Section 38 - Corrosion Protection D 38 - 1

Section 38

Corrosion Protection

A. General Instructions unduly impaired. It must be ensured that welding with all
welding processes customary in the building of ships
1. Field of Application can be conducted without impermissibly impairing the
quality of the weld seam, see the Rules for Welding,
1.1 This section deals with the corrosion protection Volume VI, Section 6.
measures specified by BKI with respect to seagoing steel
ships. Details of the documentation necessary for setting 1.5 Due to the possible strain to the system presented
up the corrosion protection system are laid down herein by cathodic protection, seawater and chemicals, only shop
(planning, execution, supervision). primers are to be used which are alkali fast and not
hydrolyzable.
1.2 Corrosion protection for other types of ship as well
as other kinds of material, e.g. aluminium, is to be agreed 1.6 The suitability and compatibility of shop primer
separately in consultation with BKI. for use in the corrosion protection system is to be guaranteed
by the manufacturer of the coating materials.
1.3 Requirements with respect to the contractors
executing the work and the quality control are subject to
2. Approvals
the conditions laid down in Section 1, N.1.1 and 1.2.
2.1 Only those overweldable shop primers may be used
1.4 Any restrictions which may be in force concerning
for which the Society has issued a confirmation of accept-
the applicability of certain corrosion protection systems
ability based on a porosity test in accordance with the Rules
for special types of vessels (e.g. tankers and bulk carriers)
for Welding, Volume VI, Section 6.
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
C. Hollow Spaces
comments and recommendations for the selection of suitable
corrosion protection systems, as well as their professional
1. General
planning and execution.
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 from normal shipbuilding
experience, need not have their internal surfaces protected.
B. Shop Primers
During assembling, however, such hollow spaces must be
kept clean and dry.
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
D. Combination of Materials
as further surface preparation is carried out and the
subsequent coatings for corrosion protection are applied.
1. General
1.2 Customarily, coatings with a thickness of 15 µm
1.1 Preventive measures are to be taken to avoid contact
to 20 µm are applied.
corrosion associated with the combination of dissimilar
Under normal yard conditions, this should provide corrosion metals with different potentials in an electrolyte solution,
protection for a period of approx. 6 months. such as seawater.

1.3 The coating must be of good resistance to withstand

1.2 In addition to selecting appropriate materials, steps
the mechanical stresses incurred during the subsequent
such as suitable insulation, an effective coating and the
working of the steel material in the shipbuilding process.
application of cathodic protection can be taken in order
to prevent contact corrosion.
1.4 Flame-cutting and welding speed are not to be
38 - 2 Section 38 - Corrosion Protection F

E. Fitting-Out and Berthing Periods in a list (Approved Coatings for Newbuildings). The current
list is obtainable from Head Office.
1. General
2.2.3 Approval does not constitute confirmation of the
1.1 For protection against corrosion arising from stray suitability and compatibility of the coatings in the corrosion
currents, such as those occurring due to inappropriate direct protection system. These points are to be ensured by either
current electrical supply to the ship for welding or mains the yard or the manufacturer of the coating materials.
lighting, as well as those arising from direct-current supplies
to other facilities (e.g. shore cranes) and neighbouring ships, 2.3 Surface Preparation
the provision of (even additional) cathodic protection by
means of sacrificial anodes is not suitable. 2.3.1 The surface must be prepared according to the
instructions of the manufacturer of the coating material.
1.2 Steps are to be taken to prevent the formation of
stray currents, and suitable electric drainage is to be 2.3.2 Surface preparation is subject to specifications in
provided. the product data sheet and must correspond to a valid surface
quality grade, e.g. SIS 055900, DIN 55928, Part 4, or ISO
1.3 Particularly in the event of lengthy fitting-out periods, 8501 1-4.
welding rectifiers are to be so arranged that stray currents
can be eliminated. 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

F. Corrosion Protection of Ballast Water Tanks (tack plates, lugs etc.) must be completely integrated into
the corrosion protection, or otherwise removed.
1. General
2.4 Application
1.1 All seawater ballast tanks having boundaries formed
by the vessel’s shell (bottom, outside plating, deck) must 2.4.1 The process of application is to be carried out
be provided with a corrosion protection system. according to the coating manufacturer’s instructions.

1.2 The following corrosion protection systems are to 2.4.2 During application the ambient conditions and
be used: procedural instructions are to be complied with, in
accordance with the details specified in the manufacturer’s
S coating,
instructions and in the approvals.
S coating and cathodic protection,
2.4.3 Surface areas which are obstructed and are thus
2. Coatings inadequately exposed to the spraying, exposed edges and
corners, as well as weld seams, must be stripe coated in
2.1 General advance to achieve a sufficient coating thickness.

2.1.1 The coatings must be, in accordance with the 2.5 Dry Film Thickness
manufacturer’s specifications, resistant against sea-water,
coastal water, harbour water and the substances they may 2.5.1 The dry film thickness of the coating systems must
contain. be in accordance with approvals and correspond to a
minimum of 250 µm.
2.1.2 The characteristics, composition and field of
application of a coating system must be documented, i.e. 2.5.2 The prescribed coating thicknesses represent the
prescribed by the manufacturer of the coating material. minimum coating thickness which must be maintained in
Details of the coating material, how it is to be processed all cases.
and its suitability for the coating system must be contained
in the product data sheet.
2.6 Documentation
2.2 Approvals
2.6.1 The work processes involved in setting up a coating
system as well as the coating materials to be used must be
2.2.1 For new buildings, the applied coatings and coating
laid down in a coating plan.
systems must be approved by BKI. The approvals must
be obtained by the manufacturers of the coating materials
2.6.2 The coating plan for ballast water tanks must be
from BKI Head Office.
submitted to BKI for approval.
2.2.2 Approved coatings and coating systems are compiled
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 DIN 50928, or equivalent.
preparation and coating materials used, are documented.
3.2 Cathodic Protection
2.6.4 This documentation is to be compiled by the coating
manufacturer and/or the contractor executing the work 3.2.1 General
and/or the yard. An inspection plan must be agreed to
between the parties involved. The papers pertaining to the For the cathodic protection of ballast water tanks in
documentation must be signed by these parties. On combination with coatings, sacrificial anodes made of zinc
completion of the coating system, the signed papers or aluminium are used. Tables 38.1 and 38.2 contain
constituting the documentation are to be handed to the recommended alloy compositions for conventional
surveyor for acceptance. The documentation is to contain aluminium and zinc anodes.
the following data:
Zinc and aluminium anodes of differing chemical
S location and date, composition may also be used, provided proof of the
cathodic protection ability is provided.
S ship and the tanks treated,
Zinc anodes may not be used in the event that operating
S manufacturer’s specifications for the coating system
temperatures in excess of 60 °C can be expected.
(number of coatings, total coating thickness,
processing conditions), Impressed current systems are not permitted in ballast water
tanks.
S product data sheet for the coating and BKI approval
number, Connections between the anodes and the surface to be
protected must provide good conducting properties.
S contractors and persons carrying out the work,
The anodes are therefore to be welded on, wherever
S surface preparation (procedure, working materials,
possible. In exceptional circumstances, where bolting on
ambient conditions),
the anodes offers the only practicable alternative, an
S condition of surface prior to coating (cleanness, adequate and durable metallic conducting connection must
roughness, existing primer, surface quality grade be provided, e.g. cable connection.
achieved),
Sacrificial anodes are not to be coated over and must be
S application (procedure, number of coatings), free from dirt and other impurities.
S application conditions (time, surface/ambient
3.2.2 Protection Current Requirement
temperature, humidity, dew point, ventilation),
For coated surfaces a protection current density of
S the date the tanks were first ballasted is to be
0,02 A/m2 shall be applied.
recorded,
In the event that ballast water tanks may be subjected to
S report of coating thickness measurement and visual
higher temperatures, for instance due to adjacent heating-oil
inspections,
tanks, the protection current density is to be increased as
S signatures of involved parties (yard, coating manu- follows:
facturer, work contractor).
For each °C over 25 °C by 1 mA/m2
2.6.5 Coating protocols already in existence and used by The protection period must be designed to last for a
coating manufacturers, work contractors, yards and ship minimum of 5 years.
owners will be accepted by BKI, provided they contain
Deviations from the values stated for protection current
the above data and are signed by all parties involved. Any
density and protection period could be accepted if a written
missing data is to be furnished.
confirmation of the owner exists.
3. Coatings combined with Cathodic Protection
3.2.3 Anode Weight
3.1 Coating The required total anode weight is calculated according
to:
3.1.1 In the case of coatings used in combination with
AG @ JS @ tS
cathodic protection, the provisions under 2 shall apply. mG = [kg]
Qg
3.1.2 In addition, the coatings must be resistant against
the cathodic protection, i.e. the coatings must not exhibit where:
any impairment of their purpose up to a potential of – 1200 AG = the total area to be protected in [m2]
mV against the copper/copper-sulphate electrode. Proof
of resistance against cathodic corrosion protection can be JS = protection current requirement in [A/m2]
provided in accordance with recognized standards, e.g. according to 3.2.2.
38 - 4 Section 38 - Corrosion Protection G

tS = protection period in [h] 3.2.4 Arrangement of Anodes

Qg = electrochemical efficiency of the anode material
The arrangement of the anodes in the tank is to be such
in [Ah/kg]
that the required protection current density can be achieved
in all areas.
The electrochemical efficiency of the anode material is to
be taken out of the manufacturer’s specification. The number and size of the anodes depends on the structural
design and the calculated current output of the anodes. When
Table 38.1 Sacrificial anodes of zinc alloys for compiling the anode plan, the current output is to be taken
applications in seawater into account for the calculation.
An increase in the number of anodes required may be
Element KI-Zn1 KI-Zn2 necessary in the following circumstances:
Al 0,10 - 0,50 # 0,10 S when frequently low filling levels lead to a limitation
in the area effectively protected by the anodes,
Cd 0,025 - 0,07 # 0,004
S when internal structures attenuate the effective
Cu # 0,005 # 0,005 current for certain areas of the tank,
S when increased current densities are necessary for
Fe # 0,005 # 0,0014 the protection of more noble materials, e.g. internals
Pb # 0,006 # 0,006 made of stainless steel.

Zn $ 99,22 $ 99,88 3.2.5 Documentation

Potential – 1,03 V – 1,03 V The documentation of the coating must be in accordance
(T = 20 oC) Ag/AgCl/Seawater Ag/AgCl/Seawater with 2.6. In addition, the papers concerning the design and
Qg computation of the cathodic protection must be submitted
780 Ah/kg 780 Ah/kg for perusal. An anode plan need not be submitted.
(T = 20 oC)
Efficiency
95%
(T = 20 oC)
G. Corrosion Protection of Cargo Holds

Table 38.2 Sacrificial anodes of aluminium alloys for 1. General

applications in seawater 1.1 On bulk carriers, all internal and external surfaces
of hatch coamings and hatch covers, and all internal surfaces
Element KI-Al1 KI-Al2 KI-Al3 of the cargo holds, excluding the flat tank top areas and
the hopper tanks sloping plating approximately 300 mm
Si # 0,10 # 0,10 Si + Fe below the side shell frame and brackets, are to have an
Fe # 0,10 # 0,13 # 0,10 effective protective coating (epoxy coating, or equivalent),
applied in accordance with the manufacturer’s recommend-
Cu # 0,005 # 0,005 # 0,02 ation. In the selection of coating due consideration shall
Mn N/A N/A 0,15 - 0,50 be given in consultation with the owner to the intended
Zn 2,0 - 6,0 4,0 - 6,0 2,0 - 5,0 cargo and conditions expected in service.

Ti – – 0,01 - 0,05 1.2 The coating used must be approved by the

In 0,01 - 0,03 – 0,01 - 0,05 manufacturer for application in cargo holds.
Sn – 0,05 - 0,15 –
1.3 The coating manufacturer’s instructions with regard
Other El. # 0,10 # 0,10 # 0,15 to surface preparation as well as application conditions and
Al Residue Residue Residue
processing must be adhered to.

Potential – 1,05 V – 1,05 V – 1,05 V 1.4 The minimum thickness of the coating without
(T = 20oC) Ag/AgCl/Sea- Ag/AgCl/Sea- Ag/AgCl/Sea- antifouling shall be 250 µm, resistant to cathodic protection
water water water
in accordance with recognized guidelines and suitable for
Qg mechanical underwater cleaning.
2000 Ah/kg 2000 Ah/kg 2700 Ah/kg
(T = 20oC)
Efficiency 2. Documentation
95%
(T = 20oC) 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 immediate vicinity of the impressed-current anodes.
contained in the coating plan.
1.7 Cathodic protection by means of sacrificial anodes
2.2 A coating report is to be compiled in such a way is to be designed for one dry-docking period.
that details of all the work processes executed, including
the surface preparation as well as the coating materials used, 1.8 In the case of other materials, such as aluminium
are recorded. for instance, special conditions must be agreed with BKI.

2.3 This documentation is to be compiled by the coating 2. Documentation

manufacturer and/or the contractor executing the work
and/or the yard. An inspection plan must be agreed to 2.1 The coating plan and the design data for the cathodic
between the parties involved. The papers pertaining to the protection are to be submitted for examination.
documentation must be signed by these parties. On
completion of the coating system, the signed papers 2.2 In the case of impressed current systems, the
constituting the documentation are to be handed to the following details must also be submitted:
surveyor for approval.
S location and constructional integration (e.g. by a
cofferdam) of the anodes in the vessel’s skin,
S descriptions of how all appendages, e.g. rudder,
H. Corrosion Protection of the Underwater Hull propeller and shafts, are incorporated into the
cathodic protection,
1. General
S electrical supply and electrical distribution system.
1.1 Vessels intended to be assigned the class notation
2.3 The work processes involved in setting up the coating
IW (In-Water Survey) shall provide a suitable corrosion
system as well as the coating materials to be used must be
protection system for the underwater hull, consisting of
laid down in the coating plan.
coating and cathodic protection.
2.4 A coating protocol is to be compiled in such a way
1.2 Coatings based on epoxy, polyurethane and polyvinyl
that details of all the work processes executed, including
chloride are considered suitable.
the surface preparation as well as the coating materials used,
are recorded.
1.3 The coating manufacturer’s instructions with regard
to surface preparation as well as application conditions and
2.5 This documentation is to be compiled by the coating
processing must be observed.
manufacturer and/or the contractor executing the work
and/or the yard. An inspection plan must be agreed to
1.4 The coating, system without antifouling, shall have
between the parties involved. The papers pertaining to the
a minimum film thickness of 250 µm, shall be compatible
documentation must be signed by these parties. On
to cathodic protection in accordance with recognized
completion of the coating system, the signed papers
standards, and shall be suitable for being cleaned underwater
constituting the documentation are to be handed to the
by mechanical means.
surveyor for approval.
1.5 The cathodic protection can be provided by means
2.6 In the case of impressed current systems, the function
of sacrificial anodes, or by impressed current systems. Under
ability of the cathodic corrosion protection is to be tested
normal conditions for steel, a protection current density
during sea trials. The values obtained for the protection
of at least 10 mA/m2 must be ensured.
current and voltage must be recorded.
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