How corten steel is made?

Corten steel is a steel with phosphorus, copper, chromium, and nickel-molybdenum added to it. These alloys improve the resistance of corten steel to atmospheric corrosion by creating a protective patina on its surface.

Corten steel will generally rust or patina within six months of atmospheric exposure. To develop and oxidize, most weathering steel types require cycles of wet/dry weather. With the protective rust that provides corrosion resistance, Corten steel can last from a few decades to over 100 years.

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Corten steel is an exceptionally strong steel grade first used in the heavy industry. Due to its copper content, it has become beloved by the architectural world for the rust-colored finish it develops. It can take anywhere from 6 months to 3 years for the finish to fully develop. Once the finish has developed, the steel underneath is protected from rust, which is why Corten is described as maintenance-free.

How does corten steel rust?

The composition of rusty steel

Corten steel is steel made with added phosphorus, copper, chromium, and nickel-molybdenum. All of these alloys increase the resistance of corten steel to atmospheric corrosion by creating a protective patina on its surface. Patina usually forms in 1 to 3 years, depending on the environmental conditions and the amount of wet and dry periods that help it adhere.

Because of the presence of phosphorus, this protective layer regenerates continuously on the surface and acts as a barrier against moisture, oxygen, and pollution.

The formation of the patina

Using moisture and air, rust forms on the surface of conventional steel. As it dries, this layer of rust becomes porous and separates from the metal, allowing a new cycle of rust to weaken it.

Corten steel corrodes the same as other steels, except that it doesn’t regenerate. When the alloys mentioned above are added, rust becomes more stable and adheres better. The sequence of wet and dry periods acting on corten steel leads to corrosion until a layer of resistant and protective metal oxide is formed. The steel becomes less permeable as the layer matures and no longer gets marks.

This orange-brown patina is not uniformly distributed all over. Bad weather can also impede its formation. Sea air, for instance, does not create a protective layer. Corrosive products present in this environment prevent rust from stabilizing.

Patinas mature by themselves in 3 years maximum. It gives corten steel a grainy appearance and different shades often enhance its aesthetics.

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