Expert insights from Thomas Meisters, SILICON Materials Engineer.
For many, winter brings real hardship. It challenges not only communities but also the infrastructure meant to protect them. According to Thomas Meisters, Materials Engineer at SILICON, corrosion is one of the most underestimated threats during the cold season.
“In winter, corrosion accelerates quietly but aggressively,” he notes. “Moisture, salt, and freezing temperatures create the perfect storm for metal degradation, which adds to industrial aging.”
- Thomas Meisters
Imagine your plant shutting down in the dead of winter because of a tiny, unseen enemy: corrosion.
This silent destroyer doesn't just damage metal; it can halt entire operations. Traditional repair methods often fail to address the root causes of corrosion under these extreme conditions.
“We see it time and again,” as Meisters explains, “Plants shut down because of major mechanical failures caused by small, preventable corrosion points that were overlooked during winter prep.”
This article outlines five key types of corrosion and field-tested strategies to fight back: the practical fixes that help facilities stay operational and corrosion-resistant through the harshest months.
“Corrosion starts with poor anchor design, wrong stud alloys, and weak welds,” says Meisters.
“It ends with your vessel’s failure. The right materials and geometry are your first line of defense.”
Across industries, aging infrastructure is used well beyond its intended service life, making it increasingly vulnerable to corrosion. The materials used during earlier construction phases often lack the durability and corrosion resistance of today’s advanced alloys. Continuous exposure to extreme conditions weakens structural components, and processing more aggressive feedstocks accelerates the corrosion process. Additionally, outdated monitoring technologies hinder early detection and mitigation of corrosion.
No industry is immune to corrosion:
Petrochemical plants face sulfur-induced weld degradation in FCC units.
Cement kilns suffer from alkali vapor corrosion, leading to spalling and lining failure.
Steel mills deal with scale and slag buildup that traps moisture and accelerates corrosion.
Shipbuilding. The combination of salt-rich air and intense exhaust heat accelerates the corrosion of anchors and welds.
Waste incineration plants battle acidic flue gases and thermal shock that rapidly degrade metal components.
Each industry faces unique challenges, yet all share a common need: tailored, corrosion-resistant solutions. Selecting the right refractory anchor is critical. When anchors corrode, linings collapse, exposing the shell to extreme heat and risking catastrophic failure.
Facing a corrosion challenge?
Our international team of metallurgical experts is here to help.
Photo Description: Poor internal welds can compromise external corrosion resistance. Using Rapid Arc Welding (RAW) significantly reduces the risk of corrosion.
Tiny but deadly.
Pitting corrosion creates small, deep holes, especially around welds and anchor contact points. It’s highly localized and often invisible until serious damage occurs. In ship hulls and high-temperature industrial settings such as cement kilns, petrochemical reactors, or incinerators, these conditions are common.
Why it happens:
Chloride ions (from salt water, cleaning agents, or process chemicals)
Acidic environments (common in petrochemical and incineration plants)
Weld defects (porosity, undercutting, or incomplete fusion)
Moisture ingress during shutdowns
Fixes:
Use high-alloy refractory anchors that offer superior protection against localized corrosive attacks
Apply RAW technology for smooth, dense welds
Conduct post-weld passivation to restore protective oxide layers
Schedule shutdown inspections to catch early signs of pitting and contact SILICON metallurgical experts for the right solution
Hidden in plain sight.
Occurs in narrow gaps between anchors and shells or within poor welds, where oxygen drops and moisture accumulates, creating localized acidic zones.
Why it happens:
Poor anchor design or placement
Incomplete weld fusion
Trapped dust, moisture, or chemicals
Lack of post-weld cleaning or inspection
Fixes:
Use open-geometry anchor designs to minimize crevice formation
Weld with full-fusion RAW Technology to eliminate gaps
Ensure proper drainage and airflow in anchor layouts to prevent moisture accumulation
When metals don’t get along.
It happens when dissimilar metals (e.g., carbon steel shells and stainless steel anchors) are electrically connected in the presence of an electrolyte like water or steam. This is a common issue in multi-material assemblies found in shipbuilding, incinerators, and petrochemical plants.
Why it happens:
Mixed metal use without insulation
Conductive fluids (e.g., saltwater, acidic condensates)
Improper material selection or welding practices
Lack of protective coatings
Fixes:
Match materials for studs, base metal and fasteners
Use insulating washers or sleeves between metals
Apply barrier coatings to isolate metals from electrolytes
Use controlled RAW to avoid metallurgical mismatches
Slow, steady, and often overlooked.
A widespread attack that thins metal surfaces, reducing load-bearing capacity and thermal resistance. This type of corrosion is often accelerated by high humidity, acidic gases, or alkali dust, especially in cement kilns, steel furnaces, and incinerators.
Why it happens:
Refractory failure caused by poor-quality anchors and deficient maintenance during shutdowns
Continuous exposure to corrosive atmospheres
Lack of protective coatings or surface treatments
Use of low-grade materials in high-risk zones
Fixes:
Select high-alloy refractory anchors for enhanced oxidation resistance
Use RAW machines and guns for consistent weld quality across surfaces to prevent premature refractory failure
Schedule Your Pre-Turnaround inspection to identify weak spots in your refractory system
From 2014 to 2023, a UK cement plant transitioned from recurring corrosion issues to full operational reliability by adopting the SILICON SpeedBolt® system. What began as isolated fixes evolved into a complete anchoring upgrade, eliminating anchor-related failures and boosting long-term efficiency.
The silent killer.
SCC combines tensile stress from thermal expansion, mechanical loads, or welding with corrosive environments, forming microscopic cracks that grow over time, often without visible warning.
In high-temperature environments like petrochemical reactors or waste incinerators, SCC can cause sudden anchor or weld failure, especially if materials are not properly stress-relieved or if corrosive agents like chlorides or sulfides are present.
Why it happens:
Residual stress from welding or poor fit-up
Exposure to chlorides, sulfides, or acidic gases
Thermal cycling and mechanical fatigue
Inappropriate material selection
Fixes:
Use flexible anchor designs that accommodate thermal expansion
Consult SILICON Material Engineer on the use of the right SCC-resistant alloys for anchors in high-risk zones and request Positive Material Identification (PMI)
Use RAW Technology to minimize residual stress
“Corrosion is unavoidable, but failure doesn’t have to be,” says Meisters. “With SILICON’s expertly designed refractory anchors, you can extend system life and ensure safe, efficient operations through winter and beyond.”
From an inspection standpoint, anchor design is a decisive factor in either accelerating or mitigating corrosion. Traditional hex mesh structures create enclosed areas where moisture accumulates, fostering corrosion in specific locations.
SpeedHex® 3 changes the game. Its open, engineered geometry improves castable flow and bonding, reduces stress concentrations, and eliminates common corrosion pathways. The result: a more uniform, durable lining that performs better under thermal cycling and mechanical load.
Don't let corrosion catch you off guard. Whether you're in shipbuilding, waste-to-energy, cement, petrochemical, or steel, no industry is immune to corrosion. But with the right strategy, you can outsmart winter’s worst.
