SEAMENSHIP & DECKWORK NOTES: Code S6

Corrosion and its Prevention

Capt. Abhishek Mishra

Galvanic / Bi-mettalic Corrosion

Galvanic corrosion is an electrochemical process in which
one metal corrodes preferentially to another when both metals are
in electrical contact, in the presence of an electrolyte.
Dissimilar metals and alloys have different electrode potentials,
and when two or more come into contact in an electrolyte, one
metal acts as anode and the other as cathode. The electro
potential difference between the dissimilar metals is the driving
force for an accelerated attack on the anode member of the
galvanic couple. The anode metal dissolves into the electrolyte,
and deposit collects on the cathodic metal.
In brief, corrosion is a chemical reaction occurring by an
electrochemical mechanism. During corrosion there are two
reactions, oxidation (equation 1), where electrons leave the metal
(and results in the actual loss of metal) and reduction, where the
electrons are used to convert water or oxygen to hydroxides
(equations 2 and 3).
Fe Fe2+ + 2e- (1)
O2 + 2H2O +4e- 4OH- (2)
2H2O + 2e- H2 + 2OH- (3)
In most environments, the hydroxide ions and ferrous ions
combine to form ferrous hydroxide, which eventually becomes the
familiar brown rust
Fe2+ + 2OH- Fe(OH)2
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

Galvanic Anode Cathodic Protection

A galvanic anode is the main component of a galvanic cathodic

protection (CP) system used to protect buried or submerged
metal structures from corrosion.
They are made from a metal alloy with a more "active" voltage
(more negative electrochemical potential) than the metal of the
structure. The difference in potential between the two metals
means that the galvanic anode corrodes, so that the anode
material is consumed in preference to the structure.
The loss (or sacrifice) of the anode material gives rise to the
alternative name of sacrificial anode.

4. Cathodic protection – The technique of offering protection to a specimen

against corrosion by providing electrons from an external source is called
cathodic protection. Specimen metal can be maintained in cathodic condition
by following methods:

(i)Sacrificial anodic method: In this method the metallic structure to be

protected is connected to a metallic wire that is above in the reactivity series.
This wire will act as anode and corrosion will occur at this more active metal
and the metallic structure which act as cathode, is protected.

(ii)Impressed current method : In this method metal specimen to be protected

is made as cathode by impressing the current from a D.C. source. Here the
specimen metal is connected to the negative terminal of the d.c. source and
other electrode is connected to the +ve terminal of d.c. source.This method is
used to protect the immersed portion of the hull of ship. Here hull is
connected to the negative terminal of the d. c. source and maintained in
cathodic condition. Blocks of noble metal like silver or lead is made as anode
by connecting to positive terminal of d. c. source. Amount of current is to be
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

impressed is analysed with the help of silver- silver chloride reference

electrode.

Surface preparation

For any given paint system, surface preparation is the single

important factor which would determine its performance. Various
surface preparation methods are adopted depending on the
requirements of the paint system used and the surface of the
substrate. The surface could be steel, galvanized steel,
aluminum, concrete or wood.

Surface preparation – Ship (above water level)

Various methods of surface preparation are adopted e.g.
degreasing, high pressure fresh water hosing, hand tool cleaning,
power tool cleaning, blast cleaning etc. Degreasing is done to
remove all oil and grease prior to manual or blast cleaning. The
most common method is by solvent washing followed by wiping
dry with clean rags. A suitable detergent solution can also be
made use of, which has to be subjected to fresh water hosing to
remove traces of detergents.
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

Surface preparation – Ship ( below water level)

Prior to the application of protective coatings below the waterline;
all marine growth and surface oxidation is removed by rotary disc
preparation with the steel substrate cleaned

COMPOSITION OF PAINTS

Components of Paint

The exact composition of a particular paint is often complex and proprietary. In

general, however, most paints contain the following.

 Pigment(s)
 Binder(or Resin)
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

 Solvent(s)
 Additives(s)

Pigments:

Paint pigments are small, hard particles that come in a wide variety of shapes.
Their principal functions are

 To provide color as required by the appearance

of the finished product

 To cover the substrate since most binders, by

themselves, are more or less translucent

 To improve the durability and to reduce gloss

 To modify flow and application properties

Examples of pigments

 Titanium oxide
 Iron oxide
 Calcium sulfate
 Clay or Silicates
Binders:

The paint binder (or resin) is the solid material that forms the bulk of the paint
film. It is generally a tough, amorphous polymeric material that gives the paint
most of its thermal, mechanical, and weathering properties.

Examples of binders

 Linseed
 Acrylic
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

 Alkyds
 Epoxies
 Vinyl resins
Comparative study of some common paint binders

Binder Heat Chemical & Weather Resistance

Resistance
Acid Alkali Solvent Water

Acrylics Medium Fair Good Very Very

Good Good

Alkyds Medium Fair Poor Poor Fair

Epoxies High Fair Good Varies Fair

Vinyl Medium Very Very Poor Very

resin Good Good Good

Solvents:

The paint solvent is a pure or mixed blend of liquid that is used to make the
paint flowable and give it the proper viscosity before its application. After the
paint film has dried, usually by baking, the solvent is no longer present.

Examples of solvents

 Toluene
 Xylene
 Water
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

Additives:

Additives are modifiers added to paint, usually in small quantities, to achieve

special effects. They modify the properties of either the wet film or the dried
paint and can affect flexibility, color fastness, gloss, solvent resistance, graffiti
resistance, conductivity etc.

General Safety Information

All paints or thinners are a combination of chemicals, most of which are

hazardous, e.g. organic solvents, epoxy resins, isocyanates etc. These chemicals
have the potential to cause skin, eye, nose and throat irritation and individuals
demonstrate a wide variation in their degree of tolerance to them. Some may
have no immediate problems, but others may develop dermatitis or other
allergic reactions on contact with only small amounts.

TYPE OF PAINTS USED ON SHIPS

(1) EPOXY PAINTS – A two-part formulation which is thoroughly

mixed just before use. Epoxy finishes are extremely hard and
durable and excellent for demanding applications. They can be
used for protecting materials such as steel, aluminum and fiber
glass. The paint film dries to a brilliant gloss. The tile-like finish is
smooth, easy to clean and lasts for years under the most severe
conditions. They are used in exposed surfaces such as deck,
superstructure etc.

a) Cargo Tanks – (solvent-based, phenolic epoxy coating)

(2) ANTI-FOULING PAINT OR BOTTOM PAINT is a specialized

coating applied to the hull of a ship or boat to slow the growth of
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Corrosion and its Prevention
Capt. Abhishek Mishra

organisms that attach to the hull and can affect a vessel's

performance and durability. Hull coatings may have other
functions in addition to their antifouling properties, such as acting
as a barrier against corrosion on metal hulls, or improving the flow
of water past the hull of a ship.

(3) ACRYLIC PAINTS – (generally are Water-borne acrylic zinc

phosphate paints) used for indoor areas where odour from solvent
borne systems are a problem.

(4) ALKYD PAINTS – (alkyd-modified petroleum resin) used in dry

cargo Holds

(5) HEAT RESISTANT PAINTS – (modified alkyd aluminum paint)

for steam pipes on deck or other heated areas.

(6) DRINKING WATER TANKS – (solvent free amine cured epoxy

coating)

STORAGE HANDLING & MIXING OF PAINTS :

Onboard ships the paint is stored in PAINT STORE. It is a store

outside the accommodation area. The store has an exhaust
blower to blow out the paint smell. The store is also protected by
water sprinkler system as the paints are inflammable in nature.
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

The Paint store has racks arrangement to store paints.

The paints are segregated as per the types. The store also has a
SHIP SPECIFIC PAINT SCHEME posted inside which tells which
paint is to be used in which place.

The other important things in paint store are:

(i) MSDS of all paints
(ii) Eye Wash liguid
(iii) Paint mixer
(iv) Paint Drum Opener
(v) Safety goggles for paint mixing

The paints should be handled in a very careful way. Following

precautions should be taken.
(i) Paint drums should be transferred using trolley as they are
normally big 20 ltr drums.
(ii) Different Paints should not be mixed together.
(iii) For Epoxy paints – (i.e. Base & Hardener type) – Correct
hardener to be mixed with correct base.
(iv) For Epoxy paints – Base and Hardener to be mixed in correct
ratio.
(v) Ship specific paint scheme to be followed.
(vi) Blower should be started before entering paint store.
(vii) Paint should be thoroughly stirred (so that solvent and
pigment mix properly) before using the paint.
(viii) Proper PPE (eye protection, gloves etc) to be used when
handling paints.
(ix) Coagulated and expired paints should not be used.
(x) Paint waste to be disposed off as per Garbage Management
Plan and not to be thrown to sea.
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

PAINT DEFECTS

(1) Adhesion Failure

Description:
 Flaking or peeling paint between the top coat and primer, or top coat
and substrate

Causes:
 Improper surface preparation
 Painting over oil, grease or other contaminants
 Improper paint cure

(2) Light Coverage

Description:
 Paint fails to fully hide the substrate surface to which it is applied

Causes:
 Inadequate film build
 Faraday cage effect

(3) Pops

Description:
 Small swelled area like a blister
 Broken edge craters if the blisters burst
 Pinpoint holes in finish
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

Causes:
 Excessive film build traps the solvent which is released during flash
or bake
 Insufficient flash off time before baking

TYPES OF CORROSION ON SHIPS :

i) General Corrosion
ii) Local Corrosion
iii) Pitting Corrosion
iii) Weld Metal Corrosion

CAUSES OF CORROSION IN BALLAST TANKS

Ballast tanks do not corrode uniformly throughout the tank. Each

region behaves distinctively, according to it electrochemical
loading. The differences can especially be seen in empty ballast
tanks. The upper sections usually corrode but the lower sections
will blister.
A ballast tank has three distinct sections: 1) upper, 2) mid or "boot
top" area and, 3) the "double bottom" or lower wing sections. The
upper regions are constantly affected by weather. This area
experiences a high degree of thermal cycling and mechanical
damage through vibration. This area tends to undergo anodic
oxidation more rapidly than other sections and will weaken more
rapidly. This ullage or headspace area contains more oxygen and
thus speeds atmospheric corrosion, as evidenced by the
appearance of rust scales.
In the midsection corrodes more slowly than upper or the bottom
sections of the tank.
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

Double bottoms are prone to cathodic blistering. Temperatures in

this area are much lower due to the cooling of the sea. If this
extremely cathodic region is placed close to an anodic source
(e.g. a corroding ballast pipe), cathodic blistering may occur
especially where the epoxy coating is relatively new. Mud retained
in ballast water can lead to microial corrosion

CAUSES OF CORROSION IN CARGO SPACES (including COT’s in Oil

Tankers)

i) Coating Not applied

ii) Localised coating defects
iii) Material of construction
iv) Microbial Attack
v) High Humidity
vi) High Temperature
vii) Structure Flexing
viii) Inadequate earthing / grounding of electrical equipment

Additionally for Cargo Tanks in tankers

i) High Sulphur Content of Oil Cargo
ii) Inert Gas Quality
iii) Water in Cargo Tanks
iv) Excessive Crude oil washing / tank cleaning

Identification of extent of corrosion in cargo tanks :

Extent of corrosion in tanks can be measured during the scheduled tank

inpections by surveyor during dry docks and during routine tank
inspection by ship staff in between dry docking period and making
reports for further comparison later.
 SEAMENSHIP & DECKWORK NOTES: Code S6
Corrosion and its Prevention
Capt. Abhishek Mishra

The standards used are Lloyd’s pocket booklet – TANK COATINGS

CONDITION GUIDE