Using similar mechanisms, Microorganisms are also able to attach to and colonize steel surfaces, where they can “eat” materials using a variety of metabolic functions.

Figure 1: Biofilm formation on steel.

Many direct and indirect microbial corrosion processes can be involved, such as sulfate reduction, acid production, iron oxidation, and direct electron transfer, leading to challenges in the diagnosis and treatment of microbial contamination issues.

Microbial corrosion is estimated to cost our global economy around $625 Billion, and is documented extensively in industries such as oil and gas, water, marine transport, and Defense.

For almost a century, case studies implicating microbial corrosion have been documented across the globe. Most of these incidents occur in assets where water is naturally present, such as oil production systems, pipelines, floating production storage and offloading (FPSO) facilities, and marine structures like jetties and wharfs.

Why water? Because microorganisms need it to survive, colonise surfaces, and ultimately drive corrosion. Once they settle, these microbes form a sticky, structured community known as a biofilm. This biofilm is required to kick-start and maintain microbial corrosion.

Meanwhile, far from the oilfields and coastal infrastructure where MIC is typically expected, a very different story has been unfolding in the vast Australian outback. Mining operations, often assumed to be too dry, dusty, and harsh for microbial activity, are experiencing rapid and unexpected corrosion in critical assets.

The mining industry is critical to our way of life as a nation. Gold mining alone encompasses more than 350 operating sites nationwide and contributes around $20 billion AUD every year, a cornerstone of regional employment, national exports, and long‑term economic stability.

Figure 2. Corrosion Assessment in WA mining industry

When corrosion issues in such a vital industry are unknown or poorly managed, it affects everyone. Naturally, I was curious to determine the cause of these issues, and so I began inspecting assets across Western Australia for what I call ‘corrosion aggravators’.

Corrosion aggravators are factors that accelerate or intensify corrosion processes. These include time of wetness (the duration a surface remains moist), the presence of aggressive species such as chlorides, and galvanic interactions that occur when dissimilar metals are in direct electrical contact. Other contributors include oxygen availability, temperature fluctuations, pH changes, and mechanical damage that exposes fresh metal surfaces.

In parallel, I examined the fundamental requirements for microbial life, such as nutrients and suitable environmental conditions that allow microorganisms to grow and form biofilms.

Figure 3. Deposit build-up on steel assets results in increased risk of MIC.

Findings from these site inspections indicated that not only can microbial life exist, but it can thrive in the gold mining industry, even in gold cyanidation tanks.

As a corrosion engineer, this immediately raised a flag. Could microbial corrosion be occurring in the outback, despite the region being far from oceans, rivers, or other obvious water sources?

The more I investigated, the more the pieces fell into place. All the fundamental requirements for microbial activity were consistently available: a reliable water source, suitable temperature ranges, and a steady supply of nutrients. Even in these remote, harsh environments, the conditions were sufficient for microbes to grow, form biofilms, and potentially drive corrosion.

Figure 4. A corrosion nodule forming in a WA bore water tank is a sign of microbial corrosion. 

Western Australian mine sites, especially gold processing plants, rely on process water; this water is pumped from deep underground bores and often contains a complex mix of dissolved minerals, picked up from the surrounding geology. In many regions of WA, this bore water is highly saline, rich in sodium chloride and other salts that can influence both processing performance and corrosion behaviour.

Process water is essential to almost every stage of gold extraction. It moves through every part of the plant, from leaching tanks up to 22 meters high to pipes, pumps, spray systems, and even access structures. In short, if it’s in the processing circuit, it’s touched by process water. And wherever water flows, so do the conditions that can enable corrosion, and, potentially, microbial activity.

Figure 5. Process water on a WA mine site with salts and other minerals is a corrosion aggravator. 

Genetic testing of process water and potable water from three major WA mine sites confirmed what the site inspections had hinted at: microorganisms are not just present, they’re thriving, and in remarkable diversity.
They were detected in bore holes, fire‑water systems, pipework, safety showers, storage tanks, and even on equipment across the processing plant.

But the critical question remained: were these microbes actually causing corrosion?

Not all microorganisms can corrode steel assets, and not all assets on a mine site are exposed to microbially contaminated water. This gap made it clear that further investigation was needed. We began focusing on two key tasks: 1) identifying which assets were at genuine risk of microbial corrosion, based on their water exposure and operating conditions, and 2) conducting targeted visual inspections to look for tell-tale signs of MIC, localised pitting, under-deposit corrosion, black or slimy biofilms, or unusual corrosion morphologies.

These steps became central to understanding where microbial corrosion could be taking hold, and where it wasn’t.

Where bore water came into contact with carbon steel (‘site steel’), evidence of microbial corrosion began to appear. Because these assets were never designed with MIC risk in mind, and no operational measures existed for contamination control, microbial activity was able to grow and spread unchecked.

One case study centered on a bore water storage tank where coating degradation had left large areas of steel exposed. The tank displayed leaks and widespread general (uniform) corrosion, which, under normal circumstances, progresses slowly over many years. Uniform corrosion typically reduces steel thickness at a predictable rate and rarely causes rapid failures.

Microbial Corrosion behaves very differently. It is localised, attacking steel through concentrated pits or under-deposit zones. These focal points can lead to rapid metal loss, perforation, and unexpected asset failure, even when the overall structure still appears sound. In this tank, the corrosion pattern and field evidence indicated that microbial activity had accelerated the degradation well beyond what uniform corrosion alone would produce.

Figure 6. Perforations to site steel, and even stainless steel as seen above, can lead to safety concerns. This image was captured from a safety shower system on a Western Australian mine site.

Leaking and visibly perforated assets from multiple mine sites were documented and sampled using a newly developed DNA sampling kit, designed to preserve microbial DNA for at least 30 days at room temperature.

Figure 7.  TECHT’s DNA sampling kits are designed for reliable field collection and preservation of microbial samples for up to 30 days at ambient temperature, enabling accurate molecular analysis of samples from remote locations.

Molecular analysis of these samples at the TECHT Laboratory revealed that diverse populations of potentially corrosive prokaryotes were concentrated specifically at the failure locations, strongly linking microbial activity to the observed damage.

To further demonstrate causation rather than coincidence, we established controlled exposure tests using site‑representative carbon steel immersed in process water. Microbial communities collected from three Western Australian mine sites were used to inoculate the test systems, which were then maintained for a two‑month exposure period. This setup allowed us to directly assess whether the microorganisms present in mine‑site water could initiate or accelerate corrosion under realistic conditions.

Figure 7. Corrosion testing in the TECHT laboratory to determine the link between microbes in process water and corrosion.

After the two‑month test period, we inspected the steel coupons and measured their corrosion rates using weight‑loss analysis (see ASTM G1-90 & NACE SP0775). This method is straightforward: you weigh the steel before the test, weigh it again afterwards, and the difference tells you how much metal has been lost. It’s a standard and trusted approach in corrosion science because it clearly shows how fast corrosion occurs over time.

The results were striking. Steel exposed to the microbial communities from mine sites showed nearly double the metal loss compared with the control samples that had no microbes added. In other words, the microorganisms were actively accelerating corrosion.

Although this work is still in the early stages, and there is much more to learn about the microbes thriving in mining environments, the findings highlight a genuine concern: MIC is likely an active and aggressive corrosion mechanism, even at inland mine sites once assumed to be low‑risk.

Looking ahead, the focus will be on developing early warning systems and targeted solutions. TECHT is currently mapping native microorganisms throughout the mining industry through the BioTECHT Division, which to date has not been achieved before. Other industries already use a range of strategies to manage MIC, design improvements, smarter materials selection, chemical dosing programs, and cathodic protection, to name a few. The challenge for mining is to determine how these tools, along with emerging technologies, can be adapted or scaled to their unique conditions. Knowing the makeup (genus, species) of the microbial communities we have to face is a critical first step. 

The question now is clear: How do we leverage both new and proven technologies to extend asset life, reduce financial losses, and improve safety across the mining industry?

And this is exactly where our passion lies at TECHT. We’re committed to delivering innovative asset integrity solutions, backed by reliable testing and expert consultancy, to support a more sustainable future, helping industry move forward with confidence, resilience, and smarter engineering.

Management of Microbial Corrosion in the mining industry starts with asset owners and the teams that drive Australia’s mine sites. Knowledge of microbial corrosion can empower more informed decisions that save operating costs, reduce incidents, and ultimately lead to a safer, more productive site. 

BioTECHT is a division of TECHT specialising in Microbiologically Influenced Corrosion (MIC).

We work closely with our clients to develop tailored and innovative microbial corrosion solutions. 

Contact us to find out how we can help you.

References

Tuck, B., Watkin, E., Somers, A. Machuca L.L. A Critical Review of Marine Biofilms on Metallic Materials. npj Mater Degrad 6, 25. 2022. https://doi.org/10.1038/s41529-022-00234-4

NACE International. (n.d.). Economic impact. http://impact.nace.org/economic-impact.aspx 

Tuck, B., Salgar-Chaparro, S. J., Watkin, E., Somers, A., Forsyth, M., & Machuca, L. L. (2022). Extracellular DNA: A Critical Aspect of Marine Biofilms. Microorganisms, 10(7), 1285. https://doi.org/10.3390/microorganisms10071285

Tuck, B., Investigating Multispecies Biofilms on Steel Surfaces in Seawater and 

Biofilm Inhibition by a Novel, Multifunctional Inhibitor. Doctoral Thesis, Curtin University, 2022.

Tuck, B. Understanding Natural Biofilm Development in Marine Environments, A Review: Microbiologically Influenced Corrosion (MIC), Technical, Water and Wastewater Technical Group, Webinar Recordings. Australasian Corrosion Association, 2021. https://www.corrosion.com.au/understanding-natural-biofilm-development-in-marine-environments-a-review/

Standards:

Corrosion by weight loss analysis: ASTM G1-90(1999)e1, Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens https://store.astm.org/g0001-90r99e01.html 

Corrosion by weight loss analysis for oilfield applications: NACE SP0775-2023, Preparation, Installation, Analysis, and Interpretation of Corrosion Coupons in Hydrocarbon Operations

For a full list of articles by the Author: Benjamin Tuck (0000-0002-4201-9864) – My ORCID

In infrastructure, failure isn’t always immediate, it often begins quietly, at the design stage. One of the most significant threats to long-term structural performance is corrosion. Yet despite its known risks, corrosion mitigation is often addressed too late in the project lifecycle, when repair costs are high and asset integrity is already compromised.

In this post, we explore how future-proofing your infrastructure against corrosion starts with intelligent, durable design. We’ll walk through the role of durable material selection, corrosion management information, and how construction quality assurance can help engineers and asset managers avoid the costliest consequences of corrosion before the first slab is poured.

This is especially relevant for developers, structural engineers, architects, and government bodies managing infrastructure in harsh or marine environments across Australia.

Why Design Matters in Corrosion Mitigation

Corrosion isn’t just a material issue, it’s a design issue. Inadequate detailing, poor material choices, or failure to assess environmental conditions can all lead to early deterioration. Many large-scale failures stem from overlooked risks during the concept or design phase.

Common design flaws that contribute to corrosion:

• Inadequate cover for reinforced concrete
• Poor detailing that allows water ingress
• Incorrect fastener or fixture specification
• Lack of understanding of corrosivity zones (e.g., coastal vs inland)
• Using incompatible materials together

The increase in the cost associated with overlooking these common issues has been summarised in de Sitter’s “Law of Fives”, which states that “one dollar spent in Initial Design and Construction equals $5 in Preventive Maintenance equals $25 in Repairs and Maintenance equals $125 in Major Repairs and Renovations”

As de Sitter stated, these values should not be taken exactly, but rather point out where attention must be focused, i.e., initial design and construction, and preventive maintenance (inspections, coating application, etc.). Hence, proactively integrating corrosion management information into the design process gives projects the best chance at long-term performance, reduced maintenance, and lifecycle cost savings.

The Importance of Corrosivity Assessment

Three elements are taken into consideration when designing a new plant or infrastructure: environmental corrosivity,  material selection, and design and construction methods. So, before selecting materials or committing to a design, understanding the corrosive environment is critical. TECHT provides corrosivity assessments that consider:

• Environmental exposure categories (e.g., marine, industrial)
• Site-specific humidity, salinity, and rainfall
• Previous failure data in the area
• Corrosion rate modeling over time

These insights are used to produce Service Life Calculations, aligning with industry standards and providing clear expectations for asset durability.

Explore our corrosivity assessment services.

What Is a Durability Plan and Why Do You Need One?

A Durability Plan breaks down your project into different environments and identifies the individual corrosion risks each component faces. This tailored analysis results in a clear roadmap for:

• Detailing changes to avoid water traps or galvanic contact
• Material upgrades where required
• Specification of coatings, cathodic protection, or barriers
• Ongoing inspection and maintenance planning

By starting with a durability mindset, asset owners avoid costly remediation later and achieve greater reliability over the asset’s service life.

Consultation with stakeholders is crucial to properly discuss corrosion mechanisms

Material Testing & Specification Review

TECHT’s ArchiTECHT team conducts material testing and provides guidance on correct specification development, to ensure materials are fit for purpose in corrosive environments.

This includes:

• Laboratory analysis for chloride ingress, carbonation, and coating failure
• On-site inspection of existing materials
• Corrosion coupon testing
• Testing to AS and ISO standards

Whether you’re building near the ocean, in a high-humidity zone, or an industrial area with chemical exposure, smart specification reduces long-term risk and gives contractors clear guidance to execute your vision reliably.

Construction Quality Assurance & Control

Even the best designs can fail without proper execution. That’s why TECHT supports projects through construction with:

• Independent QA/QC inspection services
• Specification compliance checks
• Rapid issue resolution on-site
• Documentation for asset lifecycle maintenance

Our construction quality assurance services close the loop between design and performance, ensuring the corrosion mitigation strategies put on paper are delivered in the field.

Poor QA/QC can mean issues can develop unchecked.

Future-Proofing Starts with Design

If you want long-lasting, low-maintenance infrastructure, don’t wait until corrosion appears, design against it from day one. 

From corrosivity assessments to specification reviews and QA/QC support, TECHT helps you deliver durable infrastructure backed by engineering intelligence.

Learn more about our approach to durable design engineering and corrosion mitigation on the ArchiTECHT service page, or contact TECHT to speak with a corrosion and durability specialist.

Implementation of IoT systems and software aims to streamline and simplify workflows

The good news is that technologies and strategies behind corrosion testing are rapidly evolving.

So if you manage critical infrastructure or long-life assets, understanding the latest corrosion testing insights is vital. In this post, we explore what’s changing, why it matters, and how TECHT is helping clients across Australia make smarter decisions through data-driven testing and analysis.

Why Corrosion Testing Matters More Than Ever

Globally, corrosion is estimated to cost around 3–4% of GDP, and in Australia, that translates to tens of billions of dollars in annual losses due to asset degradation, premature failure, and reactive maintenance. With harsh environments and long-distance infrastructure, the Australian market has unique challenges that make proactive corrosion management essential.

Testing provides clarity on:

• Material performance in real-world conditions
• The effectiveness of corrosion protection systems
• Early detection of microbiologically influenced corrosion (MIC)
• Quality assurance during construction or refurbishment

Whether you’re managing pipelines, tanks, bridges, or marine structures, testing data is the foundation of smarter asset decisions.

Emerging Trends in Corrosion Testing

1. A Focus on Microbiologically Influenced Corrosion (MIC)

MIC is now recognised as a major cause of hidden corrosion, especially in water, wastewater, oil and gas production, and marine assets. Testing now includes:

• Microbial and DNA sampling and preservation
• MIC diagnosis
• Biomonitoring: ATP, MPN, and Molecular analysis.
• Biofilm detection
• Biocide effectiveness
• MIC coupon exposure monitoring

Explore our MIC Service.

2. Corrosion Coupon Analysis

This method is growing in popularity for its affordability and long-term data value. Coupons can help track:

• Baseline corrosion rates
• Effectiveness of mitigation programs
• MIC-related deterioration

TECHT’s corrosion lab offers coupon testing aligned to AMPP SP0775-2013 and AMPP TM0212-2018 standards.

3. Coating Performance & QA

With more infrastructure using advanced coatings, protective paint, and disbondment testing are now core requirements. Our Perth-based laboratory conducts:

• Adhesion strength testing
• Cathodic disbondment tests
• Resistance to salt spray, moisture, and UV

Learn more about our DeTECHT corrosion engineering services.

4. Corrosion Testing for Performance Validation

As industries demand longer asset lifespans and lower maintenance costs, validating material performance under real-world conditions has become essential. At TECHT, our corrosion testing capabilities provide critical insights for engineers and asset managers.

Our laboratory offers:

• Immersion testing and corrosion analysis: rates and mechanisms.
• Electrochemical testing (LPR, EIS, CV)
• Corrosion inhibitor testing
• Under-deposit corrosion testing
• Accelerated weathering and aging simulations
• Pitting and crevice corrosion testing

These tests simulate harsh environments to assess the durability of coatings, base materials, welds, and fixings. The results support smarter material selection, design refinement, and long-term integrity planning, and is particularly important in sectors like mining, marine infrastructure, and transport.

5. Failure Investigation and Root Cause Analysis

When corrosion-related failures occur, they often carry high financial, safety, and reputational consequences. That’s why TECHT provides independent failure investigation services to identify what went wrong, and how to prevent it from happening again.

We investigate issues such as:

• Coating delamination or blistering
• Unexpected substrate corrosion beneath protective layers
• MIC-induced material degradation
• Specification or surface preparation non-compliance

Our process combines physical inspection, laboratory testing, and historical/environmental analysis to determine the root cause, document the failure, and recommend practical, engineering-backed solutions. This helps clients build better systems, improve QA/QC processes, and reduce repeat failures.

6. Concrete Durability in Corrosive Environments

From mining to marine, reinforced concrete is vulnerable to:

• Chloride ingress
• Carbonation
• Alkali–silica reaction (ASR)

We support engineers and designers with concrete testing that aligns with durability planning and lifecycle modeling strategies.

Why TECHT’s Laboratory is Different

Situated in Technology Park, Bentley (WA), TECHT’s state-of-the-art laboratory showcases cutting-edge facilities and unparalleled technical expertise from leading corrosion scientists and consultants. Our laboratory is designed for:

• Corrosion testing to Australian & ISO standards
• Biofilm and MIC investigations
• Durability assessments for coatings, concrete, and metals
• Compliance with PC2 laboratory conditions (AS/NZS 2982)

We support government bodies, asset managers, engineers, and contractors with local expertise, rapid turnaround, and tailored interpretation, not just raw results.

Whether you’re planning a new project, investigating failure, trying to improve asset performance, or want to stay compliant with standards and QA – Corrosion testing is no longer optional. It’s a strategic investment in extending asset life, reducing risk, and increasing return.

Ready to take the next step?

• Contact us for a corrosion test with TECHT
• Learn more about our laboratory & testing services
• Explore corrosion engineering solutions

At TECHT, we’ve worked alongside leading WA mine sites to develop staged corrosion management frameworks that ensure critical infrastructure remains reliable, safe, and compliant throughout the mine’s full life.

Below, we highlight three essential factors to consider when establishing a corrosion management system, based on real-world experience in mining environments, but applicable across many industries where integrity matters.

1. Issue Capture and Asset Ownership

A corrosion management system is only as effective as its ability to identify and prioritise issues.

The first step is ensuring that all personnel (whether employees, contractors, or site visitors), can report corrosion-related issues easily and that those reports are directed to the appropriate asset owner.

However, many sites suffer from fragmented systems where ownership of assets spans multiple departments, creating gaps in accountability. Establishing a clear process for ownership and issue allocation is crucial for successful long-term planning and reliability.

2. Control Through a Stepped Process

Once issues are identified, a structured and repeatable process ensures that remediation is prioritised, costed, and scheduled effectively. This is where TECHT’s methodical and data-backed frameworks prove valuable.

A typical corrosion management strategy should include:

• A condition monitoring regime or corrosion audit to identify and quantify issues
• Risk assessments based on safety, production, and environmental impact
• Prioritisation using a criticality matrix (likelihood vs. consequence)
• An integrity strategy to plan repairs according to available resources
• Technical scoping of repair methods to ensure the best return on investment
• Incorporation of QA/QC protocols and documentation
• Alignment with environmental and safety regulations, such as the Cyanide Management Code
• Ongoing benchmarking and data collection for continuous improvement

This “Goldilocks” approach ensures the right amount is spent in the right place, and prevents both over-engineering and under-protection.

3. Effective Contractor Management

Even with a solid strategy, execution can falter without proper contractor oversight. Issues often arise from incomplete documentation, vague scopes, and inconsistent expectations.

To ensure consistent outcomes:

• Standardise scoping documents, QA/QC forms, and technical specifications
• Use proformas that can be adapted quickly for unplanned works
• Provide accurate documentation to reduce ambiguity during repairs
• Assign supervision and a clear point of contact to support contractor performance

Having a robust contractor management plan leads to fewer surprises, higher-quality repairs, and better outcomes under both planned and emergency conditions.

Why a Corrosion Management System Matters

Corrosion in infrastructure like concrete and structural steel often progresses quietly and slowly, making it easy to overlook until it becomes critical. Unlike mobile or mechanical assets, these items require a modified reliability system to ensure they remain serviceable throughout their intended lifespan.

By implementing a corrosion management system that is methodical, logical, and quantitative, organisations can not only maintain regulatory compliance but significantly improve economic performance, safety, and asset life.

Need Help Setting Up Your Corrosion Management Strategy?

At TECHT, our team of corrosion engineers and condition monitoring specialists work with mining and industrial clients across Australia to build, refine, and implement comprehensive asset integrity frameworks.

Explore our corrosion management services or Get in touch with TECHT to discuss your site-specific integrity challenges.

Download our Setting up a Corrosion Management System 3 Points To Consider.pdf

In Australia, where industries such as mining, oil and gas, transportation, and infrastructure are prominent, effective corrosion mitigation practices are essential for minimising environmental impact and preserving natural resources.

This blog explores the importance of corrosion mitigation in reducing environmental harm, highlighting Australian practices and the substantial benefits they offer in terms of cost savings, environmental stewardship, and enhanced productivity.

The Environmental Impact of Corrosion

Corrosion-related failures can result in environmental pollution, habitat destruction, and resource depletion. Leaks, spills, and emissions from corroded equipment and structures can contaminate soil, water bodies, and air, leading to adverse effects on ecosystems and human health.

Moreover, the extraction and production of materials for corrosion repairs contribute to carbon emissions and resource consumption, exacerbating environmental degradation.

Australian Corrosion Mitigation Practices

Australian industries have made significant strides in adopting corrosion mitigation strategies to minimise environmental impact.

These practices include:

1. Protective Coatings: Utilising advanced coatings and surface treatments to protect metal structures from corrosion, thereby extending their lifespan and reducing the need for frequent replacements.
   
2. Cathodic Protection: Implementing cathodic protection systems to prevent corrosion of buried or submerged metallic assets, such as pipelines and storage tanks, by controlling electrochemical reactions.
   
3. Asset Monitoring and Maintenance: Regular inspection, monitoring, and maintenance of assets to detect corrosion early, address potential issues promptly, and optimise performance while minimising environmental risks.
   
4. Sustainable Materials Selection: Choosing corrosion-resistant materials and sustainable alternatives during the design and construction phase to minimise environmental footprint and lifecycle impacts.
   
5. Corrosion Prevention Training: Providing employees with training and education on corrosion prevention best practices, safety protocols, and environmental compliance to ensure responsible handling and maintenance of assets.

Benefits of Corrosion Mitigation

Effective corrosion mitigation not only safeguards the environment but also delivers tangible benefits to businesses and communities. Some of the key advantages include:

1. Cost Savings: By reducing corrosion-related failures, downtime, and maintenance costs, businesses can achieve significant cost savings over the long term, enhancing profitability and competitiveness.
   
2. Environmental Protection: Minimising the release of harmful substances into the environment and conserving natural resources contribute to sustainable development and environmental stewardship.
   
3. Regulatory Compliance: Compliance with environmental regulations and standards is essential for maintaining operational licenses, securing public trust, and avoiding penalties or litigation associated with environmental violations.
   
4. Enhanced Productivity: Reliable, corrosion-free assets operate more efficiently, delivering consistent performance, higher uptime, and improved productivity, thereby supporting economic growth and prosperity.
   
5. Reputation and Stakeholder Confidence: Demonstrating a commitment to environmental responsibility and sustainability enhances corporate reputation, fosters stakeholder trust, and attracts investment opportunities.

Corrosion mitigation plays a crucial role in reducing environmental impact, protecting natural resources, and promoting sustainable development in Australia and beyond.

By adopting proactive corrosion management practices and embracing innovative technologies, industries can minimise their ecological footprint, optimise resource utilisation, and create a more resilient and environmentally responsible future.

Together, through collective efforts and collaboration, we can mitigate corrosion’s environmental effects and build a greener, cleaner, and more sustainable world for generations to come.

As we strive to minimise the environmental impact of corrosion, industries must embrace proactive mitigation strategies and sustainable practices. 

To learn more about how TECHT can help your organisation implement effective corrosion mitigation solutions tailored to your needs, contact us today. Together, let’s build a greener, more sustainable future for our planet.

It is a 6 Trillion dollar problem globally, per year. In Australia, the cost of addressing corrosion-related issues is 4-5% of GDP!

Giles Harrison, TECHT’s Principal Corrosion Engineer has been working for over two (2) decades throughout several industries to assist asset owners in reducing this cost, improving safety and environmental outcomes, and avoiding reputational damage due to corrosion-related failures.

Asset integrity is a fundamental requirement of operational reliability across all industries. The equipment can’t work if there is nothing to support it.

In today’s work environment, where asset downtime can result in significant financial losses and safety risks, effective corrosion management is paramount. In this post, we touch on the importance of emerging technologies in shaping the future of corrosion management and their implications for industries reliant on infrastructure and equipment durability.

Specifically, how predictive analytics, advanced sensors, robotics, nanotechnology, and other innovative solutions are revolutionising asset protection and maintenance practices.

TECHT is working to provide the industry with innovative corrosion and integrity management services for a sustainable future. This discussion acts as a conversation starter and provides some insights into the transformative power of technology in safeguarding critical assets and ensuring operational resilience.

As industries continue to push the boundaries of innovation, the field of corrosion management is also undergoing a transformation, driven by emerging technologies that promise to revolutionise how we approach asset protection and longevity.

One promising advancement lies in the realm of predictive analytics and artificial intelligence (AI). Leveraging the power of data analytics and machine learning algorithms, predictive maintenance models can now forecast corrosion events with unprecedented accuracy. By analysing historical data, monitoring real-time conditions, and detecting subtle patterns, AI-driven systems can predict potential corrosion risks before they escalate, enabling proactive interventions and substantial cost savings.

Another technology poised to reshape corrosion management is the advent of advanced sensors and monitoring devices. From wireless corrosion sensors to remote monitoring platforms, these cutting-edge technologies provide real-time insights into asset health and performance. By continuously monitoring environmental conditions, material degradation, and corrosion rates, these sensors empower asset managers with actionable data, facilitating timely maintenance and mitigating corrosion-related risks.

We are already seeing the integration of robotics and automation processes holding immense potential in streamlining inspection and maintenance processes. Autonomous drones equipped with high-resolution cameras and sensors can navigate complex industrial environments, conducting thorough inspections and identifying corrosion hotspots with unparalleled efficiency. Additionally, robotic systems capable of performing in-situ repairs and protective coatings application minimise human intervention in hazardous environments, ensuring worker safety while optimising asset uptime.

The emergence of nanotechnology presents yet another frontier in corrosion management, offering novel solutions for surface protection and material enhancement. Nanocoatings, engineered at the molecular level, exhibit exceptional corrosion resistance and durability, providing superior protection against environmental degradation and chemical exposure.

Additionally, nanomaterials infused with self-healing properties can autonomously repair micro-damage, extending the lifespan of critical assets and reducing maintenance costs over time.

As we embark on this journey toward the future of corrosion management, TECHT remains at the forefront of innovation, embracing these emerging technologies to deliver unparalleled solutions to our clients.

With our unwavering commitment to excellence and cutting-edge expertise, we are poised to shape a future where asset integrity is not just maintained, but optimised for sustained performance and longevity.

Join us in harnessing the power of innovation as we pave the way for a brighter, corrosion-free tomorrow.

“I find the world of microscopic organisms fascinating. Ever since I was in school, biology has been my favourite subject, yet I only stumbled into the world of microbes by accident later in my life”. Dr. Machuca Suarez.

Her interest in microbes then grew when she realised how essential they are for life and the great impact these tiny life forms can have on the environment.

“At first, my interest lay in bioremediation, using microbes to clean up pollution. However, my focus shifted when the oil company I was working for tasked me with investigating a problem. Metal pipes and equipment were corroding too fast, and bacteria were the prime suspects. And that’s when my journey with microbial corrosion kicked off. Fast forward two decades later and thousands of miles away from the origins of my career in my native country, I’m still grappling with the same challenge, armed with more knowledge”. 

What is microbial corrosion and why does it matter?

Microbial corrosion has come to be referred to as ‘microbiologically influenced corrosion’ (MIC). In simple terms, It’s the decay of materials caused by the action of microbes. Metals, concrete, and protective paintings can all fail due to microbial action. It is a serious and costly issue that impacts industries such as oil and gas, mining, marine, and water.

MIC can lead to expensive repairs, production downtime, and major risks to safety and the environment. In 2006, bacteria caused a pipeline failure that resulted in the spill of 200,000 gallons of crude oil on the Alaska North Slope, causing significant damage to the environment and costly fines for the responsible company. 

Billions of dollars are spent globally each year on MIC.

Despite its widespread impact, many companies still only react to MIC issues when they arise. Asset owners often focus on meeting immediate deadlines and saving costs instead of considering life cycle costs. As assets age, the risk of MIC grows, yet prevention investments decline. Investigations into MIC failures often point to poor management as the main contributing factor.

Biofilms: The Hidden Culprits Causing MIC

The process is simple, but the result is complex. As bacteria float in water, they quickly attach to a surface as soon as they sense it. They anchor firmly to it using biochemical glue forming a hardy bond that is difficult to break. They multiply and attract more bacteria. All together, they create scaffolding and network structures that encase them. The result is a cluster like a multi-cellular organism, with billions of specialized bacteria living in it, with the right tools and ability to handle dangers that come their way.

Inside biofilms, microbes cooperate, communicate, and develop defense traits, making them hard to kill. In humans, this leads to the persistence of infections, while in industry, it causes material deterioration and asset failure.

Biofilms can create aggressive environments that speed up corrosion locally, most of the time in hidden places or hard to reach. This complicates detection and control, often rendering conventional treatments ineffective. Picture this like tooth decay. As decay advances, bacteria continue their damaging journey through your teeth, reaching the pulp. Their destruction persists despite increased dental hygiene practices.

The MIC challenge lies in preventing biofilm formation and combating resistant biofilms. It should not be a fight against bacteria but against their way of living. Warfare against bacteria should target their communities, fortresses, scaffolding, bridges, and ways of communication. This should be the focus of Innovative solutions for MIC control.

How to prevent MIC failures?

Back when I was a university Assoc. Professor, I oversaw research on microbial corrosion. After many years of studies, we got a handle on how microbial corrosion affects different materials, like plain steel and corrosion-resistant alloys, and in various locations, from oil fields to the deep sea.

The work underlined that every piece of equipment is different, and every location has its own conditions and quirks. Yet, there are common factors that lead to the onset of MIC: 1) a susceptible material, 2) the presence of microbes, and 3) the right environment that supports both corrosion and microbial activity. These are things like temperature, flow velocity, and water chemistry.

This understanding forms the foundation for assessing risks and developing successful strategies to mitigate them.

Use the Right Material

To prevent microbial corrosion, choose materials wisely. Biofilms form on nearly any material surface. Yet, their effect on corrosion depends on the material properties. For instance, in stainless steels in seawater biofilms can increase their corrosion potential significantly. This can speed up pitting, galvanic and crevice corrosion in susceptible steels. Yet, highly alloyed steels remain resistant to microbial corrosion.

When selecting materials, it also important to consider future project scenarios. Examples include potential subsea tiebacks of new oil accumulations to existing facilities or repurposing existing infrastructure for CO2 transport and storage. This can bring new challenges due to the mixing of water chemistries and commodities with different properties.

Cladding with MIC-resistant alloys offers internal protection to assets that will be exposed to high-risk scenarios where conventional treatments cannot be used. Likewise, non-metallic material options like antifouling or multifunctional coatings work well in areas with limited access that are challenging to clean and treat.

Laboratory tests can also aid in material selection and decision-making. Laboratory simulations can help engineers determine if a material is suitable for a specific application, and the MIC rates and mechanisms taking place in unusual substratum/environment scenarios.

Smart Design

Smart design can prevent microbial corrosion issues. If design ensures that water doesn’t gather and drains away well, it’s less likely for biofilms to grow. Sloping surfaces, smooth weld finishes, and the elimination of crevices, reduce the areas where microbes can harbor and grow easily.

The incorporation of accessible areas for inspection and maintenance ensures that any MIC issues can be identified and addressed promptly before they turn into big corrosion problems.

Biocides

Although not the most eco-friendly approach, implementing a chemical biocide regimen reduces the risk of microbial corrosion. The application of chemicals to kill bacteria is effective if done properly and managed carefully. When selecting biocides, it’s important to consider factors such as toxicity, degradation profile, optimal pH range, chemical incompatibilities, and efficiency against biofilms. Biocides should include additives such as bio-dispersants that target the biofilm matrix. Dosing rates and frequency should be adjusted based on performance checks.

Cleaning and Maintenance

Routine cleaning and maintenance are key in the fight against microbial corrosion. Following a cleaning schedule that helps remove biofilms and deposits is crucial to prevent MIC.

Deposits like sand, scales, mineral mixtures, and organic matter increase the risk of MIC. They can concentrate nutrients, encourage biofilm growth, and trigger under-deposit corrosion, which is a direct activator of MIC. Deposits also affect treatment efficiency since biocides and corrosion inhibitors can adsorb onto deposits. Therefore, techniques such as mechanical cleaning and flushing are essential.

A critical step is to implement a strategy to examine and repair sections of the pipeline that are difficult to inspect with an internal inspection device, particularly those at greater risk of MIC, including dead legs and areas prone to the accumulation of liquids and solids.

MIC in the Early Stages is Reversible

Early detection is key. This requires regular inspection of susceptible systems, checking for both corrosion and biofilm presence. Testing for bacteria, using smart inspection tools, and measuring corrosion rates in real time.

Nowadays, it is simple and cost-effective to use DNA methods to track bacteria more accurately. The key is to collect the right samples: biofilms. It is critical to design for and install devices that allow assessment of biofilms and place them at strategic locations (sampling points). Biofilm collection devices include corrosion coupons, discs, and side stream devices. Do not rely on data from bacteria in fluids only.

Understanding the function of the hundreds or even thousands of different species of microbes often identified in biofilms using DNA analysis can be challenging. What is the link between microbial diversity and corrosion rates? who are the key players? How do microbe type and concentration relate to MIC risk? These are questions that remain difficult to answer. This is why it is important to look at trends in data. There are limited real-time monitoring systems specific to MIC. Cost-effective tools for early detection of MIC are promising areas of technological development.

Implementing an Effective MIC Management System

Here Dr. Machuca Suarez recommendations for an effective MIC management system:

• Develop a MIC strategy and management plans for each asset.
• Identify threats and risks through the life cycle of the asset. Risk criteria include operating conditions (e.g., flow velocity and temperature), fluid composition, system microbiology, equipment design features (e.g. presence of crevice, dead legs), corrosion history, treatment options, capacity for monitoring, and inspection.
• Implement tailored mitigation measures. These should include a chemical treatment program and a physical clean-up strategy with a schedule.
• Conduct regular chemical performance checks.
• Construct a live database of information including microbial, corrosion, and inspection data.
• Deploy real-time MIC/condition monitoring systems.
• Conduct a recurrent review of the MIC strategy.
• Design and implement a monitoring program that includes biofilm testing, inspection, and corrosion rate measurements in representative locations.
• Develop a tailored management plan for high-risk areas that cannot be managed by chemical injection or inspection such as dead legs.

In dealing with microbial corrosion, there’s no one-size-fits-all solution. However, we can take radical action to reduce the risk of MIC and ensure equipment safety.

It begins with devising an MIC strategy and action plan for each asset. Such a strategy should include continuous assessment of threats, a regular physical cleaning schedule, using chemical treatments strategically, and a proactive plan for conducting internal inspections that assess both corrosion and biofilms. This must include a tailored strategy for inspection and management of hidden biofilm-prone areas like dead legs.

Likewise, it is essential to implement a meaningful monitoring framework. Chemical performance checks, corrosion rate measurements, and analysis of biofilms using biofilm collection devices should take place on a regular schedule.

By implementing these measures effectively, industrial facilities can greatly reduce costs and risks associated with microbial corrosion. This ensures the safety, efficiency, and durability of industrial assets, contributing to sustainable operations.

Finally, to revolutionise our approach to managing MIC we must embrace technologies that enable prediction, early detection, and real-time monitoring. We need to develop solutions to thwart biofilm formation, such as pioneering surface treatments and advanced coatings. Focusing on the biofilm matrix, we can develop more innovative and eco-friendly solutions to this pervasive MIC problem. AI promises to be a fundamental enabler of such technological solutions.

Let’s lead the charge in protecting our infrastructure and environment with smarter, innovative solutions.

The future of asset integrity and corrosion control lies in our commitment to innovation and sustainability. BioTECHT is a division of TECHT specialising in Microbiologically Influenced Corrosion (MIC).

We work closely with our clients to develop tailored and innovative microbial corrosion solutions.

Contact us to find out how we can help you.

References

• Machuca, L. L. Understanding and Addressing Microbiologically Influenced Corrosion (MIC). Corrosion and Materials, 44 (1): 88-96. 2019
• Machuca L. L. and Polomka, A. Microbiologically Influenced Corrosion in Floating Productions Systems. Microbiology Australia 39 (3). 2018. 165-169
• Machuca, L. L. et al. MIC Investigation of Stainless Steel Seal Ring Corrosion Failure in a Floating Production Storage and Offloading (FPSO) Vessel. In: R. B. Eckert & T. L. Skovhus (Eds.), Failure Analysis of Microbiologically Influenced Corrosion. (1 ed.). CRC Press. 2021
• Machuca, L. L. et al. Corrosion of carbon steel in the presence of oilfield deposit and thiosulphate-reducing bacteria in CO2 environment. Corrosion Science, 2017. 129, 16-25
• Machuca L. L., et al (2016). Evaluation of the effects of seawater ingress into 316L lined pipes on corrosion performance. Materials and Corrosion, 2014. 65 (1), 8-17. 
• Machuca L.L.  (2017). Microbiologically Induced Corrosion Associated with the Wet Storage of Subsea Pipelines (Wet Parking). In T. L. Skovhus, D. Enning, & J. S. Lee (Eds.), Microbiologically Influenced Corrosion in the Upstream Oil and Gas Industry (1 ed., pp. 361-378). Boca Raton: CRC Press.
• Tuck, B., Watkin, E., Somers, A. Machuca L.L. A Critical Review of Marine Biofilms on Metallic Materials. npj Mater Degrad 6, 25. 2022
• Energy Institute (2017). Guidelines for the management of microbiologically influenced corrosion in oil and gas production.
• For a full list of articles by the Author: https://orcid.org/0000-0002-9590-5421

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