CORROSION RESISTANCE AND DURABILITY OF PILE

INTRODUCTION
Piles are structural members that are made of steel, concrete, and/or timber. They are used to
build pile foundations, which are deep and which cost more than shallow foundations.
Despite the cost, the use of piles often is necessary to ensure structural safety.
Structures that are used for the transfer of loads from the superstructure to the sub surface
strata are known as Foundation. And Piles are a type of foundation. For a hydraulic structure
such as bridges, dams, etc. or for surfaces having high water content, the piles are driven into
the ground and under the water strata. Piles normally used in underwater structures are
subjected to corrosion. Corrosion reduces the structures stability and longevity. There is
absolutely no method for elimination of corrosion; but corrosion protection measures can be
employed for controlling the effects of corrosion. Corrosion protection can be done in
different ways, depending on the environment and other atmospheric and hydrological
factors. Types of corrosion protection include – treatment of surfaces, utilization of
inhibitors, use of coatings and sealants, cathodic and anodic protection.
Corrosion means the damage, destruction or elimination of the metals and alloys by the
chemical reaction of the metals and alloys with the environment. During the phase of
corrosion taking place, metals gets converted to metallic compounds at the top surface and
these compounds wear or deteriorate away as corrosion product. This process may also be
called as the reverse process of the extraction of metals from their ore. It is a problem that
must be addressed for a wider range, example, the automotive industry; metals are often
plated or coated for protection from the road salt and moisture. Indeed, many traditional
metal parts are presently used with polymeric components-which are not only lighter but are
also more cost effective for production. But these products are generally impervious to the
electrochemical corrosion. The selection of the base metals for piling and well-designed
structures will ensure no guarantee for absolute elimination of corrosion.
Therefore, corrosion protection methods are utilized for mitigation and controlling the effects
of corrosion on piles. Corrosion protection can be established in a number of different ways
with multiple methods applied in different environments. Types of corrosion protection
include – treatment of surfaces, utilization of inhibitors, use of coatings and sealants, cathodic
and anodic protection.

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1. Corrosion resistance and durability of steel pile

1.1. Mechanism of Corrosion of Steel in Sea Water:
On the account that steel piling in carried out in seawater, the more chemically active
(charged) surface areas (anodes) are metallically coupled to the less chemically active surface
areas (cathodes), which result in electricity flow and corrosion of the anodic areas.
Roughening of the surface occurs when the local anodic and cathodic areas consistently shift
during the corrosion process. There are times that there is no shifting of these active local
areas from their position end, and there is a localized attack on the metal and pitting occurs.
Generally, depth of pitting = ratio of the anodic sites / area of cathodic site [in contact with
the electrolyte (seawater)]. As the anode area reduces in relation to the cathode area, the
deeper is the pitting.
1.2. Corrosion Zones of Steel Pipes:

Fig. 1 Corrosion zones of steel pipes.

Tidal – It is an environment where the metals are submerged in the seawater and then
exposed to the splash zone alternately as the tide fluctuates.
Submerged – This environment zone is usually characterized by well-aerated water in
combination with the marine bio fouling organism of animal and the plant.
Atmospheric – It depends upon the temperature, pollutants, time of wetness. It is also largely
responsible for large fraction of corrosion.
Splash – It is characterized as an aerated environment of seawater where the exposed material
continually wet and there is no attachment of bio fouling.

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1.3. Corrosion Management:

Conceptual and feasibility studies of the corrosion control method are done. It is categorized
into three major phases.
Phase 1 – In this phase, the programmatic assessment of the project is done.
Phase 2 – In this phase, the physical assessment and actual remediation work is done.
Inspection of corrosion is also is carried out.
Phase 3 – In this phase, future monitoring of the repaired structure is done.
1.4. Methods for Corrosion Protection:
Protective Coating
For protection of metals from corrosion, the metal and the corrosive environment contact is
required to be cut off. The surface of metals is coated with a continuous non- porous material
inert to the corrosive atmosphere to prevent it from corrosion. The coatings are classified into
different categories –
a) Organic
b) Metallic
c) Inorganic
For Under Water Piles the types of coatings used are –
Inorganic Zinc Silicate Primers: Structures (Steel) that are immersed in seawater – jackets
below the Splash Zone, are usually not coated and protected solely by cathodic protection
system. Many anticorrosive-pigmented primers, some that passivates the steel. Inorganic
zinc silicate primers are the most effective as they essentially become anodic to the steel in a
corrosion process. The advantage of this coating - it will arrest rust creep, high degree of heat
resistance and spills of chemical.
Epoxy Coatings (High Build): Epoxies in comparison to primers and topcoats are more
chemical and abrasion resistant. It protects not only the substrate, but also the zinc primer and
all other detrimental factors. One disadvantage of epoxy coatings is that, it has very little
resistance against ultra violet rays from sunlight. This leads to the erosion of the coatings
reducing the barrier protection.
Epoxy Primers (Zinc Rich): Epoxy anticorrosive modified with Zinc will ensure a high
level of service and are tolerant to different weather conditions and compromised surface
preparation provided that the zinc loading is sufficient. It is also most effective in maintaining
the damaged areas.

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Aliphatic Polyurethane Topcoats: Polyurethane coats provide optimum resistance to UV

rays and have high degree of flexibility and high chemical resistance. It also helps to maintain
a high degree (level) of cosmetic gloss, color retention and it can be easily cleaned.
Polyurethane finishes does not provide any real anti-corrosive or barrier protection, they do
provide a high degree of protection to integrity of the coatings system.
Non-Skid Deck Coating: These coatings are that are designed and engineered with anti-slip
properties. These coatings incorporate course aggregates. The coatings are applied in very
high film builds and usually without a zinc rich primer.
Cathodic Protection (CP): Most preferred technique for mitigating underwater or marine
corrosion is cathodic protection (CP) i.e. the practice or art of using electrochemical reactions
for prevention of steel structures from corrosion. The implementation of a Cathodic
Protection system is quite simple. Let us assume, there is corroding steel in seawater, all we
require is an anode and power supply. A protective circuit is achieved between the anode,
steel (cathode), seawater (electrolyte) and power supply.
Pile Mounted Anode: This method of anode delivery is used when the anode can be tied or
attached to the piles or cathode directly. These anodes are designed for efficient distribution
of current into and around the piling.
Sled Anode: These anodes are designed and engineered for operation in either seawater
(electrolyte) or it can be buried in the mud. An anode mounted on the seabed ensures the best
spread or distribution of protection for a marine structure. The advantage of this anode is its
low profile, hence limiting the chances of damage by fishing nets, ships anchor, etc.
Application of Fiber Reinforced Polymer Composites:
Fiber reinforced polymers (FRP) are mostly used for the repair and rehabilitation of concrete
structural elements. The composites are very light in weight, are resistant to chemicals, have
high strength and in fabric form have high degree of flexibility. The FRP composite when
mixed with wet concrete makes it economical to conduct repairs on sub structure parts. When
the FRP is used, then the corroded part of the structure element is carefully removed and the
FRP composite induced concrete is applied. The FRP provides the lost tensile capacity and it
also provides the steel with lateral support. When the FRP is applied with concrete, the
spreading of corrosion to other piles is protected and it also ensures protection from UV
radiation.

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2. Corrosion resistance and durability of concrete pile.

Plain or reinforced concrete piles embedded in earth are generally considered not subject to
deterioration. The water table, if free from deleterious substances, does not affect their
durability. In extremely infrequent situations, there is the possibility that concrete piles
embedded in permeable soils may be damaged by groundwater saturated by acids, alkalies, or
chemical salts. These commercial agents can result from wastes discharging from
manufacturing plants, sewer leakage, leaching from alkali soils, or leaching of acidic
compounds from coal or cinder fill. The use of dense rich concrete with sulfate-resisting
cement is a means of minimizing the effects of a deleterious environment. Concrete piles
should not be used where severe deterioration could possibly result.
Concrete piles extending above the surface of a body of water are subject to damage from the
abrasive action of floating objects, from ice where such exists, and from sand scouring.
Damage can also result from frost action, particularly in the splash zone, and from internal
corrosion of the reinforcement causing spalling of the concrete. The principal factors
involved in these frequent types of failures are (a) composition and density of the concrete,
(b) porosity of the aggregates, and (c) concrete cover over the reinforcing steel. Normally
reinforced concrete piles are more vulnerable to spalling failure than prestressed piles
because of inherent fine cracks in the concrete that develop from shrinkage, from handling of
the piles, and from tension and shear loads.
The deterioration of concrete piles can be minimized by careful formulation of the concrete
mix, use of sound, hard aggregates, and proper mixing, placing, consolidating, and curing to
achieve hard dense concrete. The reinforcing steel should have a Minimum cover of 2 in., and
the use of galvanized reinforcing is advisible where economically permissible. Prestressing
reduces cracks in concrete and should be used whenever possible.
Piles can be protected against some agents of deterioration by use of coatings and jackets
applied to vulnerable areas. On a project under way in New Jersey where prestressed cylinder
piles will be exposed to seawater, the interior and exterior surface of the piles are to be coated
with an epoxy bonding compound immediately following sandblasting of the surface. The
epoxy bonding compound is to provide a tight seal on the pile surfaces.
On a recently completed project in Long Island involving the use of prestressed concrete pile
bents, the pile surfaces in the tide zone were protected by wrought-iron pile jackets grouted to
the piles. Right-angle sections of '1/4-in. Thick wrought iron were bolted together to form a

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square jacket, and the 1.5-in. annular space between the jacket and pile was filled with grout
put into place by a tremie.
3. Corrosion resistance and durability of timber pile.
Timber piles are subject to deterioration caused by decay, insect attack, marine borer attack,
and abrasive wear. Decay is caused by growth of fungi that need moisture, air, favourable
temperature, and food. Decay can be prevented if wood can be kept dry, rendered unsuitable
for food, or entirely embedded in earth and cut off below groundwater level or submerged in
fresh water. Thus, untreated timber piles are subject to decay and insect attack where they
project above the water table or above the ground surface, and to marine borer attack where
they project above channel bottom in saltwater.
Reasonable protection against decay and insect attack, such as termites, can be attained by
poisoning the pile by impregnating the wood with pentachlorophenal or with creosote.
Treatment with pentachlorophenal is not recommended for marine piles. Creosote treatment
by a pressure process is the most effective method of poisoning wood piles for long-term
protection. However, this treatment will not prevent ultimate damage by certain species of
marine borers, notably the liminora.
Mechanical protection of wood piles in waterfront structures has been used successfully to
protect new piles and to repair piles damaged by abrasion or by marine borers. Mechanical
devices include Gunite encasements and precast concrete jackets grouted to the piles.
Intrusion-Prepakt concrete placed inside of forms fitted to timber piles has also been used.
Such encasements generally extend from a few feet below the mud line to some distance
above the high water level.
Fabrication
It is the general practice to remove the bark from wood because timber piles generally carry
load by skin friction. A decomposed weak film ultimately develops between the bark and the
wood creating a plane of weakness.
The butts of timber piles are cuts quare and the edges chamfered. The chamfering tends to
reduce the tendency to split during pile -driving. When piles are to be driven without the aid
of water jets, it is standard practice to trim the pile tips to about a 4-in. diameter when driving
through relatively firm foundation materials. In driving through gravelly soils, it is frequently
the practice to point the pile tips and clad them with steel shoes to prevent brooming.
Timber piles can be spliced when long piles are unavailable; however, it is time consuming
and rather difficult. Sleeve joint splices have been fabricated with 8-in. and 10-in. diameter

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pipe, 3 to 4 ft long. Bolted splices have been made by using timber and steel splice bars.
Gunite splices 6 ft long have been made by utilizing spiral reinforcement surrounding %-in.
diameter longitudinal reinforcing bars covered with a 5-in. thick mortar section. In current
practice, splicing of timber piles is an infrequent occurrence.

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CONCLUSIONS
• Though there is no absolute way to eliminate all corrosion on underwater piles, there are
some effective measures to control them.
• Cathodic protection is quit simple and protective coatings are used in vast and expensive
structures.
• The FRP composites have many advantages viz. lightweight, posses high strength and
chemical resistance and moreover have incomparable flexibility.

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