Control of Corrosion on Underwater Piles

Chapter 1
INTRODUCTION
1.1 General:

Corrosion means the damage, destruction or elimination of the metals and alloys by the
chemical reaction of the metals and alloys with the environment. During the phase of
corrosion taking place, metals get converted to metallic compounds at the top surface
and these compounds wear or deteriorate away as corrosion product. This process may
also be called as the reverse process of the extraction of metals from their ore.

Fig 1. Corrosion on Underwater Piles

It is a problem that must be addressed for a wider range, for example, the automotive
industry; metals are often plated or coated for protection from road salt and moisture.
Indeed, many traditional metal parts are presently used with polymeric components-
which are not only lighter but are also more cost-effective for production. But these
products are generally impervious to electrochemical corrosion. The selection of the
base metals for piling and well-designed structures will ensure no guarantee for absolute
elimination of corrosion.

Therefore, corrosion protection methods are utilized for mitigation and controlling the
effects of corrosion on piles. Corrosion protection can be established in a number of
different ways with multiple methods applied in different environments. Types of

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corrosion protection include – treatment of surfaces, utilization of inhibitors, use of

coatings and sealants, cathodic and anodic protection.

1.2 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 a localized attack and pitting occurs. In
general, the depth of pitting is related to the ratio of the anodic sites to the area of the
cathodic site in contact with the electrolyte (seawater). The smaller the anode area
relative to the cathode area, the deeper the pitting.

1.3 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 2

Fig 2: Corrosion Zones of Steel Pipes

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1) Tidal – It is an environment where the metals are submerged in the seawater and
then exposed to the splash zone alternately as the tide fluctuates.
2) Submerged – This environment zone is usually characterized by well-aerated
water in combination with the marine bio-fouling organism of animal and the
plant.
3) Atmospheric – It depends upon the temperature, pollutants, time of wetness. It
is also largely responsible for a large fraction of corrosion.
4) Splash – It is characterized as an aerated environment of seawater where the
exposed material is continually wet and there is no attachment of biofouling.

Fig 3: Corrosion rate in Zones

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 Control of Corrosion on Underwater Piles

Chapter 2
Corrosion Management

2.1 Phases of 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.

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 Control of Corrosion on Underwater Piles

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 of an effective 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 the severity of corrosion are conducted in this phase to determine what
strategy or methods are most suitable to be applied. The development of a corrosion
control strategy would present more options 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 an 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 the oil and gas
industries

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2.2 CORROSION PROTECTION METHODS

i. Protective Coating:
For the protection of metals from corrosion, the metal and the corrosive environment
contact is required to be cut off. The surface of metals is coated with a continuous non-
porous material inert to the corrosive atmosphere to prevent it from corrosion.

The coatings are classified into different categories –

a) Organic
b) Metallic
c) Inorganic

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 underwater piles are:

1) Inorganic Zinc Silicate Primers:
Structures (Steel) that are immersed in seawater – jackets below the Splash Zone,
are usually not coated and protected solely by a cathodic protection system.
Many anticorrosive-pigmented primers, some that passivates the steel. Inorganic
zinc silicate primers are the most effective as they essentially become anodic to
the steel in a corrosion process. The advantage of this coating - it will arrest rust
creep, high degree of heat resistance and spills of chemicals.
2) Epoxy Coatings (High Build):
Epoxies in comparison to primers and topcoats are more chemical and abrasion-
resistant. It protects not only the substrate, but also the zinc primer and all other
detrimental factors. One disadvantage of epoxy coatings is that it has very little
resistance against ultraviolet rays from sunlight. This leads to the erosion of the
coatings reducing the barrier protection.
3) Epoxy Primers (Zinc Rich):
Epoxy anticorrosive modified with Zinc will ensure a high level of service and
are tolerant to different weather conditions and compromised surface preparation
provided that the zinc loading is sufficient. It is also most effective in
maintaining the damaged areas.

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4) Aliphatic Polyurethane Topcoats:

Polyurethane coats provide optimum resistance to UV rays and have a high
degree of flexibility and high chemical resistance. It also helps to maintain a high
degree (level) of cosmetic gloss, color retention and it can be easily cleaned.
Polyurethane finishes do not provide any real anti-corrosive or barrier protection,
they do provide a high degree of protection to the integrity of the coatings
system.
5) Non-Skid Deck Coating:
These coatings are that are designed and engineered with anti-slip Properties.
These coatings incorporate coarse aggregates. The coatings are applied in very
high film builds and usually without a zinc-rich primer.

ii. Cathodic Protection (CP):

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 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).

iii. Fibre Reinforced Polymer Composites

Fiber-reinforced polymers (FRP) are used for the repair and rehabilitation of concrete
structural elements. The composites are very light in weight, are resistant to chemicals,
have high strength and in fabric form have a high degree of flexibility. The FRP
composite when mixed with wet concrete makes it economical to conduct repairs on
substructure parts. When the FRP is used, then the corroded part of the structure element
is carefully removed and the FRP composite induced concrete is applied. The FRP
provides the lost tensile capacity and it also provides the steel with lateral support. When
the FRP is applied with concrete, the spreading of corrosion to other piles is protected
and it also ensures protection from UV radiation.

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iv. Anode Delivery System

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.
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 shoreside access is possible.

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3) Retractable Mount

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

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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.
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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Chapter 3
CASE STUDY

3.1 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). The 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.

3.2 Friendship Trails Bridge

Fig 4. Mesh flooring around piles Fig 5. Wrapping of FRP material

around a pile
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 miles) 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

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column-type piers located at the main channel crossing. Seventy-seven percent of the
254 piers supporting this bridge have needed to be repaired indicating that the
environment is very aggressive.

3.3 Gandy Bridge

Fig 6. Scaffolding System, Gandy Fig 7. Underwater Wrapping, Gandy

Bridge Bridge

The Gandy Bridge built-in 1970's connects St. Petersburg to Tampa. The bridge has
approximately 300 piers comprising five or eight prestressed concrete piles with 50.8cm
x 50.8 cm (20 in x 20 in.) cross-section. The original plan was to just wrap one heavily
corroded pile (Fig. 4.5). Later, the scheme was revised to include three piles. An
additional unwrapped but instrumented pile served as control

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SUMMARY

1) Though there is no absolute way to eliminate all corrosion on underwater piles,

there are some effective measures to control them. The cathodic protection is
found to be quite simple to employ and is mostly used in marine conditions. The
protective coatings are used in vast and expensive structures.
2) The FRP composites have many advantages over conventional methods such
that they are lightweight, possess high strength and chemical resistance and have
incomparable flexibility of the various ways of wrapping 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.
3) Scaffolding measures during the application of materials ensure safety and
simplifies installation. Out of the two systems 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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REFERENCES

1) L. Van Damme, W. Vreulst: ‘Low Water Corrosion Of Steel Pilings’, Pianc

Bulletin No.101,1999.
2) Abhishek Jain, Dr. Trilok Gupta and Dr. Ravi K. Sharma, (2016) “Measurement
and Repair Techniques of Corroded Underwater Piles”
3) Divya Pachauri, Saloni Trigunayat, Shubham, (2018) “Control of Corrosion of
Underwater Piles” (February 2018)
4) Kishanrao M. Godbole, Priyadarshi H. Sawant, (2016) “Reinforcement
Corrosion Assessment Through Half – Cell in Concrete Structure Exposed in
Marine Environment.”(Dec 2016)
5) R. Sen, G. Mullins, K. Suh, and D. Winters (2003) “FRP Application in
Underwater Repair of Corroded Piles”
6) Sidhant Agarwala1& Dr. Om Prakash Netula, (2017) “Study of Corrosion
Control of Underwater Piles” (July 2017)

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