Corrosion Control NAVFAC MO-307 - US Navy

306 Pages·1992·1.717 MB·English

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DROWEROF
Corrosion of shore and waterfront facilities is a common and serious problem.
Naval shore establishment losses to corrosion are estimated at over one-half billion dol-
sral .yllaunna Corrosion related costs and the adverse impact on mission readiness are
of increasing concern. Additionally a corrosion leak in a POL tank or pipeline could be
very expensive for cleanup and could effect the mission adversely. Action to control cor-
rosion or to repair corrosion damage are among the most frequent reasons for perform-
ing maintenance on shore and waterfront facilities.
Additional information or suggestions that will improve this manual are invited
and should be submitted through appropriate channels to the Naval Facilities Engineer-
ing Command, (Attention: Code 1632), 200 Stovall Street, Alexandria, VA 22332-2300.
This publication has been reviewed in accordance with the Secretary of the Navy
Instruction 5600.16A and is certified as an official publication of the Naval Facilities En-
gineering Command.
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Public Works Centers and Departments

ABSTRACT
The purpose of this manual is to serve as a technical guide for both Naval and
civilian personnel in identifying existing or potential corrosion problems, determining
the proper corrective actions, and implementing the corrective actions. As corrosion
and corrosion control are affected by both original design and construction and main-
tenance, information is presented regarding all methods for reducing corrosion even
though the information is primarily oriented toward maintenance and repair.
This manual describes the mechanisms of corrosion, the types of corrosion com-
monly experienced in naval shore facilities and waterfront structures, the methods that
can be used to control corrosion and methods for implementing an effective corrosion
control program. This manual emphasizes methods for determining the most cost effec-
tive means of controlling corrosion and practical application of corrosion control to typi-
cal problems encountered in the Naval shore establishment.
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CHANGE CONTROL SHEET
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1. NOITCUDORTNI OT NOISORROCLORTNOC l- l
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 DEFINITION OF CORROSIO N . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 SCOPE OF MANUA L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.5 IMPORTANCE OF CORROSION CONTROL . . . . . . . . . . . . . . 1-1
1.5.1 Cos t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.2 Missio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.3 Readines s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.4 Safet y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.5 Corrosivity of Environmen t . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.6 Environmental Contaminatio n . . . . . . . . . . . . . . . . . . . . . 1-3
1.5.7 Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. NOISORROC LORTNOCYCILOP 2-1
1.2 YCILOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
3. SIS YCELICAM NNOFAANOTORCOEPMI 1-3
1.3NOITCUDORTNI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.3 CIMONOCE SISYLANA SSECORP . . . . . . . . . . . . . . . . . . . . 1-3
3.3 ECNANETNIAM DNA NOITAREPO . . . . . . . . . . . . . . . . . . . 6-3
1.3.3 Costs of Increased Maintenance Resulting From Uncontrolled
noisorroC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
3.3.2 Costs Associated With Loss of Material and Cleanup of Spills . . . 3-6
3.3.3 tsoC fo laitinI ngisedrevO . . . . . . . . . . . . . . . . . . . . . . . . 6-3
3.4 CORROSION PREVENTION AND CONTROL FOR PIPELINES . . 3-6
5.3 CORROSION PREVENTION AND CONTROL FOR WATER
EGAROTSSKNAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71-3
vii
3.6 CORROSION PREVENTION AND CONTROL FOR HIGH STEEL
ANTENNA TOWERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .82-3
3.7 CORROSION PREVENTION AND CONTROL FOR STEEL PIPING
UNDER A PIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93-3
3.8 CORROSION PREVENTION AND CONTROL FOR SEAWALLS . 3-44
9.3 CORROSION PREVENTION AND CONTROL WITH COMPOSITE
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-57
3.10 CORROSION PREVENTION AND CONTROL FOR CHAIN LINK
FENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-66
11.3 LANOITIDDASTNEMMOC . . . . . . . . . . . . . . . . . . . . . . . . 47-3
4. SMROF DNA SMSINAHCEM FONOISORROC 4-1
1.4 GNIVIRD ECROF ROF NOISORROC . . . . . . . . . . . . . . . . . . 1-4
4.2 FUNDAMENTAL MECHANISM OF ATTAC K . . . . . . . . . . . . . 4-1
4.2.1 The Electrochemical Cel l . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 FORMS OF CORROSIO N . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.1 Immunit y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.2 Uniform Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.3 Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.4 Pittin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.3.5 Concentration Cell Corrosion . . . . . . . . . . . . . . . . . . . . 4-13
4.3.6 Dealloying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.3.7 Intergranular Corrosio n . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.3.8 Stress Corrosion Cracking . . . . . . . . . . . . . . . . . . . . . . 4-18
4.3.9 Hydrogen Embrittlemen t . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.3.10 Corrosion Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.3.11 Erosion Corrosio n . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.3.12 Cavitation Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
31.3.4 gnitterF noisorroC . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-4
5. SDOHTEM ROF NOISORROCLORTNOC 5-1
5.1 DESCRIPTION OF APPLICABLE CORROSION CONTROL
METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-1
viii
5. 2 USE MATERIALS RESISTANT TO CORROSIO N . . . . . . . . . . . . 5-1
5.3 USE PROTECTIVE COATING S . . . . . . . . . . . . . . . . . . . . . . 5-1
4.5 ESU CIDOHTAC NOITCETORP . . . . . . . . . . . . . . . . . . . . . 1-5
5.5 MODIFY THE OPERATING ENVIRONMENT . . . . . . . . . . . . 5-2
6. NOMMOC YTILICA FNOISORRO CSMELBORP DNARIEHT
REMEDIES 1-6
1.6 COMMON CORROSION PROBLEM S . . . . . . . . . . . . . . . . . . 6-1
2.6 ATMOSPHERIC EXPOSURE . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.1 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.2 Commonly Used Material s . . . . . . . . . . . . . . . . . . . . . . . 6-1
3.2.6 Structural Features That Lead to Corrosion . . . . . . . . . . . . . 6-2
4.2.6 Examples of Corrosion and Means for Control . . . . . . . . . . . 6-2
6.3 SUBMERGED EXPOSURE . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Commonly Used Material s . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3. 3 Structural Features That Lead to Corrosion . . . . . . . . . . . . . 6-4
6.3.4 Examples of Corrosion and Means for Control . . . . . . . . . . . 6-4
4.6 WATERSIDE (PIPING ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.1 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.2 Commonly Used Material s . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4. 3 Structural Features That Lead to Corrosion . . . . . . . . . . . . . 6-5
6.4.4 Examples of Corrosion and Means for Control . . . . . . . . . . . 6-6
6.5 UNDERGROUN D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5.1 Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.2 Commonly Used Material s . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5. 3 Structural Features That Lead to Corrosion . . . . . . . . . . . . . 6-7
6.5. 4 Examples of Underground Corrosion and Means for Contro l . . . 6-7
7. SLGON RINYTTOBNAIOOSCCORROC 7-1
1.7NOITCUDORTNI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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