corten
Weatherproof construction steel
High-Quality special steel for metal garden products
In Germany the name CORTEN steel*) stands for weatherproof construction steel that continuously develops a barrier layer as part of a weathering process. This layer protects the elements from further corrosion and results in a characteristic patina in earthy and warm color shades. Corten steel has got a service life over average. It does not need to be varnished and is recyclable. We only use especially top-quality grade S355J2W+N, material number 1.8965, that can be bended and – with the right filler material – can also be welded.
*) The name COR-TEN (steel) consists of two parts. The first part COR stands for CORrosion Resistance, the second part TEN stands for TENsile strength. The patent for COR-TEN-Stahl was applied for in the USA in 1932. Worldwide there are a lot of different sorts of weatherproof construction steel.
Corten steel - field of application
Corten steel can be used in many different contexts and surroundings: e.g. for bridge constructions, facades or crash barriers. A popular example are the crash barriers on Italian highways. In the last years corten steel has increasingly been used for metal garden objects. The characteristic patina develops a certain independent existence and keeps changing its structure and color. This property among others makes corten steel the ideal material for modern garden, landscape and urban design.
For unique quality: Delivery condition "rolled blank"
When corten steel metal sheets are produced the rollers form a so-called “roller skin”. It consists of a tightly adhering, blue-black layer out of very hard iron oxides. The “roller skin” is brittle and delays the wanted development of the patina barrier layer. In the first months of weathering, however, this “roller skin” is continuously stripped away and reveals the “real” blank steel surface. The flaking rust-brown rolled skin is disturbing and unsightly.
We at GARTENMETALL® therefore process practically only the particularly high-quality Corten steel, in which the rolled skin is pickled directly after production – i.e. before processing. This is more costly in terms of procurement and production but you can simply see the high quality of our products thanks to the optimum primary products. Not only the flaking of the rolled skin is completely eliminated but also the accuracy of laser cutting, bending and welding is much higher than with simple material with the hard and brittle rolled skin.
How the patina is developed
When the crude steel plates are produced and processed the surface has not yet developed a patina. This patina only develops under natural weathering conditions. The development of a good-looking patina starts after 2 to 3 weeks and is only complete after 1.5 to 3 years. Important for the development of the barrier layer is the alternation between humid and dry weather. If there are surface parts, that are not exposed to weathering, they are excluded from the process of patina development. To find out how to accelerate the rusting of the surface thanks to our SUPER-ROST process, click here: SUPER-ROST method with SUPER-ROST pad
Pre-oxidizing: color differences
It is hard to believe but it is just as it seems: The same material from the same production lot develops a different first rust coloring, depending on the weathering and the environmental effects.
The rust coloring is mainly influenced by the temperature and the relative humidity. With lower temperatures and higher humidity the color turns darker. Different colorings after the first rusting are leveled out after the progressive weathering of the objects. These differences in color are therefore no defect and thus no reason for rejection.
Black Stains on corten steel
In the case of air exclusion it may happen that the fresh, slightly rusted surface turns black, e.g. if the material was packed in a tight-fitting foil for transport. This coloring tapers off after a few days of natural weathering. So it is no defect and thus no reason for rejection.
It can also temporarily come to a black color change, when the corten steel surface is touched by dead leaves or plantings over a longer period of time. Remember: After removing the leaves the weathering process is started anew and the patina surface returns.
Imprints from vacuum cup on corten steel
When the raw plates are processed, they are gripped automatically at several production stations with the aid of vacuum suction cups and transported for further processing. After the first rusting these cups can leave imprints – sometimes less, sometimes very clearly visible
Among experts these imprints are called “crop circles”. They occur when the surface is disturbed by minimal rest particles of SUPER ROST, which adhere to the cups. The imprints only turn up 12 to 24 hours after the first auburn patina. Under the effect of natural weathering the imprint disappears. If this disappearance has to be fastened, the surface can be mechanically roughened and rusted again.
Note: Imprints caused by vacuum cups on the pre-rusted surface are no reason for rejection.
Corten steel classified as ecological material
Weatherproof construction steel can be classified as ecological material. It has an over-average product life span, does not need to be varnished and is completely recyclable. Corten steel contains minimal amounts (less than 1%) of high-grade copper and chrome, which make it nearly indefinitely durable and avoids rusting through.
Is corten steel or construction steel in the garden a risk to your health?
Every now and again we are asked whether weatherproof construction steel is injurious to one’s health due to its alloying components copper and nickel. If you look at how corten steel works, you will realize that the concerns are without any reason. Corten steel does not oxidize and forms a barrier layer together with its alloying components. These do not end up in the surroundings. That is why corten steel is as unproblematic as stainless steel which is used in the kitchen and in hospitals.
Problems can only occur when normal or cheap construction steel is used in the garden, which is often used for decoration objects from DIY-stores. This kind of construction steel slowly dissolves and sets free alloy components like copper and nickel which might be ingested by insects, pets or humans. The dissolved oxidation products of steel (=rust) are harmless and work as a fertilizer.
Removing deposits from terrace tiles and natural stone
Rusty deposits, e.g. caused by drain water, can be removed more or less successfully with a suitable rust remover. The cleaning success is mainly determined by: Basic material Quality and quantity of cleaning Suitability of cleaning agents
For acid-resistant floor coverings cleaners on the basis of phosphoric acid are most likely to be successful. In case of little and light stains household remedies are ideal, like table salt in combination with ascorbic acid and water. No acidic cleaners may be used with concrete bound floor coverings. Only cleaners on the basis of tannin have a chance of achieving a sufficiently good cleaning result. Since the surface turns red-purple during treatment, it is essential to ensure proper application to avoid consequential damage. In all cases, test the effect of the cleaner by using a small sample area!
Sealing corten steel
To reduce rusty deposits and protect corten steel, there is the possibility of sealing the rusty surface once the desired stainless surface with the appropriate protective layer has formed.
The seal works like a classic clear varnish and has to be renewed as required (e.g. on a yearly basis). For more information on sealing your surfaces see ROST-PROTECT®.
Corten steel as a snail barrier
Did you know that corten steel is an effective snail and slug barrier? The reason: corten steel contains a small amount of copper (<1%). If the snail creeps over the corten steel, the snail slime oxidizes the copper. This creates an irritating substance that causes the snail to immediately turn around. To ensure that snails do not undercut this barrier it has to be at least 10 cm (≈ 39.37) inside the soil.
Suggestion for tender template
“Rolled flat steel. Quality standard weatherproof construction steel corten steel Corten B ASTM A 588, quality S355J2W+N. Material number 1.8965 according to EN 10025-5 with acceptance test certificate. Surface pre-oxidized on all visible sides.”
Metal aheets and cutting
If you need cuttings, sheets or plates of plain or pre-oxidized corten steel we can offer them to you at a very good price. We can do so because we always buy big quantities ourselves. Even small steel traders and many locksmiths purchase their corten steel from us. Also ask for corten steel without “roller skin”. This material is produced by big steel manufacturers exclusively for Gartenmetall®. For a price list and further information see: SHEET-METAL-CUTTING
Reference (in excerpts)
Werkstoffblätter ThyssenKrupp Steel, No. 1.8965
Merkblatt 434 „Wetterfester Baustahl“, Stahl-Informations-Zentrum
Wikipedia „COR-TEN“
VIDEO - Corten steel rusting with SUPER ROST-PAD
Corten steel rusting
With the SUPER-ROST PADs from Gartenmetall®, the creation of a visually appealing rust finish on corten steel is possible within 24 hours. Learn in the video how the 24-hour quick rusting is done best and what you have to pay attention to. It also shows how defects – such as black spots and scratches – can be easily repaired.
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