstrate metal reactivity.



What Happens When Two Metals Are Combined?


When two metals are in contact with one another, which is often the case in the offshore environment, the more reactive metal will corrode in preference to the less reactive metal. Aluminium will therefore corrode in preference to iron when the two are connected and iron in preference to copper etc.


The galvanic series is significant when considering the design stage of offshore assets and industrial plants taking into account different materials in the construction phase.


Aluminium and zinc anodes are one galvanic corrosion protection method. Anodes are attached to steel surfaces on buried or immersed surfaces such as oil rig legs, jackets, mono piles and pipelines. The more reactive metals (aluminium and zinc) will corrode in preference to the underlying substrate.


Anodes are available in various shapes and sizes to suit the application, structure and location. One golden rule with anodes is never paint them!



What is a Dissimilar Metal?


Often coating inspectors get confused when mixing two dissimilar metals, as it is very critical to get the correct ratio of metals correct. In the case of steel as anode, it must also have the largest relative area when introducing a copper cathode, for example. If this were reversed, then the small area of the steel against the relatively large area of the copper would accelerate the corrosion process rapidly. This would result in severe corrosion due to bi-metallic size ratio differentials.


Coatings applied to cleaned steel act as a physical barrier and reduce atmospheric attack, moisture and penetration. This is known as permeability and all coatings are permeable at differing rates.


Anti-corrosive layers such as zinc primers act sacrificially and will corrode in preference to the steel substrate its designed to protect. High-build coatings will slow down the passage of moisture and general contaminants. Having a specified and correctly applied coating system has a tremendous track record in combating corrosion. So, it is therefore imperative to ensure the coating specification is correctly written and professionally applied. Using a company like Dangle will ensure your asset is protected for the maximum amount of time.




About Dangle Rope Access



Here at Dangle Rope Access, we provide a variety of comprehensive inspection, access, coatings, and composite (IACC) industrial services. Our services are available to both the private and public sectors.


We offer high-quality proven solutions that will help reduce maintenance costs in both the long and short-term. We are based in Dundee, Scotland and also have offices based in Edinburgh, along with our newly established training centre in Northern Ireland Dangle Academy. Due to our company size and structure, we are able to offer a flexible and versatile approach to the way we run our business and the services that we offer our clients. And, as a leading painting company, we’ve worked on several renewable energy projects in the UK, Europe, and the US. 


We work with both on and offshore with wind farm operators, and asset owners. For offshore wind farm maintenance, to onshore building maintenance, we can cover both the East and West coasts. 


To find out more about how our team can help you contact us today. Our friendly, professional and helpful team is always on hand to help.

Cathodic protection basics

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Ropes, typically made from high-strength synthetic materials, must meet stringent safety standards and undergo regular inspections. Carabiners, which connect various elements of the system, are engineered to withstand significant loads and feature locking mechanisms to prevent accidental opening. Descenders are crucial pieces of equipment that enable controlled descent and ascent along the rope. These devices incorporate friction-based systems to regulate speed and provide a means of stopping when necessary. Personal protective equipment (PPE) is equally vital, encompassing items such as helmets, gloves, and appropriate footwear to safeguard against potential hazards. In addition to safety gear, industrial abseilers often utilise specialised tools tailored to their specific tasks. These may include inspection cameras, cleaning apparatus, or repair equipment, depending on the nature of the work being undertaken. 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Professionals are encouraged to pursue additional specialised training in areas such as non-destructive testing, confined space entry, and advanced rescue techniques to enhance their career prospects and maintain the highest standards of safety and efficiency in the field. Industries and Sectors Utilising Industrial Abseiling Services construction, offshore oil and gas, wind energy, telecommunications, building maintenance Industrial abseiling services have become increasingly prevalent across various industries and sectors in the United Kingdom. The construction industry, for instance, frequently employs rope access technicians for tasks such as facade inspections, window installations, and structural assessments on high-rise buildings. In the offshore oil and gas sector, industrial abseilers play a crucial role in conducting maintenance and inspections on oil rigs and platforms, where traditional access methods are often impractical or hazardous. The burgeoning wind energy sector has also embraced industrial abseiling techniques for the installation and maintenance of wind turbines. Abseilers are able to access hard-to-reach areas of these structures, ensuring their optimal performance and longevity. Telecommunications is another field that benefits from rope access services, with technicians utilising abseiling techniques to install and maintain communication equipment on towers and tall buildings. Furthermore, the building maintenance sector relies heavily on industrial abseiling for tasks such as external cleaning, painting, and repairs on high-rise structures. This method proves to be both cost-effective and less disruptive compared to traditional scaffolding or cherry picker alternatives. As industries continue to evolve and expand vertically, the demand for skilled industrial abseilers is likely to increase across these and other sectors. Advantages of Industrial Abseiling over Traditional Access Methods cost-effectiveness, minimal disruption, versatility, environmental impact, hard-to-reach areas Industrial abseiling, offers numerous advantages over traditional access methods in various industrial settings. Firstly, its cost-effectiveness is notable, as it eliminates the need for expensive scaffolding or heavy machinery, resulting in significant savings for businesses. Moreover, this method causes minimal disruption to ongoing operations, allowing facilities to maintain productivity during maintenance or inspection procedures. The versatility of industrial abseiling is another key benefit, as technicians can easily navigate complex structures and access hard-to-reach areas that would otherwise pose significant challenges. This adaptability makes it an ideal solution for a wide range of industries, including construction, offshore installations, and historic building restoration. Furthermore, industrial abseiling has a reduced environmental impact compared to traditional access methods. The absence of large equipment and minimal setup requirements result in a smaller carbon footprint and less disturbance to surrounding ecosystems. The advantages of industrial abseiling, including its cost-effectiveness, minimal disruption, versatility, and reduced environmental impact, make it a superior choice for accessing challenging locations in various industrial contexts. Challenges and Limitations of Industrial Abseiling weather constraints, physical demands, height limitations, equipment restrictions Industrial abseiling, whilst an effective method for accessing challenging work environments, is not without its inherent challenges and limitations. Weather constraints pose a significant obstacle, as high winds, precipitation, and extreme temperatures can render operations unsafe or impractical. The physical demands placed upon operatives are considerable, requiring a high level of fitness, strength, and endurance to perform tasks whilst suspended at height for extended periods. Height limitations may restrict the applicability of industrial abseiling in certain scenarios, particularly when structures exceed practical rope lengths or when multiple anchor points are unavailable. Equipment restrictions further compound these challenges, as operatives must carefully consider the weight and bulk of tools and materials that can be safely transported and utilised whilst suspended. Moreover, the specialised nature of industrial abseiling necessitates rigorous training and certification, which may limit the availability of qualified personnel. These factors collectively underscore the importance of thorough risk assessments and meticulous planning to ensure the safe and effective execution of industrial abseiling operations. Future Trends and Innovations in Industrial Abseiling technological advancements, drone integration, virtual reality training, smart equipment The field of industrial abseiling is poised for significant advancements in the coming years, driven by technological innovations and a growing emphasis on safety and efficiency. One of the most promising developments is the integration of drones into abseiling operations. These unmanned aerial vehicles can be utilised for preliminary site inspections, reducing the need for human exposure to potentially hazardous environments. Virtual reality training is another area of innovation that is set to revolutionise the industry. This technology allows for immersive, risk-free training scenarios that can prepare abseilers for a wide range of situations they may encounter in the field. Such training methods are likely to enhance safety protocols and improve overall competency levels amongst practitioners. Furthermore, the advent of smart equipment is transforming the way industrial abseilers approach their work. Sensor-equipped harnesses and ropes can provide real-time data on equipment stress and environmental conditions, enabling more informed decision-making during operations. These technological advancements are not only improving safety standards but also increasing the efficiency and precision of industrial abseiling tasks. As the industry continues to evolve, it is anticipated that these innovations will become increasingly prevalent, shaping the future landscape of industrial abseiling and setting new benchmarks for safety and performance. Crucial Role of Industrial Abseiling in Infrastructure Maintenance In conclusion, industrial abseiling plays a pivotal role in the maintenance of modern infrastructure, particularly in the realm of renewable energy. As the United Kingdom strives to achieve its ambitious target of 40GW offshore energy production by 2030 , the importance of efficient and cost-effective maintenance techniques cannot be overstated. Wind turbines, a cornerstone of this renewable energy initiative, require regular inspection and upkeep to ensure optimal performance and longevity. Industrial abseiling offers a unique solution to the challenges posed by these towering structures, allowing skilled technicians to access hard-to-reach areas with minimal disruption to operations. This method not only facilitates thorough maintenance but also contributes to the overall efficiency of wind farms, thereby supporting the nation's net carbon zero reduction goals. As we progress towards a more sustainable future, the significance of industrial abseiling in maintaining our renewable energy infrastructure will only continue to grow. It is imperative that industry stakeholders recognise and invest in this crucial skill set to ensure the longevity and effectiveness of our renewable energy assets, ultimately supporting the UK's transition to a greener, more sustainable energy landscape. About Dangle Rope Access Here at Dangle Rope Access, we provide a variety of comprehensive inspection , access , coatings , and composite (IACC) industrial services. Our services are available to both the private and public sectors. We offer high-quality proven solutions that will help reduce maintenance costs in both the long and short-term. We are based in Dundee, Scotland and also have offices based in Edinburgh, along with our newly established training centre in Northern Ireland Dangle Academy . Due to our company size and structure, we are able to offer a flexible and versatile approach to the way we run our business and the services that we offer our clients. 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