Abrasive Blast Cleaning

Mill Scale

© Copyright 2016 Fitz-Coatings Ltd

 Mill Scale

Objective
The objective to this training unit is to gain a basic understanding of how mill scale is formed and the
importance of its removal during abrasive blast cleaning.

The abrasive blast cleaning operator will undoubtedly see mill scale during their duties.
The most effective method to mechanically remove mill scale is with abrasive blast cleaning.

Mill Scale
Structural steel is hot rolled.

As the steel leaves the last rolling section, the temperature on the
surface is approx. 1200°C. (2200o F)

As the steel cools, it reacts with oxygen to produce mill scale.

This is an illustration of intact new mill scale.

The mill scale is typically blue in colour from new, then turns black
over time.

Steel Manufacture
Steel is composed of iron and carbon. The iron is extracted from
iron ores, mined and then refined.

Part of the refining process is to remove oxygen from these ores

by heating them with coke and limestone to a temperature of
about 1600°C (2900o F) in a blast furnace.

There are two types of metals, ferrous and non-ferrous. Ferrous

comes from, or contains iron, while Non-Ferrous does not contain
iron.

Examples of non-ferrous metals would be copper, aluminium,

magnesium, titanium, etc.

Mill Scale
Typically the production of the steel plates is followed by storage
and ultimate delivery to the fabricator. The steel will initially have
tight mill scale attached, however, this scale will fall away from the
surface.

Some steel plates can be stored for many months and some in
corrosive (salt laden) environment.

The mill scale will not break away evenly and you may get some
pitting in areas and tight mill scale in others.

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 Mill Scale
The thickness of the mill scale is dependent upon the steel
section.

Lighter shapes of structural steel have thin scale while heavy steel
sections can have as much as 250 microns (10 mil) of mill scale
attached.

Mill scale is not a protection for the underlying surface and will
begin to fall away from a substrate.

The adhesion of the mill scale will vary depending upon thickness,
location and age.

Mill Scale
Mill scale is a complex oxide which is unstable and needs to be
removed.

As the steel is exposed to the atmosphere, water penetrates the

scale, the mill scale then loses adhesion and falls away from the
substrate.

Anything attached to the scale will also fall away from the surface,
this will include any coatings applied to the mill scale.

Mill Scale
Mill scale that is formed on steel is not uniform.

There are also a number of layers.

The scale is complex and has different levels of oxygen.

The colour of the mill scale can vary over a small area as
illustrated.

Mill Scale
Mill scale is generally brittle.

Mill scale has a lower thermal expansion than steel and cracks on
cooling

The cracks allow the moisture and oxygen to penetrate the scale.

This illustration demonstrates the different levels within the scale

and the amount of oxygen in each layer.

Mill Scale and Temperature Changes

This animation demonstrates how mill scale cracks as it has a
lower thermal expansion than steel.

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 As the temperature changes, the scale breaks away from the
surface over time.

This can be a slow process over many months or even years,

depending upon the location.

Pitting of the underlying substrate may be found as the scale falls

away from the surface.

Mill Scale
Mill scale is cathodic and the steel anodic.

As previously discussed, if the steel was stored for a period of

time, especially in marine or corrosive environments, you may find
pitting underneath the mill scale.

This is an illustration of a pitted substrate underneath a scaled

surface.

This pitting can be very dangerous in corrosion terms and may

even cause penetration of the steel surface.

Mill Scale
Illustration

Virtually intact mill scale.

Found on new steelwork.
Very difficult to remove.

Abrasive blast cleaning is generally the only option available for

removal of the mill scale, certainly for site use. The new mill scale
can have good initial adhesion and extremely difficult to remove.

A mechanical wire brush will not remove scale of this nature.

Mill Scale
Untreated mill scale after 12 months of exposure.
The condition will vary, depending upon the location of the
steel.
The scale is beginning to crack and fall away from the surface
and staining will become evident, especially in damp or wet
and corrosive environments.

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 Mill Scale

Untreated mill scale after 36 months of exposure.

The condition of the steel will vary depending upon the
location of the steel, if the steel is stored in a corrosive
environment the steel condition may be a lot worse.
It is unlikely you will find this form of uniform corrosion unless
it is stored indoors etc.
Pitting may also be found behind the layer of rust.

Mill Scale
Untreated mill scale after 8 years exposure.
Metal loss and pitting of the steel may be possible.
The condition could be considerably worse in corrosive
environments such as coastal or marine locations.
Chipping or needle gunning may be required to expose the
steel before any general preparation is conducted.

Abrasive Blast Cleaning

It is widely recognised that the best method of mill scale removal
is too abrasive blast clean.

Abrasive blast cleaning will remove mill scale at all levels.

The harder the scale the longer the abrasive blast cleaning will
take.

Acid cleaning is sometimes conducted for certain factory uses,

such as pre-galvanizing.

Abrasive Blast Cleaning

This video demonstrates the use of abrasive blast cleaning with
the use of chilled iron abrasive to remove mill scale on a new steel
structure.

Abrasive blast cleaning is the most effective and efficient method

of scale removal.

The video illustrates the speed of the abrasives and pressures

used in the blast cleaning process.

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 Coating system
Applying coatings directly over mill scale is a short-term solution.

Both the mill scale and the applied coatings will lose adhesion and
flake away from the substrate.

This illustration demonstrates a protective coating (yellow) applied

over mill scale (black).

No surface preparation had been conducted on the mill scale

before the paint was applied therefore coating failure was
inevitable.

Mill Scale under a Coating

This animation demonstrates the outcome if a paint is applied over
a surface which has the mill scale still attached.

The mill scale will eventually break away from the underlying
surface bringing the paint with it.

Generally, the most economical option for the construction

industry is to remove the scale during steel manufacturing and
apply a primer coat which can be removed or abraded and
overcoated at a later date.

Note: A simple test for telling whether steel surface residues of

mill scale (or rust and paint) are tightly adhering or loose is with a
dull putty knife. If the material (Mill Scale, Rust, or Old Coating)
CAN NOT be removed with a dull putty knife then the material is
considered tightly adhered.

Mechanical Preparation
Mechanical preparation such as disking or wire brushing will not
remove mill scale.

Loose flaking can be removed, although some areas will be tight

and intact.

Abrasive blast cleaning is the best and most economical method

of scale removal.

The age of the scale will generally dictate the removal speed and
rate.

Mill Scale Detection - Test Method

To test for mill scale you require a solution of 4% anhydrous
copper sulphate in 1% sulphuric acid with a few drops of wetting
agent and applied to the steel surface suspected of having mill
scale.

Copper will be deposited on areas free from mill scale and any
remaining patches of mill scale will appear as darker areas against
the copper background.

Extreme care must be taken with this test utilizing the correct
PPE and RPE by experienced and qualified personnel.

© Copyright 2016 Fitz-Coatings Ltd Page 5

 Summary
This training unit reviewed the production of steel and how the mill
scale is formed and eventually breaks away from a surface.

We also discussed the problems with leaving mill sale on the

surface or over painting the mill scale.

We also discussed the various options for mill scale removal.

© Copyright 2016 Fitz-Coatings Ltd Page 6