Corrosion and Its Prevention
Corrosion and Its Prevention
Corrosion and Its Prevention
CORROSION CELL
Corrosion always develops at the anode, where current leaves the
metal and enters the electrolyte, whilst a protective effect occurs at
the cathode. Thus if the whole metal surface is made sufficiently
cathodic, corrosion will not occur. This is the basic principle of
Cathodic Protection. In marine structures, such corrosion cells
may result from the use of dissimilar metals. Usually,
however, localised anodic and cathodic areas arise on the
surface of the same metal through differences in the metal
itself, variations in protective films, variations in stress
concentrations or changes in the electrolyte. i.e. aeration,
temperature and salinity.
Corrosion may be prevented by removing one or more of these
corrosive elements and for marine structures, the most practicable
method is to apply a protective coating, thus introducing an
electrical resistance between the metal and the electrolyte. Paint in
various forms normally provides the first level of protection.
However, even the most efficient coatings are subject
to defects during application or service, with inevitable
corrosion of the exposed metal.
It is therefore generally accepted that cathodic protection, in
conjunction with a high performance paint system provides the
most effective and economic safeguard against corrosion.
The Sacrificial Anode System :
Also in ICP system the Anodes are well insulated from the hull
& it’s appendages, simply because the Anodes are made of
noble metals & when ICP system is switched off, if these
Anodes are in direct contact with the hull they may cause
corrosion of hull.
Mill Scale
Mill scale, often shortened to just scale, is the flaky surface of hot rolled
steel, iron oxides consisting of Iron(II,III) oxide, hematite and magnetite.
Mill scale is formed on the outer surfaces of plates, sheets or profiles
when they are being produced by rolling red hot iron or steel billets in
rolling mills. Mill scale is composed of iron oxides mostly ferric and is
bluish black in color. It is usually less than 1 mm (0.039 in) thick and
initially adheres to the steel surface and protects it from atmospheric
corrosion provided no break occurs in this coating.
Because it is electro-chemically cathodic to steel, any break in the mill
scale coating will cause accelerated corrosion of steel exposed at the
break. Mill scale is thus a boon for a while, until its coating breaks due to
handling of the steel product or due to any other mechanical cause.
It is a nuisance when the steel is to be processed. Any paint applied over it
is wasted since it will come off with the scale as moisture laden air get
under it. Thus mill scale has to be removed from steel surfaces by flame
cleaning, pickling or abrasive blasting. All tedious operations wasteful of
energy. This is why shipbuilders used to leave steel delivered freshly
rolled from mills out in the open to allow it to 'weather' till most of the
scale fell off due to atmospheric action. Nowadays most steels mills can
supply their produce with mill scale removed and steel coated with shop
primers over which welding can be done safely.
TYPES OF CORROSION
1. Electro-chemical :
For an electro-chemical reaction, there must be anodic and cathodic areas
on the metal and a path i.e. electrolyte, for the current to flow. On a single
metal plate, different areas on the plate act as anodes and cathodes. The
anodic area is usually surrounded by the cathodic area. This anode and
cathode in the presence of an electrolyte makes up a ‘CORROSION
CELL’
Thousands of such corrosion cells exist all over the plate. The part which
acts as the anode gets destructed while the part which acts as the cathode
is protected. When atmospheric conditions are uniform such as high
temperatures when accompanied by high humidities ashore, the corrosion
cells are very small so that the plate corrodes uniformly all over forming a
thin continuous layer of rust called ‘MILL SCALE’ When conditions are
severe and non-uniform such as at sea, the corrosion cells are large and
the plate gets severely corroded at places in what is known as ‘PITTING’.
Oxygen gets absorbed in the water forming hydroxyl (OH) ions which
react with the free iron ions liberated by the anode to form rust. The
complete reaction is,
Rust is formed in between the anode (where the free iron ions are present)
and the surface of the water drop (where the hydroxyl ions are present).
Here rust is formed close to the anode and as the reaction proceeds, it may
cover the anode and stifle the reaction. Rust being porous, the reaction
does not completely stop but proceeds at a slow pace. However if the rust
is removed, corrosion will again resume, hence the rust should not be
removed unless it intended to coat the steel with paint.
3. Impingement attack
When the protective coating is removed, the surface is exposed as the
anode and becomes susceptible to corrosion. Impingement corrosion is
promoted by excessive local turbulence which results in anodic and
cathodic areas being formed, due to differing liquid velocities and/or
retention of a surface layer. If the anode which is the impingement site is
large as compared to the cathode, the corrosion will be light. However if
the cathode is large as compared to the anode, the corrosion will be
severe. If the turbulence is uniform over the whole area, the rate of
corrosion will be less. This form of attack often occurs at the waterline
especially at the bow and at inlets and outlets on the shipside. It can be
reduced by designing the system to keep turbulence to a minimum.
4. Bimetallic Corrosion
Bimetallic corrosion occurs when two metals are in direct contact with
each other or indirectly in contact through an electrolyte. To prevent
corrosion, the metals must be adequately insulated from each other or
protected by a good paint film. The more noble metal must be used for
fasteners to join the two metals. The rate of corrosion will depend on the
relative sizes of the anodic and cathodic materials. A small anode will
corrode rapidly when attached to a large cathode, e.g. a steel flange on a
copper pipe. Areas most susceptible to bimetallic corrosion are:
6. Crevice corrosion :
When an electrolyte gets trapped within a crevice, either between a joint,
or between close-fitting components or within rust, due to a chemical
reaction, corrosive ions are formed which saturate the crevice. This results
in the localised areas around the crevice becoming the cathode and
corroding the crevice.
Crevice Corrosion
Composition of Paint
A) Vehicle or Binder
The binder, commonly referred to as the vehicle, is the actual film
forming component of paint. It is the only component that must be
present; other components listed below are included optionally,
depending on the desired properties of the cured film.
The binder imparts adhesion, binds the pigments together, and
strongly influences such properties as gloss potential, exterior
durability, flexibility, and toughness.
Binders include synthetic or natural resins such as acrylics,
polyurethanes, polyesters, melamine resins, epoxy, or oils.
Binders can be categorized according to drying, or curing
mechanism.
1) Alkyd Paints – Oxidation Curing vehicle or binders –
These require oxygen to cure. When applied to a surface, the
solvent evaporates & oxygen penetrates the film helping the
binder chains to interlink. Such paints remain liquid as long as
they are in a closed paint drum – not exposed to air.These
paints can not be applied as thick coats as it will prevent
oxygen reaching bottom layers.
B) Pigment :
Pigments are granular solids incorporated into the paint to contribute
color, toughness, texture or simply to reduce the cost of the paint.
Alternatively, some paints contain dyes instead of or in combination with
pigments.
Pigments can be classified as either natural or synthetic types. Natural
pigments include various clays, calcium carbonate, mica, silicas, and
talcs. Synthetics would include engineered molecules, calcined clays,
blanc fix, precipitated calcium carbonate, and synthetic silicas.
3) Solvent
The main purpose of the solvent is to adjust the curing properties and
viscosity of the paint. It is volatile and does not become part of the paint
film. It also controls flow and application properties, and affects the
stability of the paint while in liquid state. Its main function is as the carrier
for the non volatile components. In order to spread heavier oils (i.e.
linseed) as in oil-based interior housepaint, a thinner oil is required. These
volatile substances impart their properties temporarily—once the solvent
has evaporated or disintegrated, the remaining paint is fixed to the surface.
This component is optional: some paints have no dilutant.
4) Extenders ( or Fillers)
These enhance the weather durability and consistency of the paint.
They increase the volume of paint & thereby reducing the price.
5) Auxilliaries
These are used for imparting special properties.
e.g. Walnut Shell powder is used for imparting “Anti-Skid”
property.
The leach rate i.e. the rate at which the poison is released is
governed by the type & amount of toxin in the paint, the solubility
of the binder and the design of the paint. Today high performance
Antifoulings can prevent fouling for upto 5 years.
1) Reactivable Antifouling:
Chlorinated rubber based, highly charged with cuprous oxide.
When the toxin level in the outer layer becomes low, the surface
can be scrubbed down using special automated equipment. The top
layer of the paint is removed, exposing a fresh film. Reactivation
is carried out at intervals of 1-2 years.
Pre-Heating
The plates & profiles first pass through a pre-heater, this raises the
temperature of the metal ready for blasting & removes any surface
moisture.
Blast Cleaning
Sheets & profiles are thoroughly blast cleaned.The blast chamber
removes rust and mill scale and provides a finish to
internationally recognised preparation grades.
Rust grades
Four rust grades are specified. These are defined by precise written descriptions
and photographic examples in ISO 8501-1documentation. They vary from A: mill
scale,to D: where the mill scale has rusted away and general pitting is visible.
Preparation grades
Surface preparation by blast cleaning is designated by the international standard
ISO8501. Four grades are specified, ranging from Sa 1: light blast cleaning, to Sa
3: blast cleaning to visually clean steel.
Marking
Each sheet has its own unique identification to allow subsequent
allocation and control. The mark is spray painted by computer
controlled nozzles.
Edge cleaning
To ensure optimum weld quality, the edges of the profiles are
blasted to remove paint from the weld area .
Airblast units for this operation are suitable for smaller profiles
and often precede a gascutting machine.
Conveying
The plates are now conveyed to be fabricated
into ship segments.
Surface Preparation Standards & their meaning:
Steel Structures Painting Council / Swedish Standard/Meaning
SSPC-SP-1 / - / Solvent Cleaning
SSPC-SP-2 / St 2 / Hand Tool Cleaning
SSPC-SP-3 / St 3 / Power Tool Cleaning
SSPC-SP-4 / - / Flame Cleaning
SSPC-SP-5 / Sa 3 / White Metal Blast Cleaning
SSPC-SP-6 / Sa 2 / Commercial Blast Cleaning
SSPC-SP-7 / Sa 1 / Brush Off Blast Cleaning
SSPC –SP-8/ - / Pickling(Removal of rust or millscale by
electrolysis or chemical reaction or both)
SSPC-SP-9 / - / Weathering followed by blast cleaning
SSPC-SP-10/ Sa 2.5 / Near White blast cleaning
Safety Precautions for Painting
Typical Painting Scheme – Chugoku Paints
antifouling for underwater area and boottop
Recommended
Number
Type of system Name of paint DFT
of coats (6)
(in total)
Typical
NZ primer S surface
or 1 25 (u) preparation
Holding primer (optinal)
Epicon zinc rich primer (1) 25 (u)
B-2
Umeguard SX HS 1 175 u
Multipurpose Tar-free
Epoxy Self-polishing Hiper AC 1 50 u 4
Antifouling 1st +1
generation Tin Free TFA Series* or 2-3 100-450 u
Seatender Series (2) (2-3) (100-450 u)
Hiper AC 1 50 u
Antifouling Sealer
Silvax SQ-K 1 50 u
underwater area
Recommended
Number
Type of system Name of paint DFT
of coats (6)
(in total)
Typical
NZ primer S surface
or 1 25 u preparation
Holding primer (optinal)
Epicon zinc rich primer (1) (20 u)
B-2
boottop area
Recommended
Number
Type of system Name of paint DFT
of coats (6)
(in total)
Typical
NZ primer S surface
or 1 25 (u) preparation
Holding primer (optinal)
Epicon zinc rich primer (1) 25 (u)
B-2
topside area
Recommended
Number
Type of system Name of paint DFT
of coats (6)
(in total)
Typical
NZ primer S surface
or 1 25 (u) preparation
Holding primer (optinal)
Epicon zinc rich primer (1) 25 (u)
B-2
Number Recommended
Existing
Type of Paint Name of Paint of DFT (6)
System
Coats (in total) Typical
Holding NZ Primer S or Surface
1 25 u Preparation
Primer Epicon Zinc Rich
(1) (20 u)
(optional) Primer B-2
Roswan QD HB 2 140 u
Oleoresinous Oleoresinous LZI Primer HB (2) (140 u) 5
Evamarine Finish 1 40 u
Number
Recommended
Type of system Kind of Paint Name of Paint of
DFT (in total)
Coats
NZ primer S or
Epoxy Non Zinc 1 22 u
Epicon Zinc rich primer
Epoxy Zinc Rich (1) (18 u)
Shop primer B-2
Inorganic Zinc (1) (15 u)
Elbond HM
Ultra Heat Resist (1) (15 u)
Cerabond 2000
cargo holds
Number Recommended
Existing
Type of Paint Name of Paint of DFT (6)
System
Coats (in total) Typical
Holding NZ Primer S or Surface
1 25 u Preparation
Primer Epicon Zinc Rich
(1) (20 u)
(optional) Primer B-2
Epoxy or
Epoxy Acrylic Umeguard SX (5) 2 200-300 u 2
Oleoresinous