Weathering steel (also known by the trademark COR-TEN steel) is a form of high-strength, low alloy steel originally developed in the 1930's by United States Steel. It is a steel alloy, chemically composed to form a stable rust-like appearance that can resist corrosion and abrasion, by forming a protective surface layer, or patina.
The protective layer’s increased resistance is produced by the alloying elements and their particular distribution and concentration. When subjected to the influence of the weather, the protective surface layer continuously develops and regenerates, allowing the rust to form.
Weathering steel is often used in external sculptures, the most iconic of which is the Angel of the North in Gateshead. It can be used in bridges and other large structural applications, such as the New River Gorge Bridge, and it is becoming an increasingly popular design choice for buildings, often used alongside materials such as glass and terracotta. An example of such a building is the distinctive Broadcasting Tower in Leeds (see top image).
The advantages of weathering steel are that because it is already weathered and ‘rusted’, there are very low maintenance costs, it can be installed easily, and the need for a protective paint system is removed. Studies have found that bridges fabricated from unpainted weathering steel can achieve a design life of 120 years with only nominal maintenance, due to the low corrosion rate.
However, there are several challenges to weathering steel. It is unsuitable for use in marine or coastal environments, and in humid subtropical climates the patina may continue to corrode instead of stabilising into a protective layer. In addition, interface details require careful design as run-off water from wet rusted steel may negatively impact on other materials, such as staining glass. This is a particular problem in the first years after installation.
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