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    Corrosion and Protection For Steel Pile: Yoshikazu Akira, Dr. Eng

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    Anand Jadoenathmisier
    1) Steel structures in marine and underground environments are susceptible to corrosion from oxygen and bacteria. 2) Common corrosion protection methods for steel piles and structures include protective coatings, cathodic protection, and using corrosion-resistant materials. 3) Long-term exposure tests have shown that corrosion rates of unprotected steel in soil and marine environments can exceed 1mm per year, threatening structural integrity over a 100-year design life.

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    Corrosion and Protection For Steel Pile: Yoshikazu Akira, Dr. Eng

    Uploaded by

    Anand Jadoenathmisier
    93 views45 pages
    1) Steel structures in marine and underground environments are susceptible to corrosion from oxygen and bacteria. 2) Common corrosion protection methods for steel piles and structures include protective coatings, cathodic protection, and using corrosion-resistant materials. 3) Long-term exposure tests have shown that corrosion rates of unprotected steel in soil and marine environments can exceed 1mm per year, threatening structural integrity over a 100-year design life.

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    Corrosion

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    ALWC Japan

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    1) Steel structures in marine and underground environments are susceptible to corrosion from oxygen and bacteria. 2) Common corrosion protection methods for steel piles and structures include protective coatings, cathodic protection, and using corrosion-resistant materials. 3) Long-term exposure tests have shown that corrosion rates of unprotected steel in soil and marine environments can exceed 1mm per year, threatening structural integrity over a 100-year design life.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    93 views45 pages

    Corrosion and Protection For Steel Pile: Yoshikazu Akira, Dr. Eng

    Uploaded by

    Anand Jadoenathmisier
    1) Steel structures in marine and underground environments are susceptible to corrosion from oxygen and bacteria. 2) Common corrosion protection methods for steel piles and structures include protective coatings, cathodic protection, and using corrosion-resistant materials. 3) Long-term exposure tests have shown that corrosion rates of unprotected steel in soil and marine environments can exceed 1mm per year, threatening structural integrity over a 100-year design life.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
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    of 45

    Corrosion and Protection for Steel pile

    Yoshikazu Akira, Dr. Eng.


    Researcher Port and Airport Research Institute Email: [email protected]

    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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