Corrosion phenomena and corrosion

protection of steel structure in marine

JFE steel corporation
2016/07/13

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1. Fundamentals of corrosion phenomena

2. Corrosion & corrosion protection method

under marine environment

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Fundamentals of Corrosion Phenomena

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Corrosion phenomena under neutral fresh water

Corrosion : electrochemical reaction on surface

O2
Fe2+
OH-
Water layer

e-
I
Anodic reaction Cathodic reaction
Fe Fe2+ +2e- O2+2H2O+4e- 4OH-

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Under neutral environment, Corrosion rate of steel was controlled
by diffusion of oxygen to cathodic reaction site.

Corrosion rate is calculated by Equation below,

CO 2
I z F DO 2 20A / cm 0.2mm / y
2

ICorrosion current density A/cm2)
Z: number of electrons per corrosion reaction (4)
Generally, Corrosion rate in
FFaraday constant105 C/mol), Fresh water shows 0.1mm/y.
DO2:diffusion coefficient of dissolved oxygen (10-5 cm/s),
CO2: concentration of dissolved oxygen 2.510-7mol/cm3)
thickness of oxygen diffusion layer (510-2cm)

O2 Corrosion rust layer works to

O2 Rust layer prevent oxygen diffusion.

Steel Steel
0.2mm/y 0.1mm/y 5
The effect of pH in water for corrosion rate*
0.04
Usual soil in Japan
Corrosion rate (inch/y)
0.03 Sea water in Japan

0.02

0.01

0
14 12 10 8 6 4 2
pH
Low pH (<4) causes high corrosion rate
*G.W. Whitman, R.P. Russel, V.J. Altieri: Ind. Eng. Chem., 16, 665 (1924).
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Steel corrosion in marine environment
and corrosion protection method

Steel pipe piles damaged Steel Sheet piles damaged

by corrosion by corrosion
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Factors influencing corrosion in sea water

(1) Component of dissolution

(2) Dissolved oxygen
(3) Sea water flow
(4) Temperature
(5) pH
(6) Difference of corrosion environment

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 Environment and corrosion tendency *
* CDIT
marine atmosphere
(0.020.05mmy)
Splash zone (0.30.5mm/y)
M.H.W.L
Tidal zone (0.10.3mm/y)
M.L.W.L
Submerged zone (0.10.2mm/y)

Sea bottom level Sea bottom(0.03mm/y)

Corrosion Rate
Important area for corrosion protection
High corrosion rate: Wet & Dry (very thin water layer)
Concentrated corrosion 9
 Concentrated corrosion * * CDIT

Accelerated Low Water Corrosion ALWC

Steel structure

M.H.W.L)
Taidal Rich Oxygen
zone (cathodic)
(M.L.W.L) corrosion

Poor Oxygen
(anodic)
0 0.1 0.2 0.3 0.4
Corrosion rate (mm/y) 10
 Damage of the steel pipe piles
-Piled Pier-
Load

M.L.W.L M.L.W.L
M.L.W.L

Hole by concentrated Collapse piled pier

corrosion under tidal
zone

Corrosion protection
Cathodic Protection, Organic Coating
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Corrosion protection method in marine environment
Zone Corrosion Protection Method

Marine Painting
atmosphere Lining (Organic, Inorganic (Metal, Mortar))
Splash zone Lining (Organic, Inorganic (Metal, Mortar))
Petrolatum coating and cover system
Tidal zone Lining (Organic, Inorganic (Metal, Mortar))
Petrolatum coating and cover system
Under the sea Lining (Organic, Inorganic (Metal, Mortar))
Cathodic Protection (Zinc anode)
Under the soil Cathodic Protection (Zinc anode)
Corrosion Allowance (0.020.03mm/y)
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The Standard corrosion-protection system in JAPAN*
* CDIT

(A) (B)

Coating
Splash
zone
H.W.L.
Tidal

allowance
M.L.W.L.
zone L.W.L.

Corrosion
Under L.W.L1m

Protection
the sea

Under Cathodic
the soil

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Heavy duty organic Lining (Polyethylene,Polyurethane)

Surface treatment layer

Adhesive layer
Lining layer
(Polyethylene or Coating durability:
Polyurethane ) more than 30 years
(more than 2.0mm) for steel pipe pile

Polyethylene coated steel pipe pile Polyethylene coated steel sheet pile
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 High durability metal lining
(Titanium, high grade stainless steel)
Coating durability: more than 50years

Application for high grade stainless

Application for Titanium clad Steel coating (welded type) to jacket
coating to bridge pier type steel structure 15
 Petrolatum coating and cover system
Simple surface preparation
Can be installed underwater

Sealing Repair existing

Prepared surface structure
Primer
Petrolatum-type corrosion protection material
Protection cover (FRP, Titanium, SUS)
Fixed bolt and nut

Expected life span for corrosion protection: more than 20years

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 Cathodic protection
Steel Cathodic protection is effective at the region
structure under the sea and in the soil.
This is not effective at tidal and splash zone.
M.L.W.L
Mechanism
Metal ionization tendency
O2+2H2O+4e- 4OH- Fe<<Zn, Al
e- Zn2+ Zinc acts as the anode of the
electrochemical cell and then corrodes
ZnZn2+ +e- instead of the protected steel.
Zinc, Aluminum anode
e- Anode size is designed according to life
such as 30years or more.
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 Cathodic Protection Standard* and merit in Japan
* CDIT
Cathodic protection Standard for marine environment
Electrode potential(mV vs SCE)
Environment Steel only Steel + coating (Paint)
General <770 770
Pollution <900 But,minimum
Intense current <770 1050

Sample of Aluminum anode

Zinc Anode on the existing
steel structures
Merits of Galvanic anode system
1. Easy to maintain
2. Suited to long term prevention
(Anode lifespan can be freely set up)
3. Easy to construct
4. Applicable to small isolated facilities
5. Relatively cheap life cycle cost
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 Long span exposure test for marine environment in Japan
Hazaki (faced on pacific ocean)
Suruga bay (faced to pacific ocean) (1984 (1984

General marine Intense billow

environment

ISO corrosion category(C4) Okinotorishima island (1988

Torrid zone

Tokyo bay (Chiba,) Ajigaura

19791989) (Faced on pacific ocean)
(19781998)
Moderate inner bay
Intense billow
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Relative cost and life span of corrosion protection coating
(example)
Corrosion Coating materials Coating Life span Initial Initial Suitable
Protection Thickness of corrosion or cost of environment
Coating (m) protection Repair coating

Painting Zinc paint (thick type)+Epoxy 75480 Initial atmospheric

Zinc paint (thick type)+Tar-Epoxy 75200 Initial atmospheric
Organic Polyethylene 2000 Initial All region
lining Polyurethane 2000 Initial All region
Super thick Epoxy 2000 Initial All region
Super thick Epoxy 5000 Repair Tidal, splash,
(under water hardening type) under water
Concrete Mortal (Concrete) More than Repair Tidal, splash,
lining 100mm
Petrolatum+ Petrolatum-type corrosion protection Cover3mm Initial Tidal, splash
cover material + Cover (FRP) Petrolatum or
method 23mm Repair
Anti- Titanium Clad 2.0mm initial All region
corrosion
High grade stainless steel 0.4mm initial All region
metal lining
(P.I.>38

Life span of corrosion protection :50years:30years, :20years

Initial cost Cheap Reasonable Expensive 20
Comparison of exposure test results
between Japan and Philippine

Exposure test in Phillipine

Japan Philippine*
Corrosion rate 0.1mm/y 0.150.2mm/y
Cathodic Effective Effective
protection (anode life was shorter )
Paint, lining Effective Effective
(Almost same as Japan)
*JASPP 21
 Why? Heavy duty polyurethane coating
High resistance coating
(prevention to diffuse corrosion factors to steel surface)
High Impact resistance against mechanical shock
High weatherability against U.V.
Easy repair
AC resistance (cm2)

Exposure test period (year)

Fig. AC resistance of polyurethane coating after long term exposure test*22
*JISF
 Weatherbility of polyurethane coating

Tensile strength (kgf/cm2)

Tensile strength
Elongation
Elongation(%),

Irradiation time of sun-shine weather meter (H)

Irradiation time 200H1year

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 Weatherbility of polyurethane coating
Initial coating thickness: 2.0mm
coating thickness after 50years :1.84mm (90% remain)
Coating thickness loss (m)

3.3m/200H (1year)

Irradiation time of sun-shine weather meter (H)

Irradiation time 200H1year

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Repair of damage for heavy duty coatings*
Coating defect Polyethylene coating Polyurethane coating

Steel
More than 1mm
No Repair
Heat and melting Touch up painting for
Under 1mm adhesion for small Polyurethane, Epoxy type
polyethylene sheet paint (very easy)
Steel

Large area (3060cm) Heat contraction (under water)

polyethylene tube epoxy (water hardening )
paint
Steel

larger area defect Petrolatum coating and cover system

(More than 1m)
*JASPP
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 Introduction of newly established
Spiral Steel Company
1995: Registration by Hyundai Group
1997: Plant Operation Start
2010 : Owned by Japanese shareholders:
JFE Steel Corp. 35% Maruichi Steel Tube Ltd. 30%
Sun Steel JSC. 5% Toyota Tsusho Corp 30%

Item Description
Factory Land Area 60,000 m2
Production Capacity 50,000 tons/year
OD. 400 - 3,000 mm
Production Range
Thickness 6-25 mm
Available Steel pipe pile,Steel Sheet pile,
Products Water pile, Casing for bored pile
(also heavy duty coating)
. Plant Facilities & Products of JSP 26
Heavy duty polyurethane coating
Polyurethane coating
at J-Spiral steel pipe pile

Polyurethane coated steel pipe pile

before shipment
Inspection
(coating thickness and so on)
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Thank you very much
for your attention.

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