The Consequences Of Ignoring Pipe Corrosion

Steel piping corrosion is an unstoppable and continuous process, with the end product commonly called rust. This electrochemical reaction involves the slow conversion of processed metal to its natural form, which is metal ore.

Many factors can cause pipe corrosion, and depending on the extent of these factors, signs of corrosion can start to show only after a few years. The big question is how does this happen, and what are the consequences of ignoring pipe corrosion?

We'll review everything you should know in this article, so continue reading to learn the consequences of ignoring pipe corrosion and how professionals can assist with all your piping needs.

The Effects of Pipe Corrosion

Pipe corrosion is one of the most serious threats and a source of monetary loss to any industrial or commercial building. Even in mild cases, this can trigger various problems, including a reduction in heat transfer efficiency, temporary shutdowns, and pinhole leaks.

Serious failures result in more expensive damages, lost production, personal injury, operating losses, and productivity interruption. With fire protection systems, internal corrosion can lead to even worse consequences because of the high amount of iron rust deposited, which causes a clog within the pipe, thereby altering its fire-protecting abilities.

The cost of corrosion is mostly high, and it can have health impacts on employees and people who frequently use commercial properties. Research shows that consuming water contaminated with toxic metals like copper and lead can cause different health problems.‍

Corroded pipes also alter the quality of water, which can be a waste of money in many ways:

• Potential cause of odors and stained fixtures.
• Premature failure of fixtures and plumbing systems.
• Reduction in the efficiency of hot water heaters.

Causes and Types of Pipe Corrosion

As mentioned earlier, piping system corrosion can result from different factors, the rate of which depends on the intensity of one or more of these factors:

• Water velocity, especially when high, and rapid changes in the direction of water can cause corrosion due to increased turbulence. 
• Hot water temperature increases the chance of corrosion.
• The chemical composition of water is a factor that can cause pipe corrosion. For example, a high level of calcium in the water can lead to calcium buildup within pipes, thereby causing corrosion.
• The presence of oxygen in water is another factor that can cause pipe corrosion. This is because oxygen can cause metals to degrade and gradually convert to rust. During this process, different impurities are deposited into the water and on the pipe's wall. This can create blockages and restrictions in the piping system. 
• Water pH is also a factor that can cause corrosion. If the pH is not within specified limits, it can cause harm to the protective barrier within the pipe, and this can cause corrosion.

Pipe corrosion can cause serious damage to residential, commercial, industrial, and institutional properties. Even though you can't see the interior part of your plumbing system, there are signs to look out for to help you know when corrosion has started within the pipes.

There are different causes of corrosion, and we have highlighted these causes above. However, it's important also to know the different types of corrosion that can occur. Here's an overview of these different types of corrosion:

Water corrosion

Water chemistry is one of the major contributory factors that cause pipe corrosion, and it can be due to two major factors. The pH of the water is the first factor, and when it is lower than 7, it can cause the metallic pipe system to corrode quickly. If the pH of the water is high, it won't alter the durability of the metallic pipe.

Highly oxygenated water is also a factor that shouldn't be ignored. The presence of oxygen in water can lead to oxidation reactions which can cause corrosion on pipe walls and linings. This can lead to water discoloration, restricted flow, and pipe failure.

Galvanic corrosion

This is also known as electrolysis, and it mostly results when dissimilar metals are in the water, like steel and copper piping. The main sign to look out for to identify this type of corrosion is the presence of a bluish-green deposit at the point of contact with water.

Microbiological corrosion

This is also a cause of pipe failure, and it only takes a few years to manifest fully. The corrosion is also known as bacterial corrosion. Microorganisms, particularly chemoautotrophs, usually cause it. Microbiologically influenced corrosion can affect both metallic and non-metallic piping materials.

Erosion corrosion

This type of degradation takes place within the interior parts of the pipe surface, and it occurs due to the rapid flow of air bubbles and water. The effect of this is abrasion of the piping system, and it can also trigger cavitation. Thinning of the walls of the pipe and eventual pipe failure are the final results of erosion-corrosion.

Examples of Pipe Issues Due to Corrosion

Here are some notable examples of pipe issues caused by corrosion:

Piping failure

This is usually the first sign of a corrosion problem. In many cases, failures can be minor and present in the form of pinhole leaks or severe with major losses due to water damage that is expensive to repair or replace.

Frequent pipe repairs

This also takes different forms, including replacing the entire piping system and changing to temporary clamps. In some instances, preventing corrosion from happening involves many stages of repairs, and for many years, which only leads to the loss of time and money in an attempt to stop the damages caused by corrosion. Also, failures are usually fixed without checking the hidden cause, and this only ends up being futile.

Pipe thread leaks

One of the inherent points of weakness to the pipe is the threading, which can affect up to 50% of the pipe wall. Thread leakage is usually one of the first signs of corrosion, and it's an indication of the need to perform an immediate inspection. If unaddressed, it can advance to the complete separation of the pipe and other devastating damages.

Interior pipe deposits

This is also known as tuberculation, and it's actually a death sentence for most piping systems. Internal rust deposits are usually the less dense and lighter end product of corrosion in steel pipes. The development of these deposits is a sign of extreme corrosion in the piping system.

Insulation failure

Unlike what most manufacturers advise, standard fiberglass insulation isn't an effective moisture barrier when used in cold water pipes. This is because the condensed humidity area produces a good condition for corrosion in the exterior parts of the pipes. This is a common condition in dual-temperature systems, and the resulting external corrosion losses exceed the internal corrosion rates.

Weathering damages

This damage occurs due to snow, cooling tower overspray, atmospheric conditions, and rain. However, the good thing about this form of corrosion is that it is the easiest to avoid.

This is because piping systems affected by these conditions are usually exposed, making it easier to identify the effects of corrosion. Another thing to note is that it usually takes decades for failure to occur from weathering damages, and these damages are the result of a lack of maintenance.

Get a Professional to Fix Corrosion in Pipes

We have highlighted the different causes of corrosion above and the potential problems they cause in piping systems, especially if ignored. The effects of corrosion are many, and this includes various health problems and other effects that lead to waste of money.

All of this can be avoided by paying attention to the signs of pipe corrosion on your property. To give you an edge, you can get a professional plumber to help monitor, avoid, and fix piping issues in your building.