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Corrosion and Protection for Steel pile

Yoshikazu Akira, Dr. Eng.


Researcher Port and Airport Research Institute Email: akira@pari.go.jp

Independent Administrative Institution

Port and Airport Research Institute


Aiming for technologies that can contribute to the world
Its primary goal is facilitating the smooth and efficient construction of port and airports. Another major goal is researching, developing, and improving technologies for constructing ports and airports.

Research fields (2006-2011)


n Research on infrastructure for homeland security n Research for the creation of a comfortable and beautiful homeland n Research on infrastructures for a vigorous society and economy

Independent Administrative Institution

Port and Airport Research Institute


Materials group

Long-term exposure test pier in Hasaki (1984~) Exposure test site in PARI (1964~) n n n n Corrosion and corrosion protection of steel structures Durability of materials Maintenance of port and airport facilities Others

Contents
n Corrosion of steel Corrosion Mechanism of Steel Corrosion of steel in under ground Environment Corrosion of steel in marine environment n Corrosion Protection of steel Structures Corrosion control using thickness allowance for corrosion protection methods

Port facilities - Landing pier

Airport facilities - D runway in HANEDA airport

1100m

2020m

Pier (Jacket)

reclamation

Titanium Cover Stainless steel coating


(PRE:44~, Thickness:0.4mm)

http://www.pa.ktr.mlit.go.jp/haneda.html

Design service life: 100 years

Cathodic protection
(Galvanic anode method, Al Alloy) Corrosion Protection of Steel Structures

Corrosion Mechanism of Steel (1)


Neutrality environment Fe(OH)2 H2O+1/2O2 2OH2eSteel Fe2+ Fe(OH)2 Fe2+ 2OH2eH2O+1/2O2

cathode

anode

cathode

Corrosion Mechanism of Steel (1)


Neutrality environment Fe(OH)2 H2O+1/2O2 2OH2eSteel Dissolved Oxygen Temperature Fluid velocity cathode etc Fe2+ Fe(OH)2 Fe2+ 2OHH2O+1/2O2

Influence 2e- of environment

cathode

anode

Deterioration case of steel pipe pile

Corrosion environments and corrosion tendencies in marine environment


Corrosion rate
Mean High Water Level (MHWL) Mean Sea Level(MSL) Mean Low Water Level (MLWL)
Sea bottom

(Without corrosion protection) 1. Marine atmosphere < 0.1 mm/year 2. Splash zone 0.3 mm/year 3. Tidal zone 0.1-0.3 mm/year 4. Submerged zone 0.1-0.2 mm/year 5. Below the Sea bottom 0.03 mm/year

Concentrated Corrosion Occurrence at just below MLWL

Depth

Mechanism of concentrated corrosion under marine environment


Macro cell corrosion is caused by the difference of the Dissolved Oxygen (DO) concentration. Anode Cathode Splash zone Tidal zone Submerged zone Cathode Anode DO : low DO : high : : Fe Fe2+ + 2e(Corrosion) 4OH-

O2 + 2H2O +4e-

Applicable protection methods for port steel structures


Marine atmosphere Splash zone Tidal zone M.L.W.L. M.L.W.L. -1m
Protective coating Cathodic protection Protective coating Cathodic protection Protective coating

Submerged zone

Below the sea bottom

non

Corrosion Mechanism of Steel (2)


SO42SRB H2 2H+ 2eSteel S2Fe2+ FeS Non DO environment
Microbiologically Influenced Corrosion

SRB: Sulfate- Reducing Bacteria

Corrosion Mechanism of Steel (2)


SO42SRB H2 2H+ 2eSteel S2Fe2+ FeS Influence of environment SRB Sulfate, SO42etc Non DO environment
Microbiologically Influenced Corrosion

SRB: Sulfate- Reducing Bacteria

Kind of bacteria related corrosion in soil


Bacteria
Classification Inhabiting environment pH Nourishment

SRB
Sulfate-reducing bacteria

MPB
MethaneProducing Bacteria

IOB
Iron- Oxidation Bacteria

SOB
Sulfur- Oxidation Bacteria

IB
Iron Bacteria

Anaerobic bacteria Clay, Sludge, Reclaimed ground, rust etc 5.0 ~ 9.5 SO42Lactic acid Reducing SO42- to S2Neutrality Acetic acid Reacting methane Acid environment of sulfuric acid 2.0 ~ 2.5 Fe2+ Oxidizing Fe2+ to Fe3+

Aerobic bacteria Soil, Oil field, Groundwater Sulfur that contains deposit, Fe and Mn Sewage 2.0 ~ 3.5 S, FeS Oxidizing S or FeS to sulfuric acid 6~8 Fe2+, Mn2+ HCO3-, CO32Oxidizing Fe(OH)2 to FeOOH or Fe3O4

Reaction

Microbiologically Influenced Corrosion


Exposure environment: Artificial sewage
Glucose (NH4)SO4 KH2PO4 MgSO4-7H2O CaCl2-2H2O FeCl3 (mg/L) 250 142 15.0 11.3 1.4 0.1

Corrosion of Steel in under ground Environment


p Uneven environment due to stir soil p Existing groundwater p Connected to RC structures p Variation of kinds of soil
ex. Moisture, Humidity and Soil quality

Corrosion rate of Steel in under ground Environment


Average of corrosion rate (mm/yr)

Protection of rust layer


Fig. 6.3.2

For rust covers penetration of O2 and H2O, corrosion rate has decreased with a lapse of time

Exposure time (years)


Refer: S. Moriya, S. Murase, K. Nakano, The statistical investigation into corrosion loss of the steel pope pile and sheet pipe pile under ground environment, Search for Civil Engineering Journal, 47-3, 2005 (Japanese)

Corrosion loss of Steel in under ground Environment


Average of corrosion loss (mm/yr)

Poor condition of O2
(99.7%) (95.5%) (68.3%) Ave.

O2 Supplied - from penetration from ground due to air - from rain or groundwater Amount of dissolved oxygen decrease, as depth from ground deep

Service time (years)


Ref. S. Moriya, S. Murase, K. Nakano, The statistical investigation into corrosion loss of the steel pope pile and sheet pipe pile under ground environment, Search for Civil Engineering Journal, 47-3, 2005 (Japanese)

Corrosion loss of Steel in under ground Environment


Average of corrosion loss (mm/yr)

Poor condition of O2
(99.7%) (95.5%) (68.3%) Ave.

O2 Supplied - from penetration from ground due to air - from rain or groundwater Amount of dissolved oxygen decrease, as depth from ground deep

Service time (years)

Weight loss of steel due to corrosion after 100 years in common Ref. S. Moriya, S. Murase, K. Nakano, The statistical investigation into corrosion loss of the steel pope pile and sheet pipe pile condition in soil environment was predicted about 1mm
under ground environment, Search for Civil Engineering Journal, 47-3, 2005 (Japanese)

Other Factor of Corrosion in Soil Environment


Potential of Hydrogen (pH) in soil
pH less than 4 : Heavy corrosion Organic acid (ex. Humic acid) : Heavy corrosion ?? Alkalinity environment : no influence

Microbiologically Influenced Corrosion Constituents of soil


CO2, SO2, HS : accelerating corrosion Chloride ion, Sulfate : accelerating corrosion PO43-, SiO32-, CO32-: reducing corrosion

Example of result of investigation (1)


Investigation of corrosion in PWRI
Exposure time: 17 years
-5 0 Corrosion rate (mm/yr) 0.01 0.02 0.03 0.003 0.009 0.024 0.024

Protection method 0.2m~ : painting ~0.2m : no protection

0 5

0.002 10 15 0.004 20 25 30 35 40 0.001 0.002 0.003

hardly corrodes

Example of result of investigation (2)


Corrosion rate (mm/yr) Both sides

One side : 0.0053 mm/yr

Example of result of investigation (2)


Corrosion rate (mm/yr) Both sides
Depth of ground surface (m)

10years

2years 5years

Standard of corrosion control


n Civil (Brige)

Standard of corrosion control


n Civil (Brige)

Standard of corrosion control


n architecture (Building)

Standard of corrosion control


n Civil (Port)

Standard of corrosion control


n Civil (Port)

Standard of corrosion control


n Civil (River)

Other index
n Relationship between resistivity of soil and corrosion rate
Corrosion rate Very high High Medium small Very small Resistivity of soil (ohm cm) 0 ~ 500 500 ~ 1000 1000 ~ 2000 2000 ~ 10000 10000 <

Countermeasure of corrosion (corrosion protection method)


Countermeasure Protection method Coating protection Cathodic protection Inorganic coating Combined coating Organic coating Painting Organic coating Metallic coating Mortar coating

Using anti-corrosion material Environment control Corrosion control using thickness allowance for corrosion

Countermeasure of corrosion (corrosion protection method)


Countermeasure Protection method Coating protection Cathodic protection Inorganic coating Combined coating Organic coating Painting Organic coating Metallic coating Mortar coating

Using anti-corrosion material Environment control Corrosion control using thickness allowance for corrosion

Painting
The ease of application Possible to apply to new and established structures Structural service life : several more than 10 years

20 years exposure Need of repair for long-term use

Heavy protective painting system


Primer Middle coat Top coat Zinc rich paint Epoxy, Polyurethane, Polyester, (tar-epoxy) etc. Polyurethane, Silicon, Fluoride paint

Organic coating
Underwater organic coating
Construction by underwater paint

Polyethylene lining
special surface treatment

steel adhesive polyethylene Only applicable to newly-constructed structures

Polyethylene lining

Inorganic coating mortar coating


An example of Mortar / FRP cover method
Structure

FRP cover

Mortar

FRP cover

Inorganic coating electro-deposition


Local energy wind force wave force solar power Power supply
DC power

Electrocoating CaCO3 Mg(OH)2

Structure

Seawater

Ca2+ anode Mg2+

Inorganic coating metallic coating


Covering steel with high corrosion resistance material ex. Titanium, Stainless steel Classifications for this method Titanium coating Stainless steel coating Titanium clad Stainless steel clad Thermal spraying Tokyo-bay Aqua Line (Route 409) (Al, Zn, Al-Zn alloy ) Plating (Al, Zn)
Al Zn FUKUYAMA port 12years HANEDA airport

Cathodic protection
Galvanic anode method Impressed current method

DC Power Source MLWL 1m

MLWL

HWL
Anode (Al, Zn, Mg )

HWL
Insoluble anode

Protective Current Protective Current

Finally

Detailed specification design

Performance based design


n Structural performance n Durability Corrosion of steel Maintenance based design of steel structures

Life Cycle Management System


Maintenance planning
History of utilization

Regular inspection
Designing and environmental condition

Input & reference

Database
Input & reference Inspection Prediction Countermeasure

Performance evaluation
performance

time

Remaining service life and future utilizing plan

Input & reference

Proposal on countermeasures

LCM System
Optimization of management and reduction of LCC

Book on corrosion protection of steel pipe pile


Title: Undecided Authors: Joint research group
Dr. Hamada Dr. Abe Mr. Shimizu Dr. Akira et al

Publication is scheduled in March, 2010.

Thank you very much for your kind attention

Technical Standard and Commentaries for Port and Harbour Facilities in Japan
It was revised in 2007. Shifted from specification design to performance based design
The demanded performance should keep being satisfied for the design service life. Appropriate design Appropriate construction Appropriate maintenance Materials It is necessary to select the using material in consideration of the quality, durability and economy.

Corrosion protection and repair of port steel structures


It will be revised in 2009. Shifted from specification design to performance based design Contents
n n n n n n Corrosion of steel under marine environment Note on selection of corrosion protection methods Design of protection methods Construction of protection methods Maintenance and repair of protection methods Repair and reinforcement of steel structures

Maintenance and repair of port facilities


It was issued in 2007. Contents
n Maintenance planning n Maintenance and repair based on Life cycle management n Inspection n Performance evaluation n Prediction of deterioration n Countermeasure

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