Combined Science Project: Reducing Corrosion of Iron Sheet Roofs in Schools
1. Stage 1: Problem Identification
1.1. Identify a Problem
Iron sheet roofs in schools are prone to rusting due to exposure to rain, humidity, and air
pollutants.
1.2. Problem Description
Corrosion weakens the structural integrity of roofs, leading to leaks, frequent repairs, and high
replacement costs.
1.3. How, Where, When
How: Rust forms due to oxidation when iron reacts with oxygen and moisture.
Where: Schools in humid or coastal regions (e.g., tropical climates).
When: Continuous exposure over time, especially during rainy seasons.
1.4. Statement of Intent
To investigate cost-effective methods to slow down or prevent rusting on iron sheet roofs.
1.5. How to Solve
Test different protective coatings (paint, grease, zinc galvanization) to determine the most
effective solution.
1.6. Design
Apply different coatings to small iron sheet samples.
Expose them to moisture and observe rust formation over time.
1.7. Materials/Tools Needed
Iron sheet samples
Paint, grease, zinc spray
Water spray bottle
Observation notebook
Camera for documentation
2. Stage 2: Developing Solutions
2.1. Existing Solutions
Galvanization (Zinc Coating): Common but expensive.
Painting: Cheaper but requires frequent reapplication.
Grease/Oil Coating: Temporary, attracts dust.
2.2. Three Proposed Solutions
Painting with Rust-Resistant Paint
Applying Grease/Oil Coating
Galvanizing with Zinc Spray
2.3. Advantages & Disadvantages
Solution
a) Rust-Resistant Paint
Advantages
Long-lasting,
easy to apply
Disadvantages
Can peel over time,
requires maintenance
b) Grease/Oil Coating
advantages
Cheap
easy to apply
disadvantages
Messy
attracts dirt
c) Zinc Galvanization
advantages
Highly durable
long-term protection
disadvantages
Expensive
requires professional application
3. Stage 3: Generation of Ideas
3.1. Brainstorming Raw Ideas
Use recycled oil as a coating
Combine paint with a waterproof sealant
Test natural anti-corrosion methods (e.g., lemon juice + baking soda)
3.2. Chosen Solution
Rust-resistant paint + waterproof sealant (balance of cost and durability).
3.3. Refined Solution
Apply primer before painting.
Add a waterproof sealant layer for extra protection.
3.4. Advantages & Disadvantages
Advantages
More durable than paint alone
Waterproofing prevents moisture contact
Easy to reapply
Disadvantages
Requires proper surface preparation
Slightly more expensive
May need occasional maintenance
4. Stage 4: Implementation
4.1. Action
Coat iron sheets with:
Only paint
Paint + sealant
Grease (for comparison)
4.2. Build/Test
Expose samples to water spray daily.
Observe rust formation weekly.
4.3. Observe
Record rust spots, discoloration, and coating durability.
5. Stage 5: Data Presentation
5.1. Present Results
Photos: Before/after comparisons.
5.2. Is It Functional?
Paint + sealant performed best with minimal rust.
Grease was ineffective long-term.
6. Stage 6: Evaluation & Recommendation
6.1. Challenges
Finding affordable sealants.
6.2. Achievements
Identified a cost-effective rust prevention method.
6.3. Recommendations
Schools should use rust-resistant paint with a sealant.
Further test eco-friendly coatings.
6.4. Conclusion
The best solution is paint + waterproof sealant for balancing cost and durability. Schools
should apply this to extend roof lifespan.
