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Monitoring the corrosion of steel sheet piles by means of ultrasound and

corrosion potential measurements.

Conference Paper · September 2007

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Monitoring the corrosion of steel sheet piles by means of ultrasound and

corrosion potential measurements
M. Bethencourt1,*, J.M. Sánchez-Amaya, L. González-Rovira, F.J. Botana.

Departamento de Ciencia de los Materiales e Ingeniería Metalúrgica y Química Inorgánica,

Universidad de Cádiz, Avd. República Saharaui s/n, Puerto Real-11510, Cádiz (Spain).
*Unidad de Buceo Tecnológico y Científico, CACYTMAR, Universidad de Cádiz, Avd.
República Saharaui s/n, Puerto Real-11510 (Spain). (34) 956-016792.
1
Corresponding author: manuel.bethencourt@uca.es.

Summary

Steel sheet piling is widely used in the construction of many types of maritime structures and
there are, therefore, many kilometres of sheet piling potentially at risk of marine corrosion.
Steel piling was introduced as a successor to cast iron at the beginning of the 20th century, and
consists of hot rolled or cold formed steel sections that can be interlocked to produce
continuous corrugated wall structures, where individual pieces are placed side by side. The
life expectancy of sheet pile structures will be strongly influenced by environmental factors.
Among the natural influences that might affect the useful service life of steel sheet piling
structures, it can be emphasized the damage from impact, overloading, storms, earthquake,
abrasion and corrosion.

This work discusses the application of non destructive techniques (NDT) in the investigation
of the corrosion in two lines of steel sheet pile structures, with and without coating protection,
installed in two harbours of the Bay of Cadiz, Spain. Both ultrasound (US), which allows one
to know the thickness of the sheet pile in different zones, and corrosion potential (Ecorr), were
combined to study the extension and to investigate the cause of the different corrosion
behaviours observed in these structures. The methodology applied and the results obtained
from the combined approach investigation are presented.

Keywords: carbon steel, corrosion control, potential measurements.

1. Introduction.

Structural steel is used in most metal waterfront structures because it is strong, readily
available, easily fabricated into any shape, and not excessively costly. In marine applications,
steel has many uses as a construction material. Steel sheet piling is used primarily as a
retaining wall structure for bulkheads used in the support of piers, wharves, drydocks, and
quaywalls as well as near-water, earth-retaining structures.

There are six major types and causes of steel structure deterioration in the marine
environment: corrosion, abrasion, loosening of structural connections, fatigue, overloading
and loss of original material. Corrosion is the principal cause of deterioration of steel
waterfront structures [1].

Marine environments normally encompass several exposure zones of different

aggressiveness and the corrosion performance of marine structures in these zones requires
separate considerations. Thus, the corrosion rates on steel piling surfaces normally vary

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considerably by zone. The corrosion rate profile for steel sheet piling, averaged for several
harbour installations, is shown in Figure 1 [2]. In general, the maximum reduction in metal
thickness occurs in the splash zone immediately above the mean high water level [3]. A
significant loss usually occurs below mean low water in the continuously submerged zone, at
a lower intensity than the splash zone. With the exception of those few cases where scour is a
factor, the least affected zone is usually found below the mud line, with higher losses at the
water-mudline interface. Another low loss area exists in the tidal zone about halfway between
mean high water and mean low water levels. Where steel sheet piling is exposed to water by
one side, the average corrosion rate varies from 1 to 4.5 mils per year (mpy), reaching
maximums of 3 to 14 mpy. Where both sides of the steel sheet piling is exposed to water, the
total rate of corrosion of the member is doubled. Pitting will cause localized corrosion attack
at 1.5 to 3 times the average rates over an extended exposure period.

Figure 1. Typical profile of the thickness loss resulting from corrosion of an unprotected steel
structure in seawater.

In the present contribution, corrosion of steel sheet piles exposed to marine water over
long periods has been investigated by several systematic long-term tests, Figure 2. Inspection
of underwater facilities involves the application of special skills, equipment and techniques to
examine underwater structures. The inspection requirements are similar to those for other
structures, but the methods differ considerably. The interpretation of data, obtained in this
special medium, is also quite different.

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Figure 2. Steel sheet piles in El Puerto de Santa Maria Quay, after 34 years of exposure.

2. Experimental

This work discusses the application of two non destructive techniques (NDT) in the
investigation of the corrosion in two lines of steel sheet pile structures, with and without
coating protection, installed in two harbours of the Bay of Cadiz, Spain, Figure 3a,b. The
selections quays were:

a) Exterior Quay of El Puerto de Santa Maria, built in three phases: 300 meters in 1973,
320 meters in 1980 and, finally, 150 meters in 1983, with sheet piles of nude steel.

b) La Cabezuela-Puerto Real Quay North: built in 2000: 170 meters, with sheet piles of
treated steel (in situ sand blasting with grade Sa 2.5, primed with epoxy polyamide 80
µm, and epoxy pitch, 300 µm.

Figure 3. (a) Exterior Quay of El Puerto de Santa Maria, (b) La Cabezuela-Puerto Real Quay
North.

In Ultrasonic Inspection (US), the thickness measurements are obtained because

certain types of ultrasonic waves travel at a constant speed through a material, they travel in
straight lines, and a portion of the wave is reflected when it meets an interface. The difference
in time between the detection of the front surface and back surface echoes is correlated to the
thickness of the material. In this work, an Hand Held Multiple Echo Ultrasonic Thickness
Gauge Cygnus 1 Underwater has been employed, Figure 4a. This is a digital ultrasonic
thickness gauge for underwater use, which measures thickness of metals to determine
corrosion or wastage underwater, without having to remove surface coatings.

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For monitoring electrochemical properties it has been employed a Bathycorrometer

Data Sheet H1, Figure 4b, designed to determine the corrosion status of subsea structures. The
bathycorrometer is a diver held corrosion voltmeter and works on a similar principle to the
half-cell except that instead of an earthing lead and a remote multimeter, there is a probe
which is attached to the instrument which must come into contact with the steel surface. The
voltemeter (digital) is housed in the instrument and instead of a porous pot, there is a
diaphragm. The bathycorrometer contains a silver/silver chloride half cell with a silver rod
and Ag+ and Cl- ions in solution inside the half-cell [4]. When the probe touches the steel
surface, a circuit is set up such that ferrous ions outside the instrument alter the distribution of
ions inside the pot as in the half-cell. The relative potential of the steel surface with respect to
the half-cell is measured by the voltmeter and the diver/inspector can read the voltage on the
digital readout.

The data were duplicated by means of the employment of a Patent System [5], Figure
4c. This consists in a housing stems manufactured in stainless steel AISI 316, submersible one
hundred meters, with policarbonate visor that permits to visualize the values of the measures
(pH electrode of flat surface model HI 1001 of Hanna Instruments, connected to a field pH-
meter, model HI 9025 of Hanna, and specific reference electrode Ag/AgCl (+0.262 V vs.
SHE) for the determination of potentials in seawater, connected to a high impedance digital
multi-meter Mastech 890G).

Figure 4. (a) Ultrasonic Thickness Gauge Cygnus 1 Underwater, (b) Bathycorrometer Data
Sheet H, (c) Patented System for Ecorr-pH measurements.

Ultrasonic thickness and corrosion potential measurements require a thorough removal

of marine growth and scale and can be unreliable if the surface on which the instrument is
placed is heavily pitted. To ensure a thorough inspection, the area must be cleared of all
marine growth. This can be done by various procedures, depending on surface support. A
high-pressure water jet is the most effective method for clearing marine growth sufficiently
for visual inspection. Hand tools, such as wire brushes and scrapers are sufficient for smaller
jobs. The structure cleaning can be done with a small hammer or pickax. Inspection of the
structure requires some type of underwater data recording device, such as a grease
pencil/slate, or hardwires communications with topside personnel.

Adequate training and experience are required to obtain readings and to evaluate the
measurements made with these equipments. All the measurements were carry out by means of
divers from the Technical and Scientific Underwater Unit, University of Cadiz, Figure 5a,b
(www.ubtc-cadiz.com).

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Figure 5. Divers from the Technical and Scientific Underwater Unit, working (a) in Exterior
Quay of El Puerto de Santa Maria, with the bathycorrometer (b) in La Cabezuela-Puerto Real
Quay North, with the Ultrasonic Thickness Gauge.

3. Results and Discussion.

In the structures without paint placed in the Exterior Quay of El Puerto de Santa
Maria, typical corrosion damages have been observed. The corrosion rate in the splash zone is
about 0.3 mm/year. The behaviour in the tidal zone is separated in two areas: the corrosion
rate of the area localized between high water level (HWL) and mean sea level (MSL) enlarges
progressively in the upper part from MSL, whereas the zone between MSL and mean low
water level (MLWL) became cathodic in a macro-corrosion cell and the corrosion rate of the
cathode is about 0.1 mm/year. In contrast, the zone between MLWL and low water level
LWL acts as the anode in a macro-corrosion cell and the corrosion rate in this zone is about
0.2 mm/year, but is higher when corrosion products are removed. Corrosion rates about 0.6
mm/year have been detected in this area. Figure 6 shows the tendency (mean and maximum
rates) of the sheet piles in the Exterior Quay of El Puerto de Santa Maria, with a similar
corrosion rate profile to those obtained for eight harbours installations after 19 years of
exposure, recorded by Edwards in 1963 [2]. In general terms, an appropriate reproducibility
was seen on the thickness measurements. However, the standard deviation of the values tend
to increase with the immersion time at which the sheet pile have been exposed.

In some areas, the most severe corrosion attack in the tidal zone is localized in the
portion between MLWL and LWL, and maybe is associated with a process called ALWC
(Accelerated Low Water Corrosion) [6]. ALWC is defined as the localized and aggressive
corrosion phenomenon that typically occurs at or below low-water level and is associated
with microbially induced corrosion. ALWC corrosion rates are typically 0.5 mm/side/year,
mechanism that can lead to complete perforation of steel plate. The problem is usually due to
the growth of bacterial colonies, principally SRBs (Sulphate Reducing Bacteria) which adhere
to the metal surface. SRBs can cause problems due to the corrosive, chemical and
electrochemical processes that occur as they metabolise. ALWC is seen as patches, or
succession of patches, typically in a narrow horizontal band of attack in the critical corrosion
zone, Figure 7. The existence of these colonies is confirmed by the presence of soft orange
coloured (sulphurous) deposits, Figure 8. If these deposits are wiped, a layer of black slime
(Iron Sulphide) is revealed, and bright shiny pits are observed under this layer. The reaction is
associated with the production of hydrogen sulphide gas.

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Figure 6. Sheet pile terminology adapted from Edwards [2] and corrosion rate profile for El
Puerto de Santa Maria harbour after 24 to 34 years’ exposure.

Figure 7. a) Section of marine corrosion product on steel substrate. b) Section of ALWC

patch. Adapted from [6].

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Figure 8. Corrosion patch on steel sheet pile examined in El Puerto de Santa Maria Harbour,
and maybe associated with ALWC.

This type of corrosion above mentioned has become a recurring problem for many
port management authorities worldwide, and appearance of ALWC has been noted in the
literature at the first half of the 20th century. While HLW, MSL and LWL are astronomical
tidal levels, MLWL is an experimentally determined level and approximately equivalent to
half of MSL [7]. The localising of the problem is rarely exposed by tides, and is only
completely exposed on affected steel structures at extreme low spring tides, which may only
occur four or five times a year.

Finally, although the corrosion rate of steel in submerged zone is usually about 0.1
mm/year in the Exterior Quay of El Puerto de Santa Maria, higher rates have been measured
in the absence of oxide layer (Figure 6). The break of the oxide layer could be related with the
high hydrodynamic conditions of the zone. This harbour is situated in the outlet of the
Guadalete River, and it is affected also by the tide processes. When the corrosion product is
removed from a local area, the metal is activated as a strong anode against the rest of steel
pieces with rust. These results are in good agreement with the potential corrosion
measurements, which range between -609 and -645 mV vs Ag/AgCl, showing in the diagram
of Pourbaix that the pile is corroding freely in absence of any passivity film [8].

On the other hand, painted sheet piles placed in Cabezuela-Puerto Real Quay North
didn't showed loss of thickness after seven years on site, and the potential corrosion
measurements, between -175 mV to -343 mV, indicating that the paint is working properly
and the steel is protected [9].

4. Conclusions.

- In the present paper, ultrasound (US) and corrosion potential (Ecorr) measurements
have been applied to study the corrosion degradation degree of different sheet piles.
According to the obtained results, these techniques are appropriate to monitor the
corrosion processes of these structures at different zones.

- The reproducibility of the thickness measurements is generally good, although the

standard deviations tend to increase as the age of the exposed steel increases.

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- The vertical sheet piles studied are exposed to the different marine environments
described in other works: the mud line, total immersion, the tidal zone, the splash
zone, and the marine atmosphere.

- The most severe corrosion occurs in the splash zone, where corrosion rates are
generally more than twice those the immersed portion. In the tidal zone, the corrosion
attack is specially severe in the area between MLWL and LWL, and probably is
associated with ALWC.

- The use of a thick protection coating in Exterior Quay of El Puerto de Santa Maria
involves the absence of corrosion after five years in service.

5. Acknowledgements.

This work has received financial support from the Ministerio de Educación y Ciencia (PETRI
95-0836.OP) and Autoridad Portuaría de la Bahía de Cádiz.

6. References.

[1] J.R. Davis. Corrosion in specific industries and environments, Metals Handbook:
Corrosion, ninth ed., vol 13, ASM International, Metals Park, 1987, 893.
[2] Edwards, W.E., “Marine Corrosion: Its Cause and Care,” Proceedings of the Eighth
Annual Appalachian Underground Corrosion Short Course, Technical Bulletin No. 69,
1963, 486.
[3] S.K. Coburn, Corrosion Factors To Be Considered In The Use Of Steel Piling In Marine
Structures, Pile Buck Inc., Technical Guideline, Palm City, Fla., 10A–18C. 2000.
[4] S.W. Kelly, Underwater Inspection Criteria, Naval Facilities Engineering Center, Port
Hueneme, California, 1999, 43.
[5] M. Bethencourt, F.J. Botana, M. Marcos, P 200201201 (08-09-2005).
[6] M.S. Reid (Research Manager). Management of accelerated low water corrosion in steel
maritime structures. CIRIA, London, 2005.
[7] K. Zen. Corrosion Science, 2005, 47: 10, 2353.
[8] M. Pourbaix. Lecciones de Corrosión Electroquímica. IECP, Madrid, 1987, 1552.
[9] M. Bethencourt, F.J. Botana, M.J. Cano, R.M. Osuna, J.M. Sánchez-Amaya. Simulation of
Electrochemical Processes. WIT Press, 2005, 193.

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