Galvanized Steel Piping: Failure And Replacement
Understanding Corrosion, Failure, and the Need for Professional Replacement
Galvanized steel piping has been a common choice for plumbing systems in homes and buildings for many decades. However, as these pipes age, they become prone to corrosion and failure leading to a host of problems for property owners. In this article, we’ll jump into the history of galvanized steel piping, the reasons behind its failure, the galvanic corrosion process, and the associated health hazards. We’ll also discuss why it’s essential for homeowners and management teams to replace failing galvanized steel piping with the help of a professional turnkey repipe service.
The History of Galvanized Steel Piping
Galvanized steel piping gained popularity in the early 20th century as a cost-effective and durable solution for plumbing systems. The process of galvanization involves coating the steel pipe with a layer of zinc to protect it from corrosion. This zinc coating acts as a sacrificial layer, corroding before the steel itself and thus extending the pipe’s lifespan.
Galvanized steel pipes were widely used in the construction of homes and buildings between the 1940s and the 1960s. However, as time passed the limitations of this material became more apparent and newer, more reliable options like PEX piping began to replace galvanized steel.
Why Galvanized Steel Piping Fails
Despite the protective zinc coating, galvanized steel piping is still susceptible to corrosion over time. Several factors contribute to the deterioration of these pipes:
· Age: As galvanized steel pipes age, the zinc coating wears away, exposing the bare steel to corrosion.
· Water Quality: Hard water, which contains high levels of minerals like calcium and magnesium, can accelerate the corrosion process.
· pH Levels: Water with a low pH (acidic) can also speed up the corrosion of galvanized steel pipes.
· Electrolysis: When galvanized steel pipes are connected to copper pipes, an electrochemical reaction called electrolysis can occur leading to accelerated corrosion.
As the corrosion progresses the pipes develop leaks, blockages, and other issues that can compromise the integrity of the plumbing system.
The Galvanic Corrosion Process in Galvanized Steel Piping
Galvanic corrosion is a common problem in plumbing systems that use galvanized steel piping. This type of corrosion occurs when two dissimilar metals are connected in the presence of an electrolyte, such as water. In the case of galvanized steel pipes, the zinc coating acts as one metal and the steel itself acts as the other.
When water flows through the pipes, it creates an electrochemical reaction between the zinc and the steel. The zinc, being more reactive, corrodes first sacrificing itself to protect the steel. However, once the zinc coating is depleted, the steel becomes exposed and begins to corrode as well.
This corrosion process can lead to the formation of rust, scale, and other debris within the pipes. Therefor, restricting water flow and causing leaks. As the corrosion progresses, the pipes become increasingly brittle and prone to failure.
When two dissimilar metals are in contact with each other in the presence of an electrolyte (such as water), galvanic corrosion can occur. The metal higher on the galvanic series (more noble) will act as the cathode, while the metal lower on the series (less noble) will act as the anode and corrode preferentially.
In the galvanic corrosion chart, the metals are arranged vertically according to their nobility. The further apart two metals are on the chart the greater the difference in their nobility and consequently the higher the risk of galvanic corrosion when these metals are coupled together. For example, if magnesium (at the bottom of the chart) is in contact with platinum (at the top of the chart), there will be a significant risk of corrosion for the magnesium, as it is much less noble than platinum.
To minimize the risk of galvanic corrosion, it is best to choose metals that are close together on the galvanic series when designing systems where dissimilar metals may come into contact with each other.
Problems Caused by Failing Galvanized Steel Piping
Failing galvanized steel piping can cause a wide range of problems within a plumbing system, including:
· Reduced Water Pressure: As corrosion builds up inside the pipes it restricts water flow, leading to reduced water pressure throughout the building.
· Leaks: Corroded pipes are more likely to develop leaks, which can cause water damage to the surrounding structure and promote the growth of mold and mildew.
· Discolored Water: As the pipes corrode, rust and other debris can contaminate the water supply causing it to appear yellow, brown, or reddish in color.
· Unusual Tastes or Odors: Corroded pipes can also impart unpleasant tastes or odors to the water, making it less appealing to drink or use for cooking and cleaning.
· Frequent Clogs: The buildup of corrosion and debris inside the pipes can lead to frequent clogs, requiring more frequent maintenance and repairs.
Health Hazards Associated with Failing Galvanized Steel Piping
In addition to the practical problems caused by failing galvanized steel piping, there are also potential health hazards to consider. As the pipes corrode, they can release harmful contaminants into the water supply including:
· Lead: Some older galvanized steel pipes were manufactured with lead, which can leach into the water supply as the pipes corrode. Exposure to lead can cause serious health problems, particularly in children, including developmental delays, learning difficulties, and behavioral issues.
· Iron: As the steel corrodes, it can release high levels of iron into the water. While iron is not typically harmful to health, it can cause aesthetic issues like discoloration and unpleasant tastes or odors.
· Zinc: The zinc coating on galvanized steel pipes can also leach into the water supply as it corrodes. While zinc is an essential nutrient, excessive amounts can cause gastrointestinal distress and other health problems.
Health Hazards Associated with Failing Galvanized Steel Piping
Given the numerous problems and potential health hazards associated with failing galvanized steel piping, it’s crucial for homeowners and management teams to consider replacing these pipes before they cause significant damage or put occupants at risk.
Replacing failing galvanized steel piping with modern, corrosion-resistant materials like PEX can provide numerous benefits including:
· Improved Water Quality: New pipes will not release contaminants into the water supply, ensuring that occupants have access to clean, safe drinking water.
· Better Water Pressure: Without the restrictions caused by corrosion and debris, new pipes can provide better water pressure throughout the building.
· Fewer Leaks and Clogs: Modern piping materials are less prone to leaks and clogs, reducing the need for frequent repairs and maintenance.
· Increased Property Value: Updating the plumbing system with new, reliable pipes can increase the value of a property and make it more attractive to potential buyers or tenants.
Case Study: Corrosion Failure in Galvanized Steel Piping
In 2018, thePET Preform Molding Plant in Springfield, Ohio experienced significant issues with the galvanized steel piping in its water cooling system. This system, designed to circulate cooling water, suffered severe corrosion, leading to frequent leaks and extensive repairs.
· Problem: The galvanized steel piping, crucial for the plant’s cooling operations, showed widespread corrosion, causing repeated leaks and operational disruptions. This prompted a thorough investigation to determine the root causes of the failure.
· Analysis: A detailed corrosion failure analysis was conducted, including:
Visual Inspections: Extensive rust and deterioration were observed, particularly around weld joints.
Metallographic Analysis: Microscopic examination showed significant uniform corrosion and localized pitting.
Chemical Composition Testing: Identified high levels of dissolved oxygen and other corrosive agents in the cooling water.
· Findings: The investigation uncovered several critical issues:
Corrosion Types: Both uniform and localized pitting corrosion affected the piping system.
Dissolved Oxygen: High levels of dissolved oxygen in the cooling water were a primary factor in the corrosion process.
Inadequate Water Treatment: Insufficient water treatment allowed corrosive agents to damage the piping.
Weld Joints: Severe corrosion occurred at the weld joints due to mechanical stresses and chemical attack.
· Conclusion: The case study emphasized the necessity for:
Enhanced Water Treatment: Implementing effective water treatment strategies to control dissolved oxygen levels and other corrosive substances.
Regular Maintenance: Adopting a rigorous maintenance schedule to detect and address early signs of corrosion.
Monitoring and Prevention: Establishing continuous monitoring systems to oversee water quality and piping conditions, preventing similar issues in the future.
By addressing these factors, thePET Preform Molding Plant aimed to mitigate the risk of future corrosion-related failures, ensuring the reliability and efficiency of their cooling system (SpringerLink).
Related Lawsuits: Corroding Galvanized Steel Pipes in Santa Clarita Valley
In a significant class action lawsuit, homeowners in California’s Santa Clarita Valley faced severe issues due to failing galvanized steel pipes. Represented by attorney Brian Kabateck, the homeowners alleged that foreign-made galvanized pipes used in their homes corroded prematurely upon contact with water. As the corrosion advanced, it led to holes in the pipes, causing substantial damage to properties across fifteen housing developments.
· Details of the Lawsuit: The case was brought against a wide range of defendants, including developers, suppliers, plumbing contractors, manufacturers, and water softening companies. The plaintiffs argued that these defective pipes were installed in approximately 5,000 homes, leading to widespread issues. The corrosion caused by these pipes was not just a minor inconvenience; it resulted in significant water damage, necessitating extensive repairs and replacements.
· Settlement and Impact: The lawsuit culminated in a $41 million settlement, with compensation paid by both large and small builders throughout the Santa Clarita Valley. Key companies involved in the settlement included The Newhall Land and Farming Co., American Beauty Homes, Dale Poe Development, Larwin Co., and Pacific Bay Homes. Additionally, pipe manufacturers, suppliers, contractors, and water softening companies were held accountable for their roles in the use of these defective materials.
This case highlights the critical importance of using high-quality, reliable materials in construction to prevent such widespread damage and legal repercussions. It also underscores the need for rigorous quality control and accountability in the supply chain of building materials.
The Importance of Professional Turnkey Repipe Services
Replacing failing galvanized steel piping is a complex and labor-intensive process that requires the expertise of a professional plumbing service. A turnkey repipe service can handle every aspect of the project, from initial assessment and planning to the installation of new pipes and the restoration of the surrounding area.
By working with a professional turnkey repipe service homeowners and management teams can ensure that the job is done correctly, efficiently, and with minimal disruption to the building’s occupants. These services can also help to identify and address any related issues such as outdated fixtures or inadequate water pressure. Ultimately to ensure that the new plumbing system operates at peak performance.
Protecting Your Property and Health
Failing galvanized steel piping is a serious issue that can cause a wide range of problems for homeowners and property managers. From reduced water pressure and discolored water to potential health hazards like lead contamination, the risks associated with these outdated pipes should not be ignored.
By understanding the history of galvanized steel piping, the reasons behind its failure, and the importance of timely replacement, property owners can take proactive steps to ensure the safety, reliability, and efficiency of their plumbing systems. Working with a professional turnkey repipe service is the best way to address this issue and enjoy the benefits of a modern, corrosion-resistant plumbing system for years to come.
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