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

--

Protected
Piece

Test Piece

Non Protected
Piece
Um-protected

Fitting level

Surface of test piece

--

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

--

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

--

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
--

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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