Accelerated Low Water Corrosion

Report of Working Group 44 of the Maritime Navigation Commission

International Navigation Association (PIANC) 2005

General
• Accelerated low water corrosion (ALWC) is the localised and aggressive corrosion
phenomenon that typically occurs at or below low-water level and is associated with
microbially-induced corrosion (MIC).
• ALWC rates are typically 0.5 mm/side/year average.
• ALWC most commonly occurs as a horizontal band around low water, but can be found in
patches and can extend to bed level.
• ALWC is generally recognisable as lightly adherent orange and black corrosion products over
an otherwise clean steel.
• There is no reliable basis for predicting ALWC.
The action of ALWC
• Sulphate sin the marine environment are converted into Hydrogen sulphide (H2S) by
sulphate-reducing bacteria (SRB). H2S causes direct anaerobic corrosion of the steel surface.
• The H2S also serves as food/energy for sulphate-oxidising bacteria (SOB) which convert H2S
into sulphuric acid (H2SO4). The oxidation of H2S by the SOB promotes continuous
electrolysis at the steel surface, which accelerates the standard rusting corrosion process.
• The tidal interface (low-water level) provides acceptable conditions for both SRB and SOB,
i.e. anaerobic conditions for SRB and oxygen availability for SOB. The 0.5 m above LAT is
most susceptible to ALWC.
Corrosion zones
• Atmospheric zone: Above the splash zone. Exposed to salt-laden atmosphere so rusting will
occur.
• Splash Zone: Above MHWS. Because of intermittent wetting, corrosion deposits can be
relatively dry, loosely bonded, exfoliated and quite thick, which may give the misleading
impression that little corrosion has occurred. Corrosion rates in the splash zone can be as
high as in the low-water zone where ALWC is not occurring.
• Tidal zone: Between MLWS and MHWS. Corrosion is usually slow and uniform. Oil and
other pollutants may protect steel. Corrosion rates typically 0.04~0.1 mm/side/year.
• Low water zone: LAT to 0.5 m below MLWS. Corrosion is relatively severe, typically
0.08~0.17 mm/side/year (without ALWS). With ALWC, typically 0.5 mm/side/year, with
>1 mm/side/year reported.
• Immersed zone: Corrosion relatively slow and uniform. Often, piles are passivated by
marine growth or corrosion products. At bed level, differential oxygen cells, scouring that
exposes clean steel and soil-borne SRB can accelerate corrosion. Rates of
0.04~0.13 mm/side/year are typical.
• Embedded zone: Corrosion can typically be regarded as negligible.
Typical locations of ALWC
• U-section sheet piles (Larssen): ALWC occurs on outpan flanges, but where fixed vertical
timber fenders are attached to outpans, ALWC can occur on the adjacent inpans. There is
also potential for attach on tie rods attached near LAT, as is typically due to construction
constraints. The connecting clutches are rarely attacked.
• Z-section sheet piles (Frodingham): ALWC occurs on the outer corners, mostly on the
thinner web section.
• Pipe piles: ALWC can occur anywhere around the circumference, but not evenly.
• Rolled sections: ALWC typically occurs on the ends of flanges of H-piles.
• Combi-walls: The sheet piles between the king piles are typically less noble, so more
susceptible to corrosion.
• Rear face of piles (soil side): ALWC can occur on the soil side due to SRB living in the soil.
ALWC occurs in the moist zone of the soil side caused by seepage through the structure.
Methods for controlling ALWC
• Coatings: the three mechanisms of preventing corrosion are barrier, inhibitive primer, and
galvanic (zinc rich). Selection of coating must take into account application in the marine
environment; even pre-applied coatings are likely to need a touch up after installation of the
steel item (e.g. after pile driving). Downtime of the facility is also to be considered in the
case of an existing structure. Watertight coatings such as epoxy and polyurethane provide
good long-term protection. Few underwater-applied coatings currently provide satisfactory
protection.
• Sacrificial allowance: Typically not appropriate for ALWC as the high rate of corrosion makes
the required sacrificial thickness uneconomical.
• Cathodic protection (CP): CP systems are of tow types: sacrificial (galvanic) and impressed
current. Generally, impressed current systems are used on larger structures. CP systems
can be retrofitted as well as applied to new structures. CP is only effective below water level
(below mean sea level in tidal areas), which includes the ALWC zone. A potential of -800 mV
relative to an Ag/AgCl/seawater reference electrode is required in aerobic conditions, while -
900 mV is required in anaerobic conditions. Potentials below -1100 mV may damage
materials and coatings because of hydrogen evolution.
• Wrapping: Includes factory-applied coatings, polyethylene resins and fibre-reinforced
plastics. Careful surface preparation is critical to avoid trapping chlorides inside the
wrapping. For pipe piles, a petrolatum mat is applied to the steel surface which is forced
into surface pores when the jacket is tightened. Popular for pipe/box piles and popular due
to low initial costs.
Design to avoid corrosion
• Prevent formation of galvanic cells: Avoid using different quality steels in contact with the
water (e.g. the king piles and sheet piles in combi-walls). Do not coat only the less noble
metal as damage to the coating may lead to severe corrosion due to a small anode
surrounded by a large cathode. Electrically isolate reinforcement in the superstructure from
the steel in the substructure.
• Avoid stray current damage: The point at which electric current exits the structure is
susceptible to severe corrosion; can be averted by CP. A structure can be damaged by a
nearby electric railway, the impressed current CP system on a moored ship, or the
 structure’s own impressed current CP system (parts of the structure without effective
electrical connection to the CP system).
• Avoid using unprotected steel in the ALWC zone: Use coatings or CP systems as described
above.
• Prevent erosion\wearing of coatings and corrosion products: Continuous removal of
corrosion products causes that area to become anodic relative to the surrounding steel,
which accelerates steel loss. Continuous rubbing of fenders on sheet pile walls removes
coatings and corrosion products and promotes accelerated corrosion.
Design to facilitate future inspection and maintenance
• Design coping beams to accommodate Limpet dams; avoid closely-spaced pile clusters;
develop design to accommodate future CP system even if one is not used initially.
• Inspection and maintenance by divers is expensive and quality control is difficult. CP
systems can be used to protect the structure below water. Connect mounting frames to the
structure above water only, with only guides below water, so that they can be easily be
removed from above water for inspection and maintenance.
• Determine corrosion allowances during the design stage so that the critical corrosion level is
known and can be compared with the measured corrosion.
Timing of repairs to corroded structures
• Generally, structures should be repaired before the loss of 50% of the original steel
thickness.
• Repairs should be made before holes form, as holes are more difficult to repair.
• Welding to steel less than 5 mm thick may cause difficulties.
Access for repair of sheet piles
• Limpet dams/dry setting installations (DZIs) provide excellent conditions for fitting and
welding. The work is easily accessible for inspection. Protective coatings can be applied or
CP systems installed in the dry.
• Repairs to holes by divers cannot be guaranteed as any remaining leakage cannot be visually
detected underwater.
• Working only at low tide can complicate repairs, and provides no access to areas below the
low-water level.
Cost of intervention or repair
• Cathodic protection is generally cheaper than repair, thus regular inspection to identify
accelerated corrosion before it causes problems is worthwhile.
• Early and moderate repair is cheaper than repair of severe corrosion, especially holes.