Steel corrosion increasing carbon emissions

Inadequate corrosion protection is contributing more to global CO2 emissions than the entire aviation industry.

Germany-based corrosion specialist Steelpaint is calling for urgent action to address the significant environmental impact of steel corrosion, warning that inadequate corrosion protection is contributing more to global CO2 emissions than the entire aviation industry.

With the maritime industries consuming an estimated 100 million tonnes of steel annually, premature corrosion and subsequent steel renewal work is increasing carbon emissions dramatically, said Steelpaint’s Managing Director Klaus Müller.

“Addressing this issue through effective steel protection is an economical and environmental imperative. Every premature steel asset failure triggers a replacement cycle that indirectly undermines the industry’s decarbonization efforts.”

Steel production remains one of the most carbon-intensive industrial processes. To produce a single 10m by 10m, 20mm thick steel plate, for instance, emits about 3t of CO2. Factor in transportation costs and the need for additional coatings, and the carbon footprint looms large.

“Without effective and reliable corrosion protection, early steel replacement initiates a cascade of carbon-intensive consequences – increased raw material extraction, higher energy consumption during manufacturing process, and transportation and installation – all of which contribute to a carbon footprint that extends far beyond the initial asset failure,” said Müller.

This is underscored by joint research study carried out by Curtin University and Ohio State University and published in 2022, which estimates that 25% of global steel production is lost to corrosion, with replacement and renewal accounting for 4 to 9% of total emissions globally.

Global demand for steel in 2024 was 1.8 billion tonnes and forecast to grow by 2.9% by 2030. The shipbuilding industry alone consumes 32.2 million tonnes per year, of which China, South Korea, and Japan use 88.3%.

Dmitry Gromilin, Steelpaint's Chief Technical Supervisor, said: “By extending the lifespan of steel structures with effective corrosion prevention technology we have the potential to reduce emissions further. But the link between steel protection and carbon emissions has so far been overlooked.”

Indeed, with mounting regulatory pressure and the shift toward decarbonisation, optimising the durability of steel structures does seem an important consideration if the industry is to meet the UN’s 17 Sustainability Goals.

“Coatings technology is so far advanced that, if properly maintained, maritime structures can last for decades, not only reducing the frequency and costs associated with steel replacement but also leading to a substantial decrease in greenhouse gas emissions. Global CO2 emissions from steel production could be reduced up to 1.6 gigatons annually,” said Gromilin.

The shipping industry remains one of the world’s largest emitters of CO2, producing 858 million tonnes of carbon dioxide in 2022, surpassing the aviation sector. With IMO tightening emissions regulations, companies are under pressure to adopt low-carbon solutions that extend infrastructure life cycles while reducing environmental impact.

"The focus on corrosion protection is not just about extending material lifespan, it’s about reducing emissions at their source," said Gromilin.

"With our isocyanates-free, low VOC moisture-cure polyurethane Stelcatec coating we are enabling steel assets to remain in service longer, reducing the carbon emissions at source. Stelcatec is setting a new standard for steel preservation, ensuring a more sustainable future for the industry.”

■ Contact: Steelpaint GmbH www.steelpaint.de/en/