Table of Contents
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What Is Weathering Steel?
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History and Origins of Corten Steel
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Uses and Applications of Corten Steel
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Properties of Corten Steel
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Specifications: Corten A vs. Corten B
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Welding Weathering Steel: Key Considerations
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Recommended Welding Techniques
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Challenges in Welding Corten Steel
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Post-Weld Treatment and Maintenanc
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Key Takeaways
Introduction to Weathering Steel
Weathering steel belongs to the group of low-carbon steels. The alloy elements like copper, chromium, silicon, and phosphorus in these steels are mixed with carbon and iron atoms. This specific chemistry allows the material to withstand extreme outdoor conditions by forming a protective layer.
Weathering steel is a type of steel alloy with superior yield strength capability. Its chemical composition makes it highly resistant to corrosion caused by weather and atmospheric conditions such as air and moisture. Over time, the material develops a unique oxide layer called ‘patina’, which looks like rust but acts like paint. This protective layer prevents deeper corrosion, giving it a longer lifespan even in harsh environments.
Let’s explore how welding corten steel works and why it remains a preferred choice across industries.
History and Origins of Weathering Steel
Weathering steel, also known as corten steel, was registered under the trademark Cor-Ten, which was originally developed and patented by U.S. Steel in 1933. Cor-Ten gets its name from two words: CORrosion Resistance and TENsile Strength.
As usage expanded, the American Society for Testing and Materials (ASTM) standardised it under various specifications, paving the way for more structured construction, art, and engineering applications.
Corten Steel Uses and Applications
Corten steel is used for both practical and visual appeal in the following applications:
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Engineering projects
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Architectural projects
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Construction of buildings and bridges
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Outdoor sculptures
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Marine transportation
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Roofs and walls
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Cycle hoops
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Planters
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Tree grilles
Its aesthetic appearance and corrosion resistance make it a popular choice where both design and durability are important.
Properties of Corten Steel
Corten steel is known for its impressive mechanical and aesthetic qualities, making it a preferred choice for both functional and design-driven applications.
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Anti-corrosive
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Robust metal
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Ductile
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High structural strength
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Lightweight
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Attractive appearance
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Minimal upkeep
Corten steel has a distinctive rusty, orangish-brown texture. This seamless patina gives any product or structure an aesthetic finish, blending naturally with urban and natural surroundings. Welders can apply it without worrying about chemical mixtures to achieve the weathered look, as the patina forms uniformly.
These combined characteristics make weathering steel highly suitable for long-term outdoor use, requiring low maintenance while offering both strength and style.
Specifications for Corten Steel
The primary trademark product is COR-TEN. However, ASTM has also laid down specifications as follows:
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A588 (structural panels, shapes, plates, and bars)
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A242 (steel plate up to 1.5 inches thick)
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A606-4 (corten steel sheet and coil)
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A847 (tube and pipe)
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A871-65 (plate with 65ksi yield strength)
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A709-50W (steel plate for bridges)
Corten A vs Corten B
Weathering steel is available in two main grades: Corten A and Corten B.
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Corten A (ASTM A242) is mainly used in architectural applications. Its higher phosphorus content enhances patina formation and gives a more uniform, aesthetic finish.
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Corten B (ASTM A588) is preferred for structural and heavy-duty applications. It offers higher strength but has lower phosphorus content, making it ideal for bridges and load-bearing structures.
Both grades develop a protective rust layer, but their chemical compositions are optimised for different needs.
Welding on Weathering Steel
Welding on corten steel is relatively similar to low-carbon steel. The only precaution the welders need to take is regarding the filler or electrode, which is different from mild steel.
When welding corten steel, it’s critical to select the right electrode that preserves the base metal's corrosion-resistant properties.
Recommended Electrode: AWS E7018
When choosing a welding electrode for weathering steel, AWS E7018 is most suitable. The choice of electrode depends on two factors: required strength and code requirements.
At D&H Sécheron, we recommend Lotherme 7018 and similar low-hydrogen electrodes that maintain joint strength and match the patina’s corrosion behaviour.
Best Welding Techniques for Corten Steel
When it comes to welding corten steel, the method should match the material thickness and end-use.
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Stick Welding (SMAW): Reliable and economical for structural joints.
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TIG Welding (GTAW): Clean and precise, suitable for fine applications.
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MIG Welding Corten Steel (GMAW): Fast and efficient for thin sheets.
For MIG welding corten steel, shielding gases like CO₂ and Ar-CO₂ mixtures help ensure smoother arcs and less spatter while using weathering steel-compatible filler wire.
Common Challenges When Welding Corten Steel
Despite its benefits, welding corten steel comes with some challenges:
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Heat-induced distortion or cracking
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Loss of corrosion resistance near the heat-affected zone
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Difficulty in matching the patina formation post-weld
However, with the right expertise and materials, these can be addressed. The necessary knowledge and experience in welding already exist. Hence, welders should be able to use it without any hassles.
Post-Weld Treatment and Maintenance Tips
To retain the steel’s integrity and look:
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Clean the weld area to remove slag and spatter
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Use weathering accelerators to match the patina faster
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Avoid stagnant water and ensure drainage in structural designs
This ensures that the weathering finish evolves consistently across welded and unwelded sections.
Corten steel is preferred across industries thanks to its durability, unique appearance, and natural corrosion resistance. While it may cost more upfront, its minimal maintenance and extended life make it a smart long-term investment.
Whether used in buildings, bridges, or public art, weathering steel delivers strength and style. When it comes to welding corten steel, especially using techniques like MIG welding, selecting the right electrode is key to maintaining its structural and visual integrity.
With D&H Sécheron’s expertise in welding corten steel, you can count on reliable performance and lasting results in every application.
Key Takeaways
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Durability and Corrosion Resistance: Patina shields the surface from deeper corrosion.
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Aesthetic Appeal: Orangish-brown finish integrates beautifully into various environments.
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Wide Applications: Ideal for engineering, construction, public art, and outdoor design.
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Cost Considerations: Though costlier, it offers long-term value through reduced maintenance.
Welding: Similar to mild steel but requires compatible electrodes like AWS E7018 for reliable performance
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