Contents
Steel Corrosion In Marine Environment
2. Mechanism of Corrosion
3. TYPICAL CORROSION CONTROL METHOD
3.1 Cathodic Protection
3.2 Coating & Covering Method
4. Maintenance
5. Repair
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Environment
Atmospheric
zone
Characteristics of Environment
Characteristic of Corrosion
Wind brings fine sea-salt particle
Corrosively environment varies depend on
distance from sea. Velocity and direction of
wind, rainfall, temperature, sunshine, dust,
seasonal conditions, pollution affect to
corrosion)
Corrosion rate of the part of shade where
suffered by the wind and rain is larger than
part of no suffering by wind and rain.
Splash zone
Steel surface is wetted with oxygen
rich water film and no fouling by
marine growth.
Largest corrosion rate zone
Tidal zone
Repeated wetting and drying of
structures surface due to tide of
seawater surface
Structure around tidal zone or MSL acts as
cathode of oxidation concentration cell.
Corrosion rate at coating damaged part is
normally large.
Marine growth on the structure and
seawater current affect as corrosion factor.
Structure just below MLWL part acts as an
anode of oxidation concentration cell and
corrosion late is very large.
Seabed
Possibility of sulfate reduction bacteria
presence
Sulfides suffer corrosion of structure and
effect of cathodic protection.
Backside
Above the residual water level: Sane as
environment as soil
Below the residual water level: Same as
environment as sea bed
Similar to the soil environment
Underwater
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Similar to seabed environment
Atmospheric
Zone
Splash Zone
HWL
Occur the most severe corrosion
Tidal Zone
Occur severe corrosion at from
LWL
M.L.W.L to Just below L.W.L.
Because, this part becomes an
Underwater
Sea bottom
anode of oxidation cell.
Seabed
Corrosion ratemm/yr
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Stray
Current
Corrosion
Wet
Corrosion
Natural
Corrosion
Corrosion
Dry
Corrosion
Due to stray
current from DC
transit system
Local cell action
Micro
cell
Corrosion
Bacteria
Galvanic
Corrosion
Macro cell
Corrosion
Corrosive Gas
--
Dry
battery
Electron e
Current i
Cathode
Copper
Carbon
Anode (Zinc)
H2
2e
Zn Zn2+2e
2H+
Current i
SO4
Electrolyte
Zinc
2e
Zn2+
Dilute sulfuric acid solution
H2SO42H+SO42
2H+2e2H2
Zn2+SO42 ZnSO4
Metal, high ionization, corroded
Current flows out from anode to cathode through
electrolyte and corroded
Cathode is protected vice versa.
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+200
-200
-400
-600
-800
-1000
Aluminum Alloy Anode
Zinc
Aluminum
Mild Steel
Cast Iron Steel
Lead
Brass
Copper
Bronze
SS
SS
Potential mV vs. SCE]
--
-1200
Cathodic Reaction
Anodic Reaction
H2O1/2O2+2e2OH-
FeFe++2e
Corrosive Reaction
Fe++2OHFeOH2
Electrolyte(Seawater)
Anode part
Fe++
Fe++
Cathode part
OHSteel
2e
2e
Steel surface, both of steel itself and environment is un-even, it causes potential
different by dissolve oxygen, remaining stress, temperature different, impurity,
deformation and fouling, then anode part is corroded and cathode part is protected.
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Most
Popular
M.L.W.L
L.W.L
Coating
Tidal Zone
H.W.L
Long
Bridge or
Gate
Coating
Splash Zone
Covering
Atmospheric Zone
L.W.L1.0m
Source: Corrosion Protection & Repair Manual for Port & Harbor Steel
Structures, Issued by OCDI
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Corrosion
Allowance
Seabed
Cathodic
Protection
Sea bottom
Cathodic
Protection
Underwater
Shallow and
Not
Important
Structure
Protection method with covering system for the
splash and tidal zone and cathodic protection for
underwater and seamud by aluminum alloy anode
is most common method and has high reliability.
Following covering system will be applied,
New structure: Heavy dutyApplied at factory)
Existing: Petrolatum lining or underwater epoxy
lining).
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Upper
Structure
M.L.W.L
Covering
Aluminum Alloy Anode
Steel Pile
Sea Bottom
Protective Current
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Protected
Piece
Test Piece
Non Protected
Piece
Um-protected
Fitting level
Surface of test piece
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Protected
Technical Criteria and Description for
Harbor Structures(Issued by Japan Port
Association)
Protective Potential-780mVvs Ag/AgCl
Characteristics of Aluminum Alloy
Anode ALAP-K
Potential and Current capacity, etc;
(1) Specific gravity 2.7
Potential & Current Capacity;
(1) Specific Gravity:2.62.8
(2) Driving potential to steel 0.25
(2) Closed Potential -1.05(V)
(3) Theoretical capacity:2.9Ahr/g
(3) Driving potential to steel:0.25(V)
(4) Theoretical capacity:2.87Ahr/g)
(4) Current capcity 2.6Ahr/g
Average of supplied anodesMore than2.7
(5) Anode efficiency 90
(5) Current efficiency: More than 90%
(6) Current capacity:2.6Ahr/g
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Petrolatum Lining
Specification
Thickness
Underwater work
Workability
Environment
Pollution
1. ISO St2
2. Petrolatum tape
or equivalent
3. Protect with FRP
cover
15mm
Applicable
Need much work
process for sheet piles
Non
Underwater Lining
1. ISO Sa2.5
2. Coat epoxy
resin
Mortar Lining
1. ISO St2
2. Fit FRP cover
3. Pour mortar
5mm(design)
50 to 60mm
Applicable
Applicable
Need much time for
surface preparation
Spread pitch during
blasting
Design Life
>20 years
10 to 15 years
Application
Many
Many
Evaluation
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Possibility of sink during
mortar pouring
Possibility of mortar
seepage
>20 years
Not many
PTC Covering
PTC Application
FRP Cover
Foamed PE
Petrolatum tape or sheet
Steel Pile
Petrolatum paste
Steel
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PTC APPLICATION
Surface Preparation
FLOW
Remove shell, fouling, rust and disbonded coating film from steel surfaceISO St2)
Apply Paste
Apply petrolatum paste which is purified during process of vacuum distillation of
crude oil. This is inertness agent and has proof to acid, alkaline and seawater.
Lapping Tape
After applied paste, lap petrolatum tape with 55% lapping tae.
Setting Protective Cover
Setting FRP cover on the tape and fix by anti-corrosive bolts and nuts.
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Working flow of underwater application
Lining Method
Temporary facility & curing
Due to apply sand blast, prepare for strong
scaffold and anti- marine pollution as safety
countermeasure
Surface Preparation
Use marine blast machine. Finish surface
condition is SIS Sa2.5 or equivalent
Epoxy resin mixing
Use dedicated mixer due to consists of base
and hardener resin and mix equally.
Coating
Mixed resin coat on the structure within 30min.
After mixed.
(Curing time varies according to seasonal
condition)
Inspection
Coating thickness shall be checked during and after
coating by thickness gauge to control designed
thickness.
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Structures to be protected
Performance Check of
CP System
Potential measurement
Anode consumption heck
Visual
Investigation of coating
deterioration
Non protected structures
Corrosion Evaluation
Investigation of
Repairing method
Peeling off
Strength
Visual
Thickness gauging
Detail visual
inspection
Detail thickness
gauging
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Investigation for ensuring
that CP system works
properly to the structure to
be protected.
Investigation for ensuring
that coating works properly
to the structures to be
protected.
Investigation for current
corroded conditions and
evaluation of soundness
of the existing harbor
structures.
Investigation of detail
corroded conditions for
planning of repair method
for existing harbor structure
START
Planning of repairing
investigation
Planning
Yes
Budgeting
Investigation or site
survey for repairing
Evaluation of
Soundness
Necessity of
Repairing
Budgeting of repairing
investigation cost
Investigation
Corrosion
No
Planning of Countermeasure of
Corrosion Control
Above seawaterCoating or covering
Planning of
Repairing
UnderwaterCathodic Protection
Budget of repairing and corrosion
control countermeasure
Summary of repairing &
corrosion control method
Execution of protection and
repairing work
END
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Evaluation method of soundness of structures
Evaluation of soundness in future from remaining thickness of steel
Evaluation of soundness based of actual corrosion and corrosion rate
Un-soudness
Soundness
Structural calculation,
repairing planning & corrosion
control planning
Planning of corrosion
control system to keep
current conditions of
structures
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Structural yield strength
Non protected period
After apply protection
Designed section
Design corrosion curve
Corrosion curve after
apply protection
Required section
Actual corrosion curve
Remaining life
Initial Design Life
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Elapse year
Structural yield strength
Non Protected period
After apply protection
Design section
Design corrosion
curve
Corrosion curve
after apply protection
Required Section
Actual
corrosion curve
Repairing
Remaining life
Original design life
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Elapse year
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Repair method that weld
steel plate on the corroded
pie pile or sheet piles
This can be kept sufficient
welding bead by using slit
plate
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Covering method which applies reinforced
concrete on the corroded pipe pile or sheet pile
Keep necessary strength and protected by high
alkaline concrete
Reinforcement and
protection of sheet piles
Reinforcement and
protection steel pile
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Corrosion , Protection and
Repairing of
Harbor Steel Structure
THE END
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