Section 38 - Corrosion Protection D 38 - 1

Section 38
Corrosion Protection
A. General Instructions
1. Field of Application
1.1 This section deals with the corrosion protection
measures specified by BKI with respect to seagoing steel
ships. Details of the documentation necessary for setting
up the corrosion protection system are laid down herein
(planning, execution, supervision).
1.2 Corrosion protection for other types of ship as well
as other kinds of material, e.g. aluminium, is to be agreed
separately in consultation with BKI.
1.3 Requirements with respect to the contractors
executing the work and the quality control are subject to
the conditions laid down in Section 1, N.1.1 and 1.2.
1.4 Any restrictions which may be in force concerning
the applicability of certain corrosion protection systems
for special types of vessels (e.g. tankers and bulk carriers)
must be observed. BKI must be consulted when clarifying
such issues.
1.5 Supplementary to this section, Regulations for
Corrosion Protection and Coating Systems contain further
comments and recommendations for the selection of suitable
corrosion protection systems, as well as their professional
planning and execution.
B. Shop Primers
1. General
1.1 As a rule, shop primers are used to provide protection
for the steel parts during storage, transport and work
processes in the manufacturing company until such time
as further surface preparation is carried out and the
subsequent coatings for corrosion protection are applied.
1.2 Customarily, coatings with a thickness of 15 m
to 20 m are applied.
Under normal yard conditions, this should provide corrosion
protection for a period of approx. 6 months.
1.3 The coating must be of good resistance to withstand
the mechanical stresses incurred during the subsequent
working of the steel material in the shipbuilding process.
1.4 Flame-cutting and welding speed are not to be
unduly impaired. It must be ensured that welding with all
welding processes customary in the building of ships
can be conducted without impermissibly impairing the
quality of the weld seam, see the Rules for Welding,
Volume VI, Section 6.
1.5 Due to the possible strain to the system presented
by cathodic protection, seawater and chemicals, only shop
primers are to be used which are alkali fast and not
hydrolyzable.
1.6 The suitability and compatibility of shop primer
for use in the corrosion protection systemis to be guaranteed
by the manufacturer of the coating materials.
2. Approvals
2.1 Only those overweldable shop primers may be used
for which the Society has issued a confirmation of accept-
ability based on a porosity test in accordance with the Rules
for Welding, Volume VI, Section 6.
C. Hollow Spaces
1. General
1.1 Hollow spaces, such as those in closed box girders,
tube supports and the like, which can either be shown to
be air tight or are accepted as such fromnormal shipbuilding
experience, need not have their internal surfaces protected.
During assembling, however, such hollow spaces must be
kept clean and dry.
D. Combination of Materials
1. General
1.1 Preventive measures are to be taken to avoid contact
corrosion associated with the combination of dissimilar
metals with different potentials in an electrolyte solution,
such as seawater.
1.2 In addition to selecting appropriate materials, steps
such as suitable insulation, an effective coating and the
application of cathodic protection can be taken in order
to prevent contact corrosion.
Section 38 - Corrosion Protection F 38 - 2
E. Fitting-Out and Berthing Periods
1. General
1.1 For protection against corrosion arising from stray
currents, such as those occurring due to inappropriate direct
current electrical supply to the ship for welding or mains
lighting, as well as those arising fromdirect-current supplies
to other facilities (e.g. shore cranes) and neighbouring ships,
the provision of (even additional) cathodic protection by
means of sacrificial anodes is not suitable.
1.2 Steps are to be taken to prevent the formation of
stray currents, and suitable electric drainage is to be
provided.
1.3 Particularly in the event of lengthy fitting-out periods,
welding rectifiers are to be so arranged that stray currents
can be eliminated.
F. Corrosion Protection of Ballast Water Tanks
1. General
1.1 All seawater ballast tanks having boundaries formed
by the vessels shell (bottom, outside plating, deck) must
be provided with a corrosion protection system.
1.2 The following corrosion protection systems are to
be used:
S coating,
S coating and cathodic protection,
2. Coatings
2.1 General
2.1.1 The coatings must be, in accordance with the
manufacturers specifications, resistant against sea-water,
coastal water, harbour water and the substances they may
contain.
2.1.2 The characteristics, composition and field of
application of a coating system must be documented, i.e.
prescribed by the manufacturer of the coating material.
Details of the coating material, how it is to be processed
and its suitability for the coating system must be contained
in the product data sheet.
2.2 Approvals
2.2.1 For new buildings, the applied coatings and coating
systems must be approved by BKI. The approvals must
be obtained by the manufacturers of the coating materials
from BKI Head Office.
2.2.2 Approved coatings and coating systems are compiled
in a list (Approved Coatings for Newbuildings). The current
list is obtainable from Head Office.
2.2.3 Approval does not constitute confirmation of the
suitability and compatibility of the coatings in the corrosion
protection system. These points are to be ensured by either
the yard or the manufacturer of the coating materials.
2.3 Surface Preparation
2.3.1 The surface must be prepared according to the
instructions of the manufacturer of the coating material.
2.3.2 Surface preparation is subject to specifications in
the product data sheet and must correspond to a valid surface
quality grade, e.g. SIS 055900, DIN 55928, Part 4, or ISO
8501 1-4.
2.3.3 Slag and loose weld spatters must be removed before
the coating is applied.
2.3.4 Welded or otherwise attached accessory material
(tack plates, lugs etc.) must be completely integrated into
the corrosion protection, or otherwise removed.
2.4 Application
2.4.1 The process of application is to be carried out
according to the coating manufacturers instructions.
2.4.2 During application the ambient conditions and
procedural instructions are to be complied with, in
accordance with the details specified in the manufacturers
instructions and in the approvals.
2.4.3 Surface areas which are obstructed and are thus
inadequately exposed to the spraying, exposed edges and
corners, as well as weld seams, must be stripe coated in
advance to achieve a sufficient coating thickness.
2.5 Dry Film Thickness
2.5.1 The dry film thickness of the coating systems must
be in accordance with approvals and correspond to a
minimum of 250 m.
2.5.2 The prescribed coating thicknesses represent the
minimum coating thickness which must be maintained in
all cases.
2.6 Documentation
2.6.1 The work processes involved in setting up a coating
system as well as the coating materials to be used must be
laid down in a coating plan.
2.6.2 The coating plan for ballast water tanks must be
submitted to BKI for approval.
2.6.3 The coating protocol is to be compiled in such a
Section 38 - Corrosion Protection F 38 - 3
way that all work steps executed, including surface
preparation and coating materials used, are documented.
2.6.4 This documentation is to be compiled by the coating
manufacturer and/or the contractor executing the work
and/or the yard. An inspection plan must be agreed to
between the parties involved. The papers pertaining to the
documentation must be signed by these parties. On
completion of the coating system, the signed papers
constituting the documentation are to be handed to the
surveyor for acceptance. The documentation is to contain
the following data:
S location and date,
S ship and the tanks treated,
S manufacturers specifications for the coating system
(number of coatings, total coating thickness,
processing conditions),
S product data sheet for the coating and BKI approval
number,
S contractors and persons carrying out the work,
S surface preparation (procedure, working materials,
ambient conditions),
S condition of surface prior to coating (cleanness,
roughness, existing primer, surface quality grade
achieved),
S application (procedure, number of coatings),
S application conditions (time, surface/ambient
temperature, humidity, dew point, ventilation),
S the date the tanks were first ballasted is to be
recorded,
S report of coating thickness measurement and visual
inspections,
S signatures of involved parties (yard, coating manu-
facturer, work contractor).
2.6.5 Coating protocols already in existence and used by
coating manufacturers, work contractors, yards and ship
owners will be accepted by BKI, provided they contain
the above data and are signed by all parties involved. Any
missing data is to be furnished.
3. Coatings combined with Cathodic Protection
3.1 Coating
3.1.1 In the case of coatings used in combination with
cathodic protection, the provisions under 2 shall apply.
3.1.2 In addition, the coatings must be resistant against
the cathodic protection, i.e. the coatings must not exhibit
any impairment of their purpose up to a potential of 1200
mV against the copper/copper-sulphate electrode. Proof
of resistance against cathodic corrosion protection can be
provided in accordance with recognized standards, e.g.
DIN 50928, or equivalent.
3.2 Cathodic Protection
3.2.1 General
For the cathodic protection of ballast water tanks in
combination with coatings, sacrificial anodes made of zinc
or aluminium are used. Tables 38.1 and 38.2 contain
recommended alloy compositions for conventional
aluminium and zinc anodes.
Zinc and aluminium anodes of differing chemical
composition may also be used, provided proof of the
cathodic protection ability is provided.
Zinc anodes may not be used in the event that operating
temperatures in excess of 60 C can be expected.
Impressed current systems are not permitted in ballast water
tanks.
Connections between the anodes and the surface to be
protected must provide good conducting properties.
The anodes are therefore to be welded on, wherever
possible. In exceptional circumstances, where bolting on
the anodes offers the only practicable alternative, an
adequate and durable metallic conducting connection must
be provided, e.g. cable connection.
Sacrificial anodes are not to be coated over and must be
free from dirt and other impurities.
3.2.2 Protection Current Requirement
For coated surfaces a protection current density of
0,02 A/m
2
shall be applied.
In the event that ballast water tanks may be subjected to
higher temperatures, for instance due to adjacent heating-oil
tanks, the protection current density is to be increased as
follows:
For each C over 25 C by 1 mA/m
2
The protection period must be designed to last for a
minimum of 5 years.
Deviations from the values stated for protection current
density and protection period could be accepted if a written
confirmation of the owner exists.
3.2.3 Anode Weight
The required total anode weight is calculated according
to:
m
G
= [kg]
A
G
J
S
t
S
Q
g
where:
A
G
= the total area to be protected in [m
2
]
J
S
= protection current requirement in [A/m
2
]
according to 3.2.2.
Section 38 - Corrosion Protection G 38 - 4
t
S
= protection period in [h]
Q
g
= electrochemical efficiency of the anode material
in [Ah/kg]
The electrochemical efficiency of the anode material is to
be taken out of the manufacturers specification.
Table 38.1 Sacrificial anodes of zinc alloys for
applications in seawater
Element KI-Zn1 KI-Zn2
Al 0,10 - 0,50
0,10
Cd 0,025 - 0,07
0,004
Cu
0,005 0,005
Fe
0,005 0,0014
Pb
0,006 0,006
Zn
99,22 99,88
Potential
(T =20
o
C)
1,03 V
Ag/AgCl/Seawater
1,03 V
Ag/AgCl/Seawater
Q
g
(T =20
o
C)
780 Ah/kg 780 Ah/kg
Efficiency
(T =20
o
C)
95%
Table 38.2 Sacrificial anodes of aluminium alloys for
applications in seawater
Element KI-Al1 KI-Al2 KI-Al3
Si
0,10 0,10
Si +Fe
0,10
Fe
0,10 0,13
Cu
0,005 0,005 0,02
Mn N/A N/A 0,15 - 0,50
Zn 2,0 - 6,0 4,0 - 6,0 2,0 - 5,0
Ti 0,01 - 0,05
In 0,01 - 0,03 0,01 - 0,05
Sn 0,05 - 0,15
Other El.
0,10 0,10 0,15
Al Residue Residue Residue
Potential
(T =20
o
C)
1,05 V
Ag/AgCl/Sea-
water
1,05 V
Ag/AgCl/Sea-
water
1,05 V
Ag/AgCl/Sea-
water
Q
g
(T =20
o
C)
2000 Ah/kg 2000 Ah/kg 2700 Ah/kg
Efficiency
(T =20
o
C)
95%
3.2.4 Arrangement of Anodes
The arrangement of the anodes in the tank is to be such
that the required protection current density can be achieved
in all areas.
The number and size of the anodes depends on the structural
design and the calculated current output of the anodes. When
compiling the anode plan, the current output is to be taken
into account for the calculation.
An increase in the number of anodes required may be
necessary in the following circumstances:
S when frequently low filling levels lead to a limitation
in the area effectively protected by the anodes,
S when internal structures attenuate the effective
current for certain areas of the tank,
S when increased current densities are necessary for
the protection of more noble materials, e.g. internals
made of stainless steel.
3.2.5 Documentation
The documentation of the coating must be in accordance
with 2.6. In addition, the papers concerning the design and
computation of the cathodic protection must be submitted
for perusal. An anode plan need not be submitted.
G. Corrosion Protection of Cargo Holds
1. General
1.1 On bulk carriers, all internal and external surfaces
of hatch coamings and hatch covers, and all internal surfaces
of the cargo holds, excluding the flat tank top areas and
the hopper tanks sloping plating approximately 300 mm
below the side shell frame and brackets, are to have an
effective protective coating (epoxy coating, or equivalent),
applied in accordance with the manufacturers recommend-
ation. In the selection of coating due consideration shall
be given in consultation with the owner to the intended
cargo and conditions expected in service.
1.2 The coating used must be approved by the
manufacturer for application in cargo holds.
1.3 The coating manufacturers instructions with regard
to surface preparation as well as application conditions and
processing must be adhered to.
1.4 The minimum thickness of the coating without
antifouling shall be 250 m, resistant to cathodic protection
in accordance with recognized guidelines and suitable for
mechanical underwater cleaning.
2. Documentation
2.1 The coating plan is to be submitted for examination.
A description of the work necessary for setting up a coating
Section 38 - Corrosion Protection H 38 - 5
system and the coating materials to be used must be
contained in the coating plan.
2.2 A coating report is to be compiled in such a way
that details of all the work processes executed, including
the surface preparation as well as the coating materials used,
are recorded.
2.3 This documentation is to be compiled by the coating
manufacturer and/or the contractor executing the work
and/or the yard. An inspection plan must be agreed to
between the parties involved. The papers pertaining to the
documentation must be signed by these parties. On
completion of the coating system, the signed papers
constituting the documentation are to be handed to the
surveyor for approval.
H. Corrosion Protection of the Underwater Hull
1. General
1.1 Vessels intended to be assigned the class notation
IW (In-Water Survey) shall provide a suitable corrosion
protection system for the underwater hull, consisting of
coating and cathodic protection.
1.2 Coatings based on epoxy, polyurethane and polyvinyl
chloride are considered suitable.
1.3 The coating manufacturers instructions with regard
to surface preparation as well as application conditions and
processing must be observed.
1.4 The coating, system without antifouling, shall have
a minimum film thickness of 250 m, shall be compatible
to cathodic protection in accordance with recognized
standards, and shall be suitable for being cleaned underwater
by mechanical means.
1.5 The cathodic protection can be provided by means
of sacrificial anodes, or by impressed current systems. Under
normal conditions for steel, a protection current density
of at least 10 mA/m
2
must be ensured.
1.6 In the case of impressed current systems, over
protection due to inadequately low potential is to be avoided.
A screen (dielectric shield) is to be provided in the
immediate vicinity of the impressed-current anodes.
1.7 Cathodic protection by means of sacrificial anodes
is to be designed for one dry-docking period.
1.8 In the case of other materials, such as aluminium
for instance, special conditions must be agreed with BKI.
2. Documentation
2.1 The coating plan and the design data for the cathodic
protection are to be submitted for examination.
2.2 In the case of impressed current systems, the
following details must also be submitted:
S location and constructional integration (e.g. by a
cofferdam) of the anodes in the vessels skin,
S descriptions of how all appendages, e.g. rudder,
propeller and shafts, are incorporated into the
cathodic protection,
S electrical supply and electrical distribution system.
2.3 The work processes involved in setting up the coating
system as well as the coating materials to be used must be
laid down in the coating plan.
2.4 A coating protocol is to be compiled in such a way
that details of all the work processes executed, including
the surface preparation as well as the coating materials used,
are recorded.
2.5 This documentation is to be compiled by the coating
manufacturer and/or the contractor executing the work
and/or the yard. An inspection plan must be agreed to
between the parties involved. The papers pertaining to the
documentation must be signed by these parties. On
completion of the coating system, the signed papers
constituting the documentation are to be handed to the
surveyor for approval.
2.6 In the case of impressed current systems, the function
ability of the cathodic corrosion protection is to be tested
during sea trials. The values obtained for the protection
current and voltage must be recorded.