Beruflich Dokumente
Kultur Dokumente
for boats ^
Marine corrosion has been a problem
ever since boatbuilders started using
in saltwater
metals on boats. When electricity
came aboard, the problem grew even
worse. Many marine publications have
carried articles on the various causes of
underwater corrosion and on that often
confusing term, electrolysis. Nevertheless,
the OSU Extension Service' Sea Grant
marine advisory staff continues to receive
requests concerning the causes and
prevention of underwater corrosion: How
much zinc is needed to protect a boat?
What other types of cathodic protection
can a mariner use? How does corrosion
relate to faulty marine wiring? And so on.
To obtain reliable answers to such
questions, despite the seemingly
unlimited number of variable conditions
involved, the authors worked with other
members of the marine advisory staff to
organize technical workshops
investigating what successful marine
service sources are, in fact, practicing.
These workshops—Marine Technical
Institutes—were held in Coos Bay and
in Astoria.
This bulletin is a dividend of the
experience and common practice
examined during the institutes. It
summarizes practical technical literature
and documents opinions of industry
specialists and boat owners with
substantial experience under a range of
working conditions. The findings apply
primarily to working watercraft.
Recognize that the subject is very
complex because adequate cathodic
protection measures quite often are
destroyed by faulty marine wiring. The
intent of this bulletin is to offer clear
information on how to protect your boat
cathodically, assuming its marine
electrical system is healthy. (The glossary,
page 8, defines each term that appears
in italics.)
^G
Oregon State University
Extension Marine Advisory Program
A Land Grant / Sea Grant Cooperative
SO 46 November 1979
Corrosion is one of the biggest
maintenance problems in vessels of all
sizes, particularly in saltwater. It costs
money, and it can cost lives if critical
equipment weakened by corrosion is not
replaced or repaired in time (figure 1).
Corrosion above the water line is one
thing; your only defense there is frequent
inspection and careful attention to
painting, cleaning, and greasing.
Corrosion of hull fittings and metals
below the water line, however, is another
matter. This you can control by cathodic
protection, and this bulletin describes
how you can achieve adequate
protection, using either zinc sacrificial
anodes or impressed current systems.
Corrosion is an electrochemical
process in which a chemical reaction
takes place, creating a flow of electrical
charge, or current, between two unlike
metals. This chemical action between Figure 1.—Severe stray-current corrosion caused this kind of damage to a steel power cruiser.
Quick action saved this vessel from sinking because of hull perforation.
two unlike metals can destroy one of
the metals. When that metal is a
propeller, strut, or shaft, the damage can
grow expensive.
One cannot understand or design an
Connecting wire or bolt
adequate cathodic protection system
without a basic knowledge of
direct-current (d.c.) electrical theory.
r Electron flow
Ohm's Law is a handy starting point:
Briefly, it states that current (I) in a
I
circuit is proportional to the potential Seawater
difference (E) across a circuit. The more
resistance (R) in that circuit, the less the Zinc
amount of current. Ohm's Law can be
Copper
written mathematically as
Zinc ions enter Copper is
potential (volts) solution (zinc
Current (amps) = protected
resistance (ohms)
corrodes)
E
or I = —■ Figure 2a.—Current will flow between two different metals
R in seawater that are connected together electrically.
///////////in/j////i/i/n//i/////n/n///i//////////i//////i/////////////nTn/{//i///iri
Electron flow
Side view of Steel
zinc anode —' Zinc ions mounting strap
enter solution
Figure 2b.—A cutaway view of a zinc anode mounted to a metal plate or fitting.
In other words, given a certain voltage, impressed-current cathodic protection Hull-potential measurement provides
the lower the resistance, the greater the devices. (See "Controlled voltage a fairly scientific way to "zinc" a boat.
current; the higher the resistance, the systems.") In this method, you simply add zincs to
smaller the current. The units of A second kind of corrosion, the boat until the hull potential reaches
electrical characteristics—current, stray-current corrosion, is often the the desired value: for steel, about-0.85
potential (another name for voltage), culprit when severe damage of volt versus a silver-silver chloride
and resistance—are defined as follows. underwater metals takes place. In fact, reference electrode. The optimum
One ampere of current will flow through according to several marine electricians, potentials for copper and aluminum are
a 1-ohm resistance when a potential of stray currents cause 90 % of underwater about -0.65 and-0.95 volt, respectively.
1 volt is impressed across the resistance. corrosion problems. This kind of corrosion Another method is to install zinc
All electrical conductors have resistance. can arise from many sources, including anodes, then inspect to see if you
faulty or inadequate wiring, either on installed enough when you haul your
Voltage is often compared to water
the boat or in the shore power connection. vessel out of the water after a year.
pressure. Then, the water flowing under
All forms of underwater corrosion are If the anodes are 50 to 80% consumed,
pressure through a pipe behaves like
often referred to as "electrolysis," but you have probably used the right
electricity. The amount of water moving
this label is widely misused. From a amount. The best summary of common
through the pipe is analagous to the
troubleshooting point of view, it is practice that the authors have been able
current. The frictional resistance to water
important to understand the difference to assemble appears as table 1; it reflects
flow within the pipe is the counterpart
between galvanic action and the amounts of zinc that representative
of the electrical resistance. Most of the
stray-current corrosion. The next sections working boats are using and
discussion that follows relates to factors
describe how you can protect your vessel knowledgeable service sources are
on and around boats in saltwater (and
from both forms. recommending.
to a less severe extent, to those in
The table presents a consensus of
freshwater) that can reduce the
recommended amounts of zinc for seven
unwanted current that causes corrosion.
typical boat sizes, based on technical
literature and on the experiences of
Preventing galvanic action marine electricians, boatyards, and users.
The commonest defense is the use of These recommendations assume that the
Types of corrosion zinc sacrificial anodes. The determination larger boats have more underwater
of how many zincs to use, and of what hardware than smaller boats, such as
The simplest kind of corrosion to
size, seems to be more an art than a radio ground plates and keel coolers.
understand and prevent is called galvanic
science. Many marine electricians decide Note, too, that calculations of values for
action; it occurs any time two different
how much zinc to install by measuring table 1 are for a boat underway, rather
metals are connected together electrically
the potential of the hull relative to a than sitting at the dock. The resulting
and immersed in an electrolytic solution
reference electrode hung over the side. higher values apply more to work boats
such as seawater. (Salt dissolved in water
(Many skippers permanently mount than to pleasure boats.
is an electrolyte; it makes the solution a
conductor of electricity.) reference electrodes and monitor meters
on their vessels.)
Figure 2a shows an electrical diagram
of galvanic action—a battery of sorts.
Figure 2b shows how this action occurs
on your boat. All metals tend to corrode,
but some do so more actively than others
—zinc, very much more so. In the
example, zinc is corroding and protecting Table 1.—Pounds of zinc recommended for boats underway
the copper by providing electrons (water velocity of 5 knots or greater)9
through the connecting wire to the
copper and preventing the loss of 48-ft
electrons from copper. 22-ft Troller
The zinc installed to protect copper Dory or or 58-ft
fittings is said to be a "sacrificial cruiser. 32-ft 32-ft combi- Combi-
anode." Thus, a piece of zinc OB or Inboard Aux. 40-ft nation nation 78-ft
that is attached to the boat corrodes Hull material I/OB troller :sailboat Troller boat boat Dragger
before the structural components do.
Wood or fiberglass 2-4 18-28 4-7 40-60 50-75 65-100 105-160
Another way to achieve protection is
Steel or ferrocement 20-30 70-105 45-65 110-165 160-235 230-345 405-610
with an external source, such as the
Aluminum 0-15 30-45 10-20 55-80 80-120 120-185 225-340
boat's battery, that-may also supply
electrons to the protected metal; this * For the larger boats, this assumes use of 11.5-lb. rectangular anodes. Coverage assumes
method is the basis for the typical conditions of speed, paint condition after 1 year, salinity, and no electrical problems.
For inboard vessels it also assumes copper alloy prop, ground plate, and keel cooler.
22.5-lh size Figure 3.—Typical zinc anodes (photos
courtesy of Federal Metals Corporation).
Figure 4.^Suggested placement of zinc anodes on each side of a 65-ft steel shrimper
(each bar symbol indicates one 11.5-lb anode).
wm Steel washer
needs. A steel hull with a good paint job
needs far less zinc than one with old,
badly worn paint and bare spots. Users
of impressed-current devices with
ammeters see this effect: As the season
Zinc progresses and the paint wears, the
anode current drawn by the system steadily
increases; at haul-out time it can be
several times greater than at launching.
Water-flow velocity. Much more
current is drawn from the zincs when
t Steel strap, hull or rudder '- Paint or corrosion products
make poor electrical contact.
your vessel is underway than when it is
moored (unless an a.c. stray-current
problem exists; see "Stray current
Figure 5.—this is what happens if your zinc anodes have no cast-in straps or inserts. corrosion"). In fact, most of the experts
recommend smaller amounts of zinc for
still water than for moving water. The
amounts needed differ by anywhere from
two to six times. In still water, the
Factors influencing Attack on wood is sometimes called products of the electrochemical reactions
the proper amount of zinc "wood electrolysis" and may show inside build up at the surfaces of the anode and
There are a lot of ifs, ands, and buts the hull as a powdery substance near underwater metals and lower the voltage
in the use of zinc. Remember that the through-hull fittings and other protected of the galvanic "battery." As Ohm's Law
"correct" amount of zinc can vary metals. If you suspect that wood explains, the current is reduced.
greatly, depending on your particular electrolysis is taking place, taste a small Moving water rinses off the surface
boat, where and how you use it, and quantity of the deposit. If it tastes salty, products of the electrode reactions and
other factors. you are simply getting salt buildup keeps the voltage of the galvanic
because of a leak. If it tastes bitter, combination high. Then, as Ohm's Law
Overprotection. Unfortunately, it is
possible to "overprotect" a boat—to use however, you are tasting lye—and you shows, the current is also higher. Vessels
too much zinc on it—and actually cause probably have an overprotection that spend most of their time at sea or
damage to the hulls of wooden or situation. You can remove lye deposits by moored in tidal flow areas need more
aluminum boats. Overprotection can washing with distilled white vinegar, zinc than ones that spend most of their
endanger oil-based paint, too—even on but you need to deal with the cause of time in still water.
a steel boat. Modem steel boats with the problem—too much zinc— Water salinity. Salinity affects the need
epoxy or vinyl paint systems are immediately. Aluminum is also attacked for cathodic protection; boats in saltwater
relatively immune to overprotection, but by hydroxide ions, as pitting of hulls need a great deal more zinc than boats
paint bubbling can occur even with them underwater has demonstrated. in freshwater or brackish water. (The
under some conditions. For these reasons, it is a good idea to resistance of freshwater is much higher;
The cause of this overprotection is the have a marine electrician measure your therefore, the current flowing for the
hydroxide ions (the active ingredient hull potential, especially if you have a same potential is lower.)
in caustic soda or lye) produced by the wooden or aluminum boat. Hull-potential
electrochemical reaction on the surface of monitoring is probably your best
the protected metal. These hydroxide insurance against both galvanic and
ions chemically attack wood, aluminum, stray-current corrosion. In fact, most
and oils. experts recommend installing a
permanent hull-potential monitoring
meter and reference electrode.
For a small outlay of money, you can
buy portable equipment to measure hull
potential, but it is usually a better idea
to have this service performed
occasionally by an experienced marine
electrician or electronics expert. Most
active harbors have at least one person
available who can make this kind of
measurement.
Purity of the anode metal. Zinc anode Bonding allows one zinc anode to
material with more than about 0.005^ protect several fittings, as long as the
iron tends to form a scale over its anode is of sufficient size. The only
surface. Thus it corrodes poorly and really tricky job is bonding the propeller
provides very little protection to a boat. and shaft; The film of oil on the gears
Melting down old zinc anodes and in the gearbox acts as an insulator. You
casting new ones presents a risk of can solve this problem by using a shaft
introducing iron contamination. Some brush, or you can leave the
remelted anodes work well; others do propeller/shaft combination unbonded
not. To be completely safe, specify and protect it separately with a zinc nut
anodes conforming to military cap or shaft collar.
specification MIL-A-18001 H. Figure 6
shows what a properly corroding zinc
anode looks like.
Magnesium anodes are also available,
but magnesium is generally unsuitable
for marine use; the voltage it produces
in reaction with the protected metal is
too high—usually causing overprotection.
Special aluminum alloys have recently
come into use as anode materials;
however, for applications on small vessels
they are not widely available, and thev
have not yet been proven in service,
as have zinc anodes. Some aluminum
anodes contain mercury, and the
manufacturers caution against their use
in estuaries or inshore operations.
Bonding of boats. One final note about
zincs: You can achieve greater flexibility
by bonding—tying together electrically
all of the underwater parts of your boat,
using a heavy copper conductor (see
figure 7). Bonding is recommended for
all boats for a number of reasons, not
the least of which is suppression of radio
noise. Figure 6.—A properly corroding zinc anode: (above) a closeup of the anode; (below) a f idler
view of the hull area.