Mechanistic Pathways of External Corrosion in Buried Water Pipelines: Integrating Electrochemical Kinetics, Iron Oxide Phase Evolution, and Microbially Influenced Corrosion with Soil Environmental Controls

External corrosion of buried ferrous water mains remains the dominant driver of structural failure in aging water distribution networks, yet the mechanisms linking soil physical and chemical heterogeneity to corrosion kinetics and product phase evolution have not previously been synthesized into a unified critical framework. This review evaluates three partially competing accounts of electrochemical degradation—anodic dissolution coupled to oxygen reduction within porous rust layers, redox cycling of iron oxide phases driven by seasonal soil moisture fluctuations, and microbially influenced corrosion (MIC) mediated by direct extracellular electron transfer (EMIC) and chemical metabolite pathways (M-MIC)—and assesses the weight of evidence for each. We demonstrate that corrosion products retain electrochemical activity long after formation, functioning as dynamic redox mediators that continue the reactions responsible for their own growth: the reduction of lepidocrocite under anoxic conditions regenerates Fe2+ ions that sustain anodic dissolution and catalyze oxygen reduction, while repeated soil moisture cycles drive the irreversible transformation of γ-FeOOH to Fe3O4, which fundamentally alters the conductivity and cathodic capacity of the rust layer. The widely cited universal critical-moisture threshold of 65% water-holding capacity (WHC) is evaluated and found to be a single-point approximation contradicted by texture-resolved experimental data that show the critical degree of saturation ranges from Sr ≈ 0.5 in sand to Sr ≈ 0.8 in clay. Modern machine learning analyses of field corrosion databases confirm that chloride content, pH, pipe-to-soil potential, and water content are the four highest-ranked predictors of maximum pit depth, consistent with the mechanistic framework developed here. The classical cathodic depolarization model of SRB-driven corrosion is evaluated against EMIC evidence and found insufficient: measured pure-culture SRB corrosion current densities range from 14 to 135 µA cm−2, not the milliampere-level values reported in some earlier reviews. An explicit research agenda is proposed to address the five most consequential unresolved mechanistic questions.

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Publication Details

Journal
Corrosion and Materials Degradation
Published
2026-07-27
DOI
https://doi.org/10.3390/cmd7030046
Primary Topic
Corrosion Behavior and Inhibition
Type
article
Field-Weighted Citation Impact
0.00

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article

Mechanistic Pathways of External Corrosion in Buried Water Pipelines: Integrating Electrochemical Kinetics, Iron Oxide Phase Evolution, and Microbially Influenced Corrosion with Soil Environmental Controls

Ehsan Roshani, Nafiseh Ebrahimi, Mojtaba Momeni, Misagh Khanlarian
Corrosion and Materials Degradation
Corrosion Behavior and Inhibition
article

Mechanistic Pathways of External Corrosion in Buried Water Pipelines: Integrating Electrochemical Kinetics, Iron Oxide Phase Evolution, and Microbially Influenced Corrosion with Soil Environmental Controls

Ehsan Roshani, Nafiseh Ebrahimi, Mojtaba Momeni, Misagh Khanlarian
article en

Abstract

External corrosion of buried ferrous water mains remains the dominant driver of structural failure in aging water distribution networks, yet the mechanisms linking soil physical and chemical heterogeneity to corrosion kinetics and product phase evolution have not previously been synthesized into a unified critical framework. This review evaluates three partially competing accounts of electrochemical degradation—anodic dissolution coupled to oxygen reduction within porous rust layers, redox cycling of iron oxide phases driven by seasonal soil moisture fluctuations, and microbially influenced corrosion (MIC) mediated by direct extracellular electron transfer (EMIC) and chemical metabolite pathways (M-MIC)—and assesses the weight of evidence for each. We demonstrate that corrosion products retain electrochemical activity long after formation, functioning as dynamic redox mediators that continue the reactions responsible for their own growth: the reduction of lepidocrocite under anoxic conditions regenerates Fe2+ ions that sustain anodic dissolution and catalyze oxygen reduction, while repeated soil moisture cycles drive the irreversible transformation of γ-FeOOH to Fe3O4, which fundamentally alters the conductivity and cathodic capacity of the rust layer. The widely cited universal critical-moisture threshold of 65% water-holding capacity (WHC) is evaluated and found to be a single-point approximation contradicted by texture-resolved experimental data that show the critical degree of saturation ranges from Sr ≈ 0.5 in sand to Sr ≈ 0.8 in clay. Modern machine learning analyses of field corrosion databases confirm that chloride content, pH, pipe-to-soil potential, and water content are the four highest-ranked predictors of maximum pit depth, consistent with the mechanistic framework developed here. The classical cathodic depolarization model of SRB-driven corrosion is evaluated against EMIC evidence and found insufficient: measured pure-culture SRB corrosion current densities range from 14 to 135 µA cm−2, not the milliampere-level values reported in some earlier reviews. An explicit research agenda is proposed to address the five most consequential unresolved mechanistic questions.

Corrosion and Materials DegradationVol. 7(3)
Western University (CA), National Research Council Canada (CA)
National Research Council Canada
Openalex Percentile: Top 20%
Corrosion Behavior and Inhibition
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