Control of Corrosion on Underwater Piles

CHAPTER 1

INTRODUCTION

1. INTRODUCTION:

Corrosion is the destruction of metals and alloys by the chemical reaction with
the environment. During corrosion the metals are converted to metallic compounds at
the surface and these compounds wears away as corrosion product. Hence corrosion
may be regarded as the reverse process of extraction of metals from ore.

Corrosion and in particular corrosion of metal structures, is a problem that must

regularly be addressed in a wide variety of areas, for example, in the automotive
industry, metal parts are often plated or coated to protect them from road salt and
moisture in hopes of increasing their longevity. Indeed, many traditional metal parts
are currently being used with polymeric components, which are not only lighter but
also more cost effective to produce. But these are generally impervious to
electrochemical corrosion often experienced by metals. Even with the proper selection
of base metals and well-designed systems or structures, there is
no absolute way to eliminate all corrosion. Therefore, corrosion protection methods
are used to additionally mitigate and control the effects of corrosion. Corrosion
protection can be in a number of different forms/strategies with perhaps multiple
methods applied in severe environments. Forms of corrosion protection include the
use of inhibitors, surface treatments, coatings and sealants, cathodic protection and
anodic protection.

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CHAPTER 2

LITERATURE REVIEW

[1]. DIVYA PACHAURI: Structures that are utilized for the exchange of burdens from
the superstructure to the sub surface strata are known as Foundation.

Furthermore, Piles are a sort of establishment. For water powered structure, for
example, spans, dams, and so on or for surfaces having high water content, the heaps
are crashed into the ground and under the water strata. Heaps typically utilized as a
part of submerged structures are subjected to consumption. Erosion decreases the
structures steadiness and life span.

There is positively no technique for disposal of erosion; yet consumption security

measures can be utilized for controlling the impacts of consumption. Erosion security
should be possible in various routes, contingent upon the earth and other air and
hydrological factors. Kinds of erosion security incorporate – treatment of surfaces, use
of inhibitors, utilization of coatings and sealants, cathodic and anodic assurance.

[2] Abhishek Jain, Dr. Trilok Gupta and Dr. Ravi K. Sharma

Structures that are utilized for the Exchange of burdens from the superstructure to the
sub surface strata are known as Foundation. What's more, Piles are a sort of
establishment. For water powered structure, for example, spans, dams, and so forth
or for surfaces having high water content, the heaps are crashed into the ground and
under the water strata.

Heaps ordinarily utilized as a part of submerged structures are subjected to erosion.

Erosion decreases the structures security and life span. There is positively no
technique for end of erosion; yet consumption security measures can be utilized for
controlling the impacts of consumption. Erosion assurance should be possible in
various routes, contingent upon the earth and other air and hydrological factors. Kinds
of consumption insurance incorporate – treatment of surfaces, usage of inhibitors,
utilization of coatings and sealants, cathodic and anodic security

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CHAPTER 3

CORROSION OF STEEL

3.1 Corrosion Mechanism of Steel in Sea Water:

On steel piling in seawater, the more chemically active surface areas (anodes)
are metallically coupled through the piling itself to the less chemically active surface
areas (cathodes) resulting in a flow of electricity and corrosion of the anodic areas.
General surface roughening occurs when these local anodic and cathodic areas
continually shift about randomly during the corrosion process. Sometimes these active
local areas do not shift position end, therefore, the metal suffers localized attack and
pitting occurs. In general, the depth of pitting is related to the ratio of the anodic sites
to the area of cathodic site in contact with the electrolyte (seawater). The smaller the
anode area relative to the cathode area, the deeper the pitting.

3.2 Zones of Corrosion of Steel Piles:

Examination of corroded marine piles reveals several distinct areas of attack.

It is convenient to divide these areas into five zones, each having a characteristic
corrosion rate as shown in Fig 3.1

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Fig 3.1 zone of corrosion of steel plates

3.3 Corrosion Management

Before deciding on the methods for control of corrosion to be applied,

conceptual and feasibility studies have been carried out. Typically, corrosion
management can be divided into three major phases.

Phase 1 of the program is the programmatic assessment of the project. This

phase is the planning stage for a corrosion management program to take place. It
initiates the program to be implemented on structures that are found to be under the
threat of corrosion. For the planning stage, three main requirements are sought,
namely the strategy, budget and schedule needed to overcome the problem raised
from corrosion of reinforcement. This is seen as an important part for an effective

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management program as feasibility studies are normally conducted to determine the

serviceability of the structure after treatment.

Phase 2 of the program involves physical assessment and actual remediation.

Inspections for severity of corrosion are conducted in this phase to determine what
strategy or methods are most suitable to be applied. Development of corrosion control
strategy would present more option to the management program. Remedial work
would be carried out once the proper strategy has been recognized.

Phase 3 of the program mainly deals with future monitoring of the repaired
structure. Currently and historically, most of the corrosion control programs are driven
by response to incident or urgent need, rather than systematically identifying and
managing the existing resources. This can be overcome by implementing internal or
external monitoring system using current technology practiced in oil and gas industries
is as shown in Fig. 3.2.

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Fig.3.3 The overall flowchart for an effective corrosion management program

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CHAPTER 4

CORROSION PROTECTION METHODS

4.1 Protective Coating:

In order to protect metals from corrosion, the contact between the metal and
the corrosive environment is to be cut off. This is done by coating the surface of metals
with a continuous non-porous material inert to the corrosive atmosphere.

Surface coatings are broadly classified into three

a). Metallic coatings

b). Inorganic Coatings

c). Organic Coatings

Individual coatings are formulated to perform specific functions and must be

selected to become components of a total system designed for optimum results
considering the environment and service expectations.

The different types of coatings used for under water piles are:

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4.1.1 Inorganic Zinc Silicates Primers:

Steel structures that are permanently immersed in sea water, such as jackets in the
area below the Splash Zone, are typically not coated for various reasons and protected
solely by cathode protection systems consisting of sacrificial anodes or impressed
current arrays, which can be maintained as required by underwater contractors.
Various anticorrosive pigmented primers are available, some that passivate the steel
but the most effective are inorganic zinc silicate primers which essentially become
anodic to the steel in a corrosion cycle. The primary advantage of this type of coating
is that it will arrest rust creep, or undercutting of the coatings surrounding the damaged
area, and confine corrosion to the point of the damage. These coatings also provide a
high degree of resistance to heat and chemical spills.

4.1.2 High Build Epoxy Coatings:

Epoxies are generally more abrasion and chemical resistant than primers and topcoats
and, in this case, protect not only the substrate itself, but the zinc primer as well from
all of these detrimental factors. However, one drawback with epoxy coatings is very
poor resistance to ultra violet from sunlight and most will chalk and fade rapidly. This
leads to an erosion of the coatings’ film thickness, reducing the barrier protection of
the system.

4.1.3 Aliphatic Polyurethane Topcoats:

Polyurethane finish coats are generally acknowledged as providing optimum

resistance to UV and high degrees of flexibility and chemical resistance. They also
help to maintain a very high level of cosmetic gloss and colour retention and can be

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cleaned very easily, generally with low pH detergents and fresh water pressure
washing. Although polyurethane finishes offer no real anticorrosive or barrier
protection to the substrate, they do provide a high level of protection to the integrity of
the coatings system.

4.1.4 Zinc Rich Epoxy Primers:

Zinc modified epoxy anticorrosive will provide a high level of service and are more
tolerant to compromised surface preparation and ambient weather conditions provided
the zinc loading of the formula is sufficient. Zinc rich epoxy is also most effective in
maintaining damaged areas and breakdown of the coatings systems applied at new
construction as it is compatible with alternate methods of surface preparation such as
power tool cleaning and UHP Hydro Blasting.

4.1.5 Non-Skid Deck Coatings:

Coatings specifically designed with anti-slip properties normally incorporate very

course aggregates for an exaggerated profile. They are applied in very high film builds
and normally without a zinc rich primer. When primers are required, they are usually
epoxy types.

4.2 Cathodic Protection:

The preferred technique for mitigating marine corrosion, based on historical

performance and measurable results, is cathodic protection (CP) - the practice of
using electrochemical reactions to prevent the corrosion of steel structures. The

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reason for increased acceptance: cathodic protection prevents corrosion on

underwater structures.

In theory and practice, the implementation of a CP system is quite simple.

Assuming you already have corroding steel in seawater, all you need is an anode, a
power supply, and engineering talent. A protective circuit is accomplished between the
anode, steel (cathode), power supply and electrolyte (seawater).

4.3 A TYPICAL ANODE DELIVERY SYSTEM:

Fig. 3.1 Pile mounted anode

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4.3.1 Pile Mounted Anodes:

Pile mounted anodes are designed for efficient current distribution in and around
pilings where the complex geometry of the facility precludes remote placement of the
anodes. These delivery systems are suitable for direct attachment to pilings. The Flat
Back Pile Mounted Anode was designed specifically for H-Piles, and can also be
configured for installation on sheet piling.

4.3.2 Disk Anode:

The disk anode was designed in conjunction with the U.S. Army Construction
Engineering Research Lab for use on navigational locks and dam gates. This anode
system is also suitable for use on seawater intake structures, vessel internals, and
sheet piling when shore side access is possible.

4.3.3 Retractable Mount:

Fig. 3.2 Retractable mount

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For installations where it is deemed necessary to access the anode for periodic
maintenance, or when current is only required on a periodic basis, the retractable
anode allows the user to easily retrieve the anode. The above illustration is rotated
by 90 degrees.

4.3.4 Sled Anode:

Anodes mounted on the sea bed typically afford the best spread of protection on a
marine structure. Sled anodes can be designed for operation in either seawater or
buried in the mud. The Post Tension Sled was developed to ensure anode
operation out of the mud when resting in silty and soft sea beds. By adjusting the
height of the concrete sled, the mesh anode sled can also be designed for
operation out of the mud. The advantage of this type of sled is its low profile,
thereby limiting the potential for, damage by anchors fishing nets, etc.

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Fig. 3.3 Sled anode

4.3.5 Suspension Anodes

Suspension Anode Delivery Systems allow for strategic placement of anodes in and
around a marine facility, providing optimum distribution of current. Many suspended
anode systems are also suitable for mounting on pilings, or other structural steel.

Fig 3.4 Suspension anode

2 4.3.6 Rod Anode

Although incorporated into a variety of anode delivery systems, the rod anode is most
commonly used for the cathodic protection of seawater intake structures and vessel
internals.

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4.4 Application of FRP Composites:

Fibre reinforced polymers (FRP) have long been used for the repair and retrofit
of concrete structural elements. Their lightweight, high strength and resistance to
chemicals offer obvious benefits. In fabric form, they provide unparallel flexibility.
Moreover, as fibres can be oriented in any direction, their use can be optimized. This
makes FRP particularly suited for emergency repairs where damage can be multi-
directional and speed of strength restoration critically important.

Fig 4.5 Repair and retrofit of concrete structural elements using FRP composites

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The emergence of new adhesives that allow FRP to be bonded to wet concrete
surfaces makes it possible to economically conduct emergency repairs on sub-
structure elements. Fig.4.6 shows impact damage that led to both cross-section loss
and breakage of the spiral ties. Conventional repairs will require the cross-section to
be enlarged to accommodate new ties. If instead, FRP were used it would only be
necessary to re-form the cross-section and apply bi-directional layers that could
restore lost tensile capacity while providing equivalent lateral support to the
longitudinal steel. Moreover, the application of a protective UV (ultra-violet) coating on
the wrap of the right colour will render the repaired pile indistinguishable from other
undamaged piles. The aesthetics of FRP repair is one of its unheralded benefits.

Fig.4.6 Impact damage that led to both cross-section loss and breakage of the spiral
ties

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4.5 Case Study for Application of FRP Composites

4.5.1 Allen Creek Bridge

Allen Creek Bridge is located on the busy US 19 highway connecting Clearwater

and St. Petersburg, FL. The original bridge built in 1950 was supported on reinforced
concrete piles driven into Allen Creek. In 1982, the bridge was widened and this new
section was supported on 35 cm (14 in.) square prestressed piles.

The waters from Allen Creek flow east into Old Tampa Bay that in turn joins
then Gulf of Mexico to the south. The environment is very aggressive; all the
reinforced concrete piles from the original construction had been rehabilitated
several times. At low tide, the water level in the deepest portion of the creek is about
0.76 m (2.6 ft). Maximum high tide is about 1.89m (6.2 ft). This shallow depth meant
that the underwater wrap could be carried out on a ladder.

➢ Preparatory work

Pile surfaces were covered with marine growth that had to be scraped off.
Additionally, two of the four corners that were not rounded but chamfered had to be
ground using an air-powered grinder. This was a difficult operation particularly for
sections that were below the water line. A quick-setting hydraulic cement was used to
fill any depression, discontinuities and provide a smooth surface. Just prior to wrapping
the entire surface was pressure washed using freshwater to remove all dust and
marine algae.

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➢ Instrumentation

Instrumentation was installed to allow linear polarization and corrosion potential

measurements to be made. An innovative instrumentation scheme was developed that
eliminated the need for wiring and junction boxes. This was an important consideration
since the piles were located in relatively shallow waters that were accessible on foot.
Several piles supporting the structure had been defaced and the probability of
vandalism was very real. FRP wrapping -- Two different schemes using two different
materials were evaluated. In each scheme four piles were wrapped with two other
instrumented piles serving as controls. In the first scheme, cofferdam construction was
used and the piles wrapped using a bi-directional FRP in a wet lay up under dry
conditions. As this was wrapped under ‘perfect’ conditions, its performance provided
means for evaluating piles that were directly wrapped in water using a new water
activated resin The latter scheme was a pre-preg system developed by Air Logistics.
The pre-preg was easy to install since all the material came in labelled hermetically
sealed packets. After applying an initial epoxy layer, the packets were opened
according to the layout scheme and the FRP material applied. A shrinkage wrap was
applied at the end to allow the FRP to cure. On an average, it took between 30 minutes
to 45 minutes to wrap a pile over a 1.5 m depth depending on the number of layers of
material that had to be applied.

4.5.2 Friendship Trails Bridge:

This is the oldest of the Gandy Boulevard bridges crossing Tampa Bay. It was
originally constructed in 1956 and was slated for demolition in 1997. Thanks to
community activists, the bridge was saved, refurbished and rehabilitated. In 1999, the
bridge was re-opened as a pedestrian bridge and re-christened as the “Friendship
Trails Bridge”. The 4.2 km (2.6 mile) structure is now the longest over-water
recreational trail in the world. The bridge has 275 spans supported by 254 reinforced
concrete pile bents and 22 column type piers located at the main channel crossing.

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Seventy seven percent of the 254 piers supporting this bridge have needed to be
repaired indicating that the environment is very aggressive.

➢ Preparatory work

All piles wrapped were 50.8 cm x 50.6 m (20 in. x 20 in.) reinforced concrete piles and
wrapped over a depth of 1.5 m that extended all the way to the underside of the pile
cap. The waters are approximately 4.88 m (16 ft) deep. This meant that ladders could
no longer be used to apply the FRP in this situation. An innovative scaffolding system
was designed and fabricated. It was lightweight, modular yet sufficiently rigid when
assembled to support 4-6 people. The scaffolding was suspended from the pile cap
and extended 2.74 m (9 ft) below. Its mesh flooring provided a secure platform around
the pile that allowed the wrap to be carried out unimpeded in knee deep waters Fig.
3.7.

Fig 3.7 Mesh flooring around piles

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➢ Instrumentation:

Unlike the Allen Creek Bridge where vandalism was a real concern, the piles of the
Friendship Trails Bridge are located in deeper and more turbulent waters. Moreover,
as the majority of the piles supporting this bridge had been repaired and some were
instrumented, the element of novelty was absent making vandalism less likely. In view
of this, an instrumentation system developed by the Florida Department of
Transportation was selected. This required both wiring and junction boxes. The
scheme uses rebar probes Fig. 3.8 that are installed at different elevations close to
the reinforcing steel. Changes in the direction of the corrosion current between these
locations can indicate if the FRP is working as expected. Reductions in the measured
current compared to unwrapped controls were also expected to provide an index of
the efficacy of the FRP wrap. The drawback with this system is that it takes time for
the equilibrium state around the probe to be attained. Until this time, data may not be
meaningful.

Fig. 3.8 Use of rebar probes in instrumentation

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➢ FRP wrapping:

Two different FRP systems were used. One was the same pre-preg system with a
water-activated resin used in the Allen Creek Bridge. The other was Fyfe’s system that
used resins that cure in water. The pre-preg system was used to wrap four piles – two
using carbon and two using glass. The wet-layup system from Fyfe required on-site
saturation of the fibres. Two piles were wrapped with fibreglass using this system. Of
the two, one was an experimental FRP system that combined wrapping with a
sacrificial cathodic protection system. Two other unwrapped piles in a similar initial
state of disrepair were used as controls to evaluate the performance of the wrapped
piles. Application was facilitated through the use of a scaffolding system mentioned
earlier Fig. 3.7.

Fig. 3.9 Wrapping of FRP material around piles

The pre-preg system was applied as in the Allen Creek Bridge and posed no
problems. The Fyfe system was more challenging since the FRP material had to be
saturated on-site. Access to foundations of an adjacent bridge provided a convenient

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staging post for the on-site impregnation Fig. 3.9. On an average the operation took
90 minutes to complete.

Fig. 3.10 On-site saturation, Friendship Trails Bridge, Tampa

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CHAPTER 5

STANDARDS AND CODES

5.1 Standards and Codes

There are no Indian standards codes as such for the control of corrosion. The latest
editions of the following organizations’ standards, codes, and guidelines shall be used
for the design of corrosion control systems:

• NACE International (formerly The National Association of Corrosion

Engineers)

• RP0169 – Control of External Corrosion on Underground or Submerged

Metallic Piping Systems

• American Society for Testing and Materials (ASTM)

• ASTM D512 – Standard Test Methods for Chloride Ion in Water

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• ASTM D516 – Standard Test Method for Sulfate Ion in Water

• ASTM G51 – Standard Test Method for measuring pH of Soil for Use in

Corrosion Testing

• American Railway Engineering and Maintenance-of-Way Association

(AREMA)

• Federal Highway Administration (FHWA)

• Publication FHWA-NHI-00-044 – Corrosion/Degradation of Soil

Reinforcements for Mechanically Stabilized Earth Walls and Reinforced Soil

Slopes

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CHAPTER 6

CONCLUSIONS

6.1 Conclusions:

Though there is no absolute way to eliminate all corrosion on under water piles,
there are some effective measures to control them. The cathodic protection is found
to be quite simple to employ and mostly used in marine conditions. The protective
coatings are used in vast and expensive structures. The FRP composites have many
advantages over conventional methods such that they are light weight, possess high
strength and chemical resistance and moreover have incomparable flexibility.

Of the various ways of wrapping of FRP composites, transverse wrapping is

found to be the easiest as otherwise, the longitudinal pieces are awkward to handle
and difficult to position. Bi-directional material is the best option. Scaffolding measures
during the application of materials ensures safety and simplifies installation. Out of the
two system of FRP application, the pre-preg system is easier to use. On-site FRP
saturation can be problematic. High winds and high tides should be avoided during the
process.

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CHAPTER 7

REFERENCES

7.1 References:

• R. Sen, G. Mullins, K. Suh and D. Winters: ‘FRP application in underwater

repair of corroded pipes’, FRPRCS-7 (the 7th International Symposium on Fiber
Reinforced Polymer Reinforcement for Reinforced Concrete Structures), November 7-
10, 2005 New Orleans Marriott
• http://www.quakewrap.com/frp%20papers/FRPApplicationinUnderwaterRepair
ofCorrodedPiles.pdf

• Underwater steel structures: inspection, repair and maintenance

http://www.corrdefense.org/Technical%20Papers/UNDERWATER%20STEEL%20ST
RUCTURES%20INSPECTION%20REPAIR%20AND%20MAINTENANCE.pdf

• Marine cathodic protection

http://www.farwestcorrosion.com/fwst/anodimpr/elg04.htm

· L. Van Damme, W. Verhulst: ‘Low Water Corrosion Of Steel Pilings’, Pianc Bulletin
No.101,1999.

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