Premature Failure of Galvanized Fire Sprinkler Pipes in Coastal Conditions: Evidence of Sequential Atmospheric and Aqueous Corrosion

This case study investigates the rapid through-wall perforation of newly installed hot-dip galvanized (HDG) fire sprinkler pipes in a coastal Mediterranean environment. Failure occurred along the internal waterline of horizontal sections within a short service period. Forensic analysis—comprising metallography, SEM, and EDS—identified a synergistic atmospheric–aqueous corrosion mechanism. Marine aerosol exposure during pre-service storage led to significant chloride enrichment and localized depletion of the 40–50 μm zinc coating, initiating early-stage pitting. Upon commissioning, stagnant water established oxygen concentration gradients and differential-aeration cells, driving localized anodic dissolution. Additionally, sulfate-reducing bacteria (SRB) contributed to accelerated degradation through microbiologically influenced corrosion (MIC), as suggested by sulfur-bearing tubercles. The findings demonstrate that standard galvanizing thickness alone does not ensure longevity in high-salinity environments if atmospheric “preconditioning” occurs. These results underscore the necessity of shielding internal pipe surfaces during storage and construction to prevent premature failure. This case study informs predictive maintenance and material selection for stagnant-water systems in coastal regions.