How to Prevent Steel Corrosion in Your Building
A Comprehensive Guide to Understanding Structural Steel Failure
Steel is a vital component of many buildings and structures, but steel failure can pose a significant challenge.
Corrosion can often be concealed behind surfaces, leading to severe safety risks for occupants and costly issues for building owners. Without periodic inspections or proper maintenance, these problems can go unnoticed and worsen over time. Ensuring the safety, longevity, and overall integrity of a building not only protects its occupants but also helps preserve its value in a competitive real estate market.
Below is a guide explaining the complexities of steel failure, its impact on safety and building management, and the importance of proactive inspection and maintenance strategies. All of this knowledge contributes to the long-term structural integrity of your facility.
Want to know what things you should be aware of to identify potential steel corrosion? Watch the video below to hear from GHP’s Senior Vice President of Architecture, Mark Smith.
Top 3 Risks of Structural Steel Corrosion
Structural instability
Corrosion can weaken the steel structure, causing it to lose its load-bearing capacity. Corroded steel can also deflect or deform that can lead to movement or collapse of the building elements it is supporting. This can cause structural instability that makes the building unsafe for use and poses a risk of severe injury to building occupants.
Reduced service life
As metal corrodes, it becomes more vulnerable to damage from external forces such as wind, earthquakes, and natural disasters. This can result in premature replacement or expensive repairs.
Increased maintenance costs
Corrosion requires ongoing maintenance to prevent it from worsening. This includes regular inspections, cleaning, and repairs. The cost of these maintenance activities adds up over time and can become a significant financial burden for building owners.
What Does Steel Corrosion Look Like?
Corrosion occurs when metal is exposed to moisture, oxygen, and other environmental factors that can cause it to degrade over time. Corrosion can compromise the integrity of a building or infrastructure, leading to potential safety hazards, reduced load-bearing capacity, and expensive repairs.
Several visual signs can indicate the presence of corrosion on structural steel:
Rust or discoloration: Often appears as a reddish-brown discoloration on the surface of the metal. If the corrosion is severe, the rust may be flaky or powdery in texture.
Cracks or fissures: Found on the surface of the steel. These may be visible to the naked eye or require close inspection.
Pitting corrosion: Causes small pits, craters, or crevices to form on the surface of the steel. These can range in size from small pinholes to larger craters.
Swelling or deformation: May be visible as a bulge or distortion on the surface of the metal.
Flaking or peeling paint: Often used as a coating to protect steel from corrosion, paint can become compromised. It may expose the metal to further corrosion or indicate the presence of corrosion beneath the surface. It may also trap damaging moisture between the coating and the steel.
Climate and geographic location can also impact the severity and rate of corrosion on steel structures:
Humidity: High humidity levels can increase the amount of moisture in the air and accelerate the corrosion of steel.
Temperature: Temperature fluctuations can cause steel to expand and contract. Changes in steel’s size and shape creates areas where moisture can collect and cause corrosion.
Precipitation: Areas with high levels of precipitation from rain, snow, and ice are conducive to corrosion, particularly if the steel is not properly protected against moisture.
Coastal regions: The proximity to saltwater can increase the rate of corrosion due to the salt content in the air. Special measures are typically taken to protect steel in coastal environments.
A building’s age is another factor. Exposure to the environment and other factors over time can lead to corrosion and eventually structural damage. Details to watch out for are:
Wear and tear: As a building ages, it may experience wear and tear from daily use, exposure to the elements, and other factors. This can damage protective coatings on the steel, allowing moisture and other corrosive elements to come into contact with the metal.
Maintenance and repair history: Inadequate or incomplete repairs may allow corrosion to spread, leading to further damage.
Changes in building codes: Building codes and standards are continually evolving, with new requirements for corrosion protection and prevention being introduced over time. Older buildings may not meet current standards, which can increase the risk of corrosion.
How Cladding Can Corrode Steel
Exterior insulation and finish system (EIFS) is a type of cladding used in many commercial and residential buildings. While EIFS can provide excellent insulation and weatherproofing, it can also contribute to steel structural failure if it is not properly installed or maintained.
The main risks are moisture intrusion and air infiltration. EIFS is designed to be a barrier against water intrusion, but if it is damaged or improperly installed, it can allow water to seep into the underlying structural components of a building. This can lead to corrosion of the steel elements.
Another consequence of damage to EIFS is the accumulation of moisture within the cladding system. Trapped moisture can lead to further deterioration of the cladding, as well as the underlying steel structure.
The biggest challenge? All of this happens behind the EIFS cladding and may not be obvious from an initial visual inspection. If left unaddressed, this results in costly repairs or even catastrophic structural failures.
Indicators of EIFS failure include:
Cracking, bulging, or peeling of the EIFS surface
Water infiltration, resulting in damp or stained interiors
Mold or mildew growth on the EIFS surface or within wall cavities
Discoloration or staining on the exterior surface
Delamination where the EIFS layers separate from one another or the underlying substructure
Rust stains at EIFS control joints that may be a sign of corrosion of steel elements behind the cladding
Exterior trim or other architectural details that appear to be pulling away from the building's surface
Pooling of water on floors, decks, or other horizontal surfaces in the vicinity of steel structural members
3 Ways to Prevent Steel Failure in Your Building
Reinforcing and restoring structures is a complex process. The first step is being aware of potential issues and understanding typical building lifecycles and maintenance requirements. But when it’s time to take action, it requires expert guidance and execution.
1. Inspections and assessments
Regular inspections and assessments are crucial for ensuring the safety and integrity of any building. Qualified professionals with experience in structural engineering and restoration should carry out these evaluations. Thorough assessments can identify potential problems early, allowing for timely remedial actions.
These inspections should examine various aspects of a building's structure, systems, and components. This includes the foundation, framing, mechanical systems, plumbing systems, and other features that may be susceptible to wear and tear, corrosion, or other forms of deterioration.
2. Professional assistance and execution
After identifying potential issues, it is crucial to enlist the help of professionals who can provide the necessary support. This may involve hiring forensic architects, structural engineers, restoration specialists, or other experts who can assist in reinforcing and restoring a building's structural integrity.
These professionals work with property owners and managers to develop a comprehensive plan of action, taking into account the unique features, issues, and requirements of the building in question. This plan may include repairing or replacing damaged or corroded components, reinforcing weak points in the structure, and implementing preventative maintenance measures. By taking these actions, you can prolong the life of the building and ensure safety for occupants.
3. Ongoing maintenance and improvement
The process of reinforcing and restoring structures is not a one-time event. It is an ongoing commitment. Regular maintenance and improvements are essential to ensuring the continued safety and integrity of any building. It’s important to undergo periodic inspections and timely repairs, plus stay informed about new technologies and best practices in the field of structural engineering and restoration.
Property owners and managers should also establish open lines of communication with their professional team of experts. A collaborative relationship allows for continuous improvement and adaptation to the evolving needs of their buildings.
"I believe in reinforcement as a good approach. Many times, when you cut out a structural system and replace it, you're actually impacting the overall frame and it could have an adverse effect."
—Mark Smith, AIA, LEED AP Senior Vice President Architecture
The Benefits of Proactive Reinforcement and Restoration
Being proactive in reinforcing and restoring structures brings potential benefits to property owners and managers:
Safety: Help prevent accidents, injuries, and fatalities associated with structural failures by doing regular inspections, maintenance, and necessary reinforcements.
Longevity: Extend the useful life of a building, allowing owners to maximize their investment and decrease the overall cost of ownership.
Value preservation: Help preserve a building’s value in the real estate market, making it more attractive to potential buyers or tenants.
Compliance: Meet current building codes and safety regulations, reducing the risk of fines or penalties for non-compliance.
Environmental sustainability: Reduce energy consumption and create a smaller environmental footprint for the building, contributing to a more sustainable future.
Conclusion
Steel failure in structures is both a safety and financial concern for building owners and occupants. Oftentimes, corrosion can be hidden behind surfaces, making it difficult to identify without regular inspections and proper maintenance.
With new regulations and increased scrutiny on steel inspection processes, it is more important than ever for property owners and managers to stay informed and proactive in maintaining their buildings' structural integrity. This ensures the safety of building occupants, minimizes costly repairs, and increases adherence to regulatory standards.
Taking care of your steel structure is an act of planning for the future. In the long run, proactive attention leads to more sustainable, secure, and valuable properties.