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FIRST EDITION: JANUARY 1999

SECTION N
CORROSION PROTECTION

1 INTRODUCTION..................................................................................................2
2 SCOPE OF GUIDELINES....................................................................................2
3 PHILOSOPHIES OF CORROSION PROTECTION............................................2
4 THEORY OF CORROSION.................................................................................2
4.1 Basic principles of corrosion..............................................................................2
4.2 Factors affecting corrosion.................................................................................3
4.2.1 The Atmosphere.........................................................................................3
4.2.2 Water..........................................................................................................3
4.2.3 Soil.............................................................................................................3
4.3 TYPES OF CORROSION.................................................................................4
4.3.1 Uniform Corrosion:....................................................................................4
4.3.2 Localised Corrosion:..................................................................................4
5 CORROSION CONTROL.....................................................................................5
5.1 Design for corrosion protection..........................................................................5
5.1.1 Design requirements...................................................................................5
5.1.2 Material selection.......................................................................................6
5.1.3 Procedure for coating selection..................................................................6
6 CORROSION PROTECTION...............................................................................7
6.1 General...............................................................................................................7
6.1.1 Surface preparation....................................................................................7
6.1.2 Application.................................................................................................8
7 MAINTENANCE OF CORROSION PROTECTION..........................................8
8 QUALITY ASSURANCE.....................................................................................8
9 SAFETY AND HEALTH......................................................................................9
9.1 General...............................................................................................................9
9.2 Ventilation and dust control...............................................................................9
9.3 Handling/storage/transport...............................................................................10
9.3.1 Materials...................................................................................................10
9.3.2 Coated articles..........................................................................................10
10 APPLICABLE STANDARDS.............................................................................11

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
[Link] - 11-Jul-25 N-1
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FIRST EDITION: JANUARY 1999

SECTION N
CORROSION PROTECTION

1 INTRODUCTION

The building of community water supply schemes reinforces the needs to employ
sound corrosion principles to ensure extended delivery of water.

In the field of water supply highly corrosive conditions are encountered.

The life of the equipment will depend on the quality of the corrosion protection and its
maintenance.

2 SCOPE OF GUIDELINES

These guidelines are covering the basics of corrosion and its prevention which is
encountered on water supply schemes.

They are intended to guide designers, engineers and operators and shall be used
together with detailed specifications, recognised standards (SABS, ISO, DWS ) and
engineering expertise.

3 PHILOSOPHIES OF CORROSION PROTECTION

The smaller water supply schemes will generally be situated in remote rural areas.
Under these conditions equipment of high quality, long life and low maintenance is a
requirement to promote an assured supply and low life cycle cost.

This can be achieved by the use of corrosion resistant materials, simple and effective
designs, and high quality corrosion systems.

4 THEORY OF CORROSION

4.1 Basic principles of corrosion

Corrosion is a process of the conversion of a metal to a metallic compound. It is called

an electrochemical reaction because the chemical change is accompanied by the
passage of an electric current.

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4.2 Factors affecting corrosion

There are three main natura environments affecting the corrosion rate:
 the atmosphere
 water
 soil

4.2.1 The Atmosphere

The following factors have an influence on the rate of corrosion:

 Relative humidity and time of wetness:
In the atmosphere serious corrosion of steel occurs when the relative humidity
(RH ) is above 70 % .
 Atmospheric contaminants: salts; winds and sunshine
 Contaminants from sea-salt nuclei or industrial pollution can cause severe
corrosion. Winds play a role as the distributor of the corrosive elements.
 Radiation from the sun damages organic coatings.
 Atmospheric pollution (SO2) together with water forms an acid that attacks
metal.

4.2.2 Water

The tendency of metal to corrode in water depends on the characteristics of the water.
The main factors affecting the corrosivity of water are:
 acidity
 oxygen - increase corrosivity
 soluble salts - increase corrosivity

4.2.3 Soil

The main factors affecting corrosion are:

 conductivity - increase corrosivity ( clays )
 oxygen content
 differential pH
 sulphate-reducing bacteria

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GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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4.3 TYPES OF CORROSION

4.3.1 Uniform Corrosion:

This corrosion prevails if oxidation and reduction sites constantly shift in location and
the tractional coverage of sites is roughly the same. In other works, when anodes and
cathodes change position continuously. A typical example is when most metals are
exposed to the atmosphere or water.

4.3.2 Localised Corrosion:

 Pitting corrosion:

If an oxidation site is small and surrounded by a much larger reduction area, then
pitting can result. Local defects in a protective layer on metals becomes a small
oxidation area.

Stainless steel, aluminium and copper are typical examples of metals suffering
from pitting corrosion.

 Crevice corrosion:

Crevice corrosion is found between metallic sections or metal to non-metal joints.

(Flange joints, notches in welds) It also occurs under deposits. (Welding beads,
sand, bottom of tanks).

 Galvanic corrosion:

If two different types of metal are in contact with each other in the presence of an
electrolyte (water), a galvanic couple can form. In this case the metal acting as the
anode will corrode.

Metals and alloys may be graded according to how active or noble they are in any
specific electrolyte. This grading is known as a galvanic series.

Magnesium Anodic end

Zinc ---------------------------------
Aluminium Zinc protects
Cadmium steel
Steel ---------------------------------
Lead
Stainless steel
Nickel
Copper Cathodic end

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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The corrosion rate of the anode of the couple depends on:

1. the difference in potentials ie. how far they are apart in the galvanic series,
2. the ratio of the surface areas of anodic metal to cathodic metal, and
3. to a lesser degree the physical distance between the metals.

 Differential aeration:

This corrosion is caused by differential amount of oxygen in the electrolyte.

Differential aeration occurs at crevices, in areas just under the water line (splash
zone), underground bolts etc.

 Microbiologically influenced corrosion (MIC):

Sulphate-reducing bacteria live in low or no oxygen content environments where

the pH is near neutral. Their life progress gives off sulphides, which are excellent
electrolytes and aggressive to metal. An indication of this type of corrosion is the
smell of hydrogen sulphide and the presence of sulphide corrosion products.

 Cavitation corrosion:

This corrosion is caused by the attack on a metal surface through collapsing water
vapour bubbles in fast flowing water. The collapsing bubbles explode pieces of
metal off the surface, and if this situation carries on for too long, the whole metal
structure can be weakened.

5 CORROSION CONTROL

There are basic main methods:

 Insulating the surface from the environment by means of protective coatings
 Cathodic protection
 Attention to design

5.1 Design for corrosion protection

5.1.1 Design requirements

A good design will reduce corrosion and ease corrosion protection. Corrosion control
start s on the drawing board.

The designer must pay attention to the following main aspects:

 water retention areas
 bimetallic couples
 crevices
 accessibility
DEPARTMENT OF WATER AFFAIRS AND FORESTRY
GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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 handling
 mechanical preparation ( sharp edges, weldspatter & slag )

NOTE: Bimetallic couplings will be discussed in more detail because they are so
common.

Corrosion of steel is greatly accelerated if it is in electrical contact with a more noble

metal in the presence of an electrolyte (see Galvanic corrosion). Dissimilar metals
should be avoided where possible. If such contact cannot be avoided minimise the
problem by one or more of the following:
 try to electrically insulate them (sealants, gaskets)
 keep the size of the cathode (noble metal) to an absolute minimum
 thoroughly coat the junction between metals; it may be necessary to coat the
stainless steel surfaces to reduce the cathodic area to zero.

5.1.2 Material selection

It is important to marry the correct material to the operating conditions and

consideration of corrosion resistance must be taken in conjunction with a knowledge
of the material's overall properties.

NOTE: In cases where maintenance of coatings are practically impossible or very

costly , it is recommended to use Stainless steel ( 304L; 316L ) to ensure long life of
equipment.

It is recommended to avoid of coating of Hot-dip galvanized surfaces.

5.1.3 Procedure for coating selection

When choosing candidate systems, consider the following factors:

 Design life of coating system (extended life).
 Simple application & maintenance.
 Sophisticated system should be applied by specialist.
 Cost effectiveness ( good system for less money )

Basic suggestions for coating systems:

 Atmospheric conditions
1. Hot-dip galvanizing
2. Organic coatings: Multipurpose epoxies
Epoxies ( no exposure to radiation )
Epoxies & Polyurethane top coat (exposure to radiation)
3. Bitumen aluminium coating s are not acceptable.

 Immersion conditions
1. Organic coatings: Epoxies
Polyurethanes ( elastoplastic etc.)
All Organic coatings need maintenance.
2. Corrosion resistant materials: Stainless steel
DEPARTMENT OF WATER AFFAIRS AND FORESTRY
GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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 Soil
1. Coating systems: Bitumen
Epoxies
Cement mortar
Polyurethanes,polyethylene
2. Tape wrapping
3. Cathodic protection: in conjunction with Organic coating

6 CORROSION PROTECTION

6.1 General

 Surface preparation of substrate is of primary importance.

 No success in corrosion protection without proper surface preparation.
 Application of corrosion protection: all steps to be done in accordance with the
specification.
 Quality of equipment and applicator.
 Sophisticated protection should be done by specialist.

6.1.1 Surface preparation

 Standards:
ISO 8501-1 cleanliness:
Sa3 - for immersion condition
Sa 2 1/2 - for atmospheric condition
Surface profile: 50-100um

 Humidity:
Time factor before coating; not longer then 4 hours (RH,<70%)

 Contaminants:
Residual Dust and Debris; water soluble salts.

Manual cleaning is not acceptable (wire brushing, needle gun).

Abrasive blast cleaning is recommended.

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GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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6.1.2 Application

 Coating Materials: in accordance with a specification

 Environments: relative humidity ( max 85%)
temperature - surface, ambient
 Conditioning of material mixing, thinning, straining , induction time, pot life
 Method of application in accordance with a specification
equipment
overcoating time
applicator
curing time

Surface preparation and application of corrosion protection shall be in accordance

with the specification and the data sheet product recommendations.

7 MAINTENANCE OF CORROSION PROTECTION

All types of corrosion protection need maintenance.

All systems should be inspected for corrosion initiation or damage at regular planned
intervals, e.g. 6 to 12 months.

Systems should not be allowed to deteriorate to the extent that the primer or the
substrate became exposed.

Compatible material should be used for maintenance.

8 QUALITY ASSURANCE

Quality assurance means that all items are protected in accordance with the
specification and the Quality documents ( SABS0157; ISO9002 ).

It is essential to comply to the Quality plan.

Inspected at regular interval’s six months in aggressive environment (immersion) and

at intervals of one year in mild environment.

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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9 SAFETY AND HEALTH

9.1 General

Recommendation for dealing with typical aspects of safety and health which arise in
coating application.

It is the duty of users, in so far as they are responsible for safety and health.

Two major causes:

 Health risks: gases/vapours
liquid in the paint
powder/dust

 Fire/explosion risks: during storage/transport

during application

It must be ensured, that all acts and manufacturer’s safety and health requirements are
met, especially the Qccupational Health and Safety Act No.85 of 1993.

 Risk of injury

Eyesight Eye protection (surface preparation, application)

Hearing Hearing protection (operation with high level of noise).
Respiratory system Respiratory protection
Good ventilation

9.2 Ventilation and dust control

Ventilation is not only necessary for reasons of safety. The quality of a coating system
is greatly affected by the amount and type of any residual solvent in the coating when
the resinous binder cures or dries. Adhesion, water resistance, mechanical and
chemical properties can all be adversely affected when solvents are trapped. Very
slow evaporation of trapped solvents can also develop internal stresses due to
shrinkage.

The ventilation must be maintained throughout the application process and for a
period after application is completed. Product data sheets mention any special
ventilation requirements. Hot ventilation air can cause skin curing of epoxy coatings
and although it may be necessary to produce a dry substrate before painting, hot
ventilation air should be replaced by cool dry ventilation air as soon as possible after
application of any coat is completed. Ventilation air should be directed to the base of
the tank or compartment and should also be extracted by exhaust fans of correctly
balanced capacity.

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
[Link] - 11-Jul-25 N-9
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9.3 Handling/storage/transport

9.3.1 Materials

 Packing

All coating materials in the manufacturer’s original sealed containers with labels.
No leakage
Components in a good condition for use

 Storage

Approved dry and enclosed store

Temperature in range 0 degrees C - 40 degrees C
Avoid the accumulation of old stock
Adequate fire extinguishers
Signs inside and outside store
Containers shall remain closed
Combustible materials shall not be kept

A separate store shall be provided for tools and equipment.

9.3.2 Coated articles

 Handling
Lifting lugs/brackets
Special lifting harness, nylon slings, rubber protected chains and shocks
Adequate curing period for system (7 - 28 days)
Special supports, packings and casting on the vehicles to avoid chafing.
Special wrapping of coated pipes and small items.
Minimise site handling

 Storage

Separators : Coated surfaces not in contact (wrapping, packaging, crates)

Stacking: No ponding where cover is not provided
Timber: Soft wood is good

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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10 APPLICABLE STANDARDS

 Standardised corrosion protection specification (DWS)

 ISO 8501-1
 SABS IS0 4628/1-6
 SABS 180 2808
 SABS 064
 SABS 1200HC
 SABS method 769
 SABS method 770
 SABS method 772
 SABS 1217

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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APPENDIX A:
TYPICAL GENERAL CORROSION SPECIFICATION

A/ NEW PROJECT

Material: Mild steel

Environment: Immersion
Coating: Epoxy

Action Material Standard/Dimension

Abrasive blast cleaning Clean angular abrasive Sa 3; ISO 8501-1
Within a maximum of 4 Polyamide/amine cured 300-360 microns total dry
hours apply the first coat of epoxy film thickness; heed
sufficient no. of coats to manufacturer's overcoating
obtain the specified time requirements
thickness

Note: Allow the system to cure fully.

DEPARTMENT OF WATER AFFAIRS AND FORESTRY

GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
[Link] - 11-Jul-25 N-12
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B/ REPAIR

PATCH OVERCOATING REHABILITATION

a/ Organic coatings: - as for patch repair - removing whole existing
- cleaning with abrasive - whole surface shall be system - clean the
paper to bright metal surface degreased and abraded to a substrate by abrasive
- surrounding coat shall be matt finish - blasting
feathered for a distance of removing all contaminants - application of a new
20 mm beyond the damaged by washing corrosion system in
areas - remove all - allow to dry accordance with the
dust,debris and clean the - application of additional specification
surface (degreasing;water) coats over the whole surface
- allow to dry - in accordance with the
- apply the specified coating specification
in accordance with the
specification with overlap
the undamaged area by
25mm
b/ Metallic coatings: HDG
- in accordance with the
SABS763 - clean damaged
area; griding,blasting
- repair process: - thermal
spray -
zinc rich coating

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GUIDELINES FOR THE DEVELOPMENT AND OPERATION OF COMMUNITY WATER SUPPLY SCHEMES
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