Corrosion-induced thickness loss in steel quay walls

Abstract

Maritime ports are key components of global logistics networks, with steel quay walls providing berthing capacity and operational continuity. Their long-term structural performance is governed by corrosion driven by interactions between salinity, hydrodynamics, microbiological activity, and climatic conditions. Given that across Europe, many twentieth-century structures have exceeded their design life, reassessment of safety and residual capacity is essential. Conventional assessments typically use deterministic, uniform corrosion profiles based on simplified environmental classifications. In practice, however, field data show that corrosion is spatially variable, has short correlation lengths, and involves co-existing uniform and localised mechanisms. The scarcity of long-term, spatially detailed measurements has limited of site-specific deterioration models to be validated and included in design codes. This study analyses corrosion in steel quay walls at the Port of Rotterdam using ultrasonic thickness measurements and laboratory surface-morphology data. The database quantifies mean wall-thickness loss and spatial variability, enabling systematic comparison with design prescriptions. To interpret the observed variability, the study develops a stochastic corrosion representation based on random-fields, allowing explicit incorporation of spatial heterogeneity into structural assessments. The outcomes highlight the limitations of uniform corrosion assumptions and provide a basis for improved reliability evaluations and lifecycle-management strategies for ageing port infrastructure.