Abstract
Some natural gas distributors for residential and commercial buildings in Brazil use galvanized steel tubes and fittings manufactured by the hot-dip zinc process that are supported by the specifications contained in the Brazilian Standards. Zinc coating is one of the most widely used methods to provide protection against corrosion. It is therefore essential that national and international tube manufacturers and installation and maintenance companies in civil construction also meet the defined national and international standards, especially when the tubes and fittings are used for natural gas in residential buildings. This two-way communication could eliminate most issues that delay or prevent superior galvanizing quality. Low standards lead to the deterioration of the zinc coating and the metal base of the pipes, which may lead to leaks, such as fluids, flammable gases, and other toxic products, and potentially jeopardise residential and commercial buildings. Here the importance of ensuring the quality of zinc-coated pipes is demonstrated through a series of analyses on natural gas pipe corrosion used in civil construction in Brazil. Based on Brazilian standards, the zinc mass determination per square meter, uniformity tests (Preece test) and metallographic evaluation of the deposited zinc layer were carried out on samples of galvanized tubes for natural gas. An experiment was also developed to reproduce the same conditions of subfloors (mortar beds) where there is penetration of water and humidity reaching the galvanized pipes. Metallographic analysis showed that samples of galvanized tubes by the hot-dip zinc galvanizing can have discontinuities and defects in zinc layer. Such defects associated with penetration and/or permeation of the water and humidity in the subfloor favor the corrosive process and consequently can cause gas leaks and probable accidents in residential buildings. Keywords: Corrosion, galvanized steel, zinc coating, quality, natural gas pipes, civil construction.
Highlights
Some natural gas distributors for residential and commercial buildings in Brazil use galvanized steel tubes and fittings manufactured by the hot-dip zinc process that are supported by the specifications contained in the Brazilian Standards
The importance of ensuring the quality of zinc-coated pipes is demonstrated through a series of analyses on natural gas pipe corrosion used in civil construction in Brazil
The natural gas distribution companies in some Brazilian cities currently use galvanized pipes manufactured by the hot-dip zinc process for residential and commercial buildings that are supported by Brazilian Standards ABNT [1,2,3]
Summary
The natural gas distribution companies in some Brazilian cities currently use galvanized pipes manufactured by the hot-dip zinc process for residential and commercial buildings that are supported by Brazilian Standards ABNT [1,2,3]. Mainier [4] attributed many of these issues to the premature corrosion of galvanized steel pipes, which are due to the poor quality of their coatings and/or the chemical additives used for mortars. Once placed to the subfloors (mortar beds), these can result in corrosion of the zinc coating, which leads to localised corrosion points (holes) in the carbon steel and eventual gas leaks. The objective here is to highlight the critical importance of high-quality hot-dip zinc galvanized coatings in natural gas pipelines that are used in civil construction. A critical view on this issue, with regard to the use of this material for natural gas and its behaviour in concrete and mortar environments, is taken
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