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Anti-corrosion treatments for steel structures: protection and durability for every environment

Written by Redazione on 22 January 2025. Posted in Insights.

Steel structures are a key pillar in many industries and modern construction due to their combination of strength, flexibility and versatility. However, steel, despite its many qualities, is vulnerable to corrosion, a phenomenon that can compromise its durability and safety. Without proper protective treatments, exposure to environmental factors such as moisture, salinity or chemicals can lead to progressive degradation, causing significant structural damage and costly repair work.

The application of anti-corrosion treatments is therefore essential to preserve the performance and integrity of steel, especially in critical contexts such as industrial infrastructure, civil buildings and logistics facilities. Thanks to advanced technologies and a wide range of available solutions, it is now possible to customize anti-corrosion treatments to meet the specific needs of each project, improving the durability and safety of structures.

Why does steel need anti-corrosion treatments?

Corrosion is a natural process that occurs when steel, an iron material, comes into contact with oxygen and moisture, forming iron oxide, commonly known as rust. This phenomenon is not only an aesthetic problem, but can seriously impair the mechanical properties of the material, making it more brittle and less resistant to loads.

The main causes of corrosion include:

Humidity and weather conditions: rain, fog and high humidity accelerate the oxidation process.
Chemical exposure: in industrial environments, steel can be attacked by acidic or alkaline substances in air or liquids.
Marine environments: salinity in coastal air is one of the most aggressive causes of corrosion.
Mechanical stress conditions: micro-cracks or abrasions can expose untreated steel, promoting the infiltration of corrosive agents.

The consequences of corrosion are many: reduced structural strength, increased risk of failure, increased maintenance costs, and loss of functionality of structures. Therefore, the adoption of anti-corrosion treatments is not only a strategic choice, but a necessity to ensure the safety and sustainability of steel constructions.

Main anti-corrosion treatments for steel

Today, there are numerous anti-corrosion treatments, each of which meets specific application and environmental needs. Among the most widely used are:

Hot dip galvanizing: one of the most popular methods of protecting steel. Hot-dip galvanizing involves immersing the material in a bath of molten zinc, creating a protective barrier against moisture and chemicals. This treatment is particularly suitable for structures exposed outdoors, such as fences, fire escapes, and supporting structures for industrial buildings. A significant advantage is the long duration of protection, which can exceed 50 years under normal conditions.
Anti-corrosion paints: epoxy and polyurethane paints offer combined protection against corrosion and chemicals. These treatments are often chosen for aesthetic applications, where a visually pleasing finish is required in addition to strength. For example, modular fences manufactured by Mantiero can benefit from customized coatings in terms of color and chemical resistance.
Galvanic treatments: this process involves the application of a metal coating, such as zinc, nickel or chromium, by electroplating. Ideal for high-precision applications, electroplating is used to protect industrial components, such as forged wheels and heavy-duty rails.
Polymer coatings: materials such as polyethylene and fluoropolymers provide outstanding protection against chemical corrosion. These treatments are particularly useful in aggressive environments, such as the chemical and maritime sectors, where steel is constantly exposed to corrosive substances.

Each treatment has advantages and limitations, but the correct choice depends on the operating environment and the intended use of the facility. A detailed comparison table allows you to compare major treatments based on factors such as durability, cost, and resistance to corrosive agents.

The importance of anti-corrosion treatments in industry

Anti-corrosion treatments are not only a matter of protection, but are also a strategic investment to extend the service life of steel structures. In industrial settings, where operating conditions can be particularly severe, these treatments ensure reliable performance and reduce costs associated with maintenance and repairs.

In the construction industry, steel load-bearing structures, such as those used for prefabricated sheds, overhead cranes and fire escapes, must withstand a variety of environmental factors. Without appropriate anticorrosion treatments, the durability and safety of these structures could be compromised. Mantiero Angelo S.r.l., for example, incorporates advanced anticorrosion treatments into its designs to ensure optimal performance in harsh environments.

In industry and logistics, anti-corrosion treatments are essential for items such as rails, forged wheels, and dryer carts. These components are subject to high loads and continuous exposure to moisture and chemicals, making corrosion protection a key factor in avoiding operational failures.

One practical case involves Mantiero’s applications in the brick industry, where anti-corrosion treatments are used to protect structures and components intended to work in high heat and corrosive atmospheres. With these solutions, companies can reduce operating costs and ensure greater reliability of their facilities.

Heat treatments are an essential step in the steelmaking process, improving its mechanical and chemical properties. These processes allow the microstructure of the material to be modified, optimizing such characteristics as strength, ductility and workability, and prepare the surface to receive more effective anti-corrosion treatments. Although heat treatments are not specifically designed to counter corrosion, they improve the overall performance of steel, making the material more suitable for durable protective coatings.

The most common heat treatments

Some of the most widely used processes for treating steel include:

Tempering: tempering is a process in which steel is heated to high temperatures, often above 800 °C, followed by rapid cooling, usually by immersion in water or oil. This treatment greatly increases the hardness of the material, improving its resistance to wear and deformation. It is especially important for components subjected to high mechanical stress, such as forged wheels, rails and heavy-duty support elements. However, hardening can make the steel more brittle, which makes subsequent tempering treatment necessary.
Tempering: tempering is performed immediately after quenching to reduce the brittleness of the steel and improve its ductility and resilience. In this process, the material is heated at lower temperatures than in tempering (between 150 °C and 650 °C), allowing internal stresses to relax. Tempering is particularly useful for structural elements such as beams, load-bearing columns and modular enclosures, which must combine strength and flexibility to respond to varying operating conditions.
Annealing: annealing is a heat treatment that involves heating steel to high temperatures, followed by controlled cooling, often in air or closed furnaces. This process softens the material, improving its processability and reducing residual stresses. It is ideal for complex components, such as support floors and dryer carts, where high precision is required in subsequent processing steps. Annealing is also used to prepare the steel for further surface treatment, ensuring a homogeneous structure.

Combined effects with anti-corrosion treatments

One of the most relevant aspects of heat treatments is their preparatory role for subsequent anti-corrosion treatments. A hardened and polished steel, for example, has a more uniform and compact surface, improving the adhesion of coatings such as hot-dip galvanizing or epoxy paints. This not only increases the effectiveness of the anticorrosive treatment, but also prolongs its life, reducing long-term maintenance costs.

In addition, heat treatments can affect steel’s resistance to stress corrosion, a condition in which mechanical stresses accelerate material degradation. The combination of quenching and tempering, for example, reduces internal microstresses, making the steel less susceptible to these phenomena.

Industrial applications and practical benefits

Heat treatments find application in a wide range of industries, from construction to logistics and manufacturing. In metal building structures, for example, hardening is used to strengthen overhead cranes and fire escapes, ensuring reliable performance even under extreme conditions. In the brick industry, however, heat treatments are essential to ensure the strength of components such as kiln cars and forged wheels, which are exposed to high temperatures and corrosive environments.

The main benefits offered by these treatments include:

Increased durability of steel structures, even under harsh operating conditions.
Reduced operating costs due to less frequent maintenance.
Optimizing the performance of anti-corrosion coatings, providing longer-lasting protection against external agents.

Heat treatments, when integrated with advanced anti-corrosion coatings, are a comprehensive and strategic approach to ensuring the safety and durability of steel structures. Their application results in higher-performance and more durable materials capable of meeting the technical and environmental requirements of the most demanding industries.

Advanced technologies for corrosion protection

As technologies evolve, anti-corrosion treatments for steel are becoming more sophisticated, offering solutions that combine high performance and sustainability. Among the most interesting innovations are:

Nanotechnology coatings: these treatments take advantage of nanometer particles to create a highly durable protective layer. Due to their microscopic structure, nanotechnology coatings offer more uniform and durable protection against corrosion, heat and chemicals. They are particularly suitable for components exposed to extreme conditions, such as kiln cars or metal structures for the brick industry.
IoT technologies for corrosion monitoring: integration of smart sensors enables real-time monitoring of the state of steel structures. These devices collect data on humidity, temperature, and exposure conditions, providing early indications of the need for maintenance work. For industrial applications such as overhead cranes or fire ladders, continuous monitoring can prevent sudden failures and ensure greater operational safety.
Green coatings with low environmental impact: more and more companies are developing eco-friendly anti-corrosion treatments, reducing the use of harmful chemicals. For example, water-based coatings or solvent-free paints are ideal choices for projects that aim for sustainability.

These technologies represent a step forward in improving the performance and reducing the environmental impact of anti-corrosion treatments, making them increasingly indispensable for modern industrial and architectural applications.

Maintenance and inspection of treated facilities

Even steel structures treated with the best anti-corrosion systems require regular maintenance to ensure their durability and functionality over time. Preventive maintenance is essential to detect any signs of wear or deterioration before they become critical.

Major maintenance activities include:

Periodic inspections: regular visual inspection allows for the detection of surface damage, such as scratches, blisters or cracks in anti-corrosion coatings. These defects, if left untreated, can expose the steel to corrosion and compromise the entire structure.
Advanced detection techniques: tools such as ultrasound and laser analysis can identify microcracks or signs of internal corrosion, invisible to the human eye. These technologies are particularly useful for complex or difficult-to-inspect structures, such as support platforms or dryer carts.
Remedial action: when coatings show signs of degradation, prompt action should be taken with new applications of galvanizing, paint, or polymer coatings. Mantiero, thanks to its in-house painting department, offers quick and customized solutions for restoring existing steel structures.

Regular maintenance not only preserves the characteristics of the structures, but also reduces long-term costs by avoiding costly repair work or complete replacement of components.

Comparison of anti-corrosion treatments

The following table compares the main anti-corrosion treatments according to the criteria of durability, cost, applications and resistance to external agents:

Treatment	Duration	Cost	Resistance	Applications
Hot dip galvanizing	Up to 50 years old	Medium	High	Load-bearing structures, stairs
Anti-corrosion paints	10-20 years	Low	Media	Fences, aesthetic elements
Nanotechnology coatings	Over 50 years	High	Very high	Extreme industrial environments

Anti-corrosion treatments for steel structures: the key to durability

Anti-corrosion treatments for steel structures are not just a technical detail, but a key component in ensuring the safety and durability of buildings. Thanks to advanced solutions, such as galvanizing, polymer coatings, and nanotechnology, it is now possible to protect steel in even the harshest environments.

These innovations, combined with regular maintenance and advanced monitoring techniques, offer a comprehensive approach to preserving facility integrity, reducing operating costs, and promoting sustainability. Mantiero Angelo S.r.l. stands as a point of reference for those seeking reliability and quality in anti-corrosion treatments, ensuring tailored solutions for every industrial or construction need, contact us now to learn more.