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Report on the Causes of Ships Rudder Breakdown
A Case Study in Research I
Presented by:
E/Cdt Bepitel, Breylle L.
E/Cdt Veloso, Ryan P.
Crankshaft-III
Presented to:
C/E Denise C. Valdez
Instructor
January 2013
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TABLE OF CONTENTS PAGES
Appendix
List of Figures
Synopsis
Glossary
3
4
5
Chapter 1 - Introduction
1.1 Background of the Study 6
1.2 Parts of a Rudder 7
1.3 Types of Rudders 8
1.4 Types of Rudder Failures 9
Chapter 2 - Narrative
2.1 Causes of Rudder Failure
2.1.1 Stock failure 10-11
2.1.2 Delamination 12
2.1.3 Cavitation 13-15
Chapter 3Analysis of Data
3.1 Rudder Failure Repairs
3.1.1 Rudder Stock Repair 16-18
3.1.2 Delamination Repair 18-23
3.1.3 Cavitation Repair 24-29
Chapter 4Conclusion 30
Chapter 5Recommendations 31
5.1 Actions to be taken during MOB in the berth
Sources 32
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APPENDIX
List of Figures
FIGURE PAGES
Fig. 1 Damaged Rudder Stock 10
Fig. 2 Delaminated Rudder Skin/Coating 12
Fig. 3 Cavitation of a Rudder 13
Fig. 4 Rudder Stock Repair 16-17
Fig. 5 Drilling and Filling of Delaminated Area 19
Fig. 6 Removing the Skin and Repairing the Core 21
Fig. 7 Grid 2 Ft By 2 Ft Squares in Indexed Locations of Cavitated Rudder 24
Fig. 8 Critical Repairs to a Rudder that has Suffered Cavitation 24
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SYNOPSIS
Ships rudder breakdown is a constant expense and interruption to ship
owners and operators.
A great deal of effort goes into the design and manufacture of rudders
because they are such an important part of a vessel. As any ship owner
knows, a ships rudder is particularly prone to damage. The problem features
more prominently in high speed container carriers and other fast ships, which
are more seriously affected than slower vessels. However, it is a potentialproblem and hazard for all ships and boats.
If a rudder is not given the proper protection against different rudder failures
such as rudder stock failure, delamination and cavitation, these result in
frequent, costly repairs to or replacement of this vital part of the ships
underwater equipment. The financial consequences can be substantial for
the owner. So far, the bulk of efforts to relieve this problem are quite effective
somehow.
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GLOSSARY
Cathodic Protection(CP)- is a technique used to control the corrosion
of a metal surface by making it the cathode of an electrochemical cell
Epoxy - has a wide range of applications, including metal coatings,
use in electronics / electrical components, high tension electrical
insulators.
Erosion corrosion -is a degradation of material surface due tomechanical action, often by impinging liquid, abrasion by a slurry,
particles suspended in fast flowing liquid or gas, bubbles or droplets,
cavitation.
Fiberglass - is a fiber reinforced polymer made of a plastic matrix
reinforced by fine fibers of glass.
Fouling -is the accumulation of unwanted material on solid surfaces to
the detriment of function.
Oxidation -is defined as the interaction between oxygen molecules
and all the different substances they may contact, from metal to living
tissue.
Shipowner -is the owner of a merchant vessel (commercial ship).
Turbulence- is a flow regime characterized by chaotic and stochastic
property changes.
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1. CHAPTER I
INTRODUCTION
1.1 Background of the Study
A rudder is a device used to steer a ship, boat, submarine, hovercraft,
aircraft or other conveyance that moves through a medium (generally
air or water). A rudder operates by redirecting the fluid past the hull.
In basic form, a rudder is a flat plane or sheet of material attached with
hinges to the ships after end. Often rudders are shaped so as to
minimize hydrodynamic drag. On simple watercraft, a tilleressentially,
a stick or pole acting as a lever armmay be attached to the top of
the rudder to allow it to be turned by a helmsman. In larger vessels,
cables, pushrods, or hydraulics may be used to link rudders to steering
wheel.
Through normal use, rudders go through a lot of stress. With every turn,
the skin on each side is subject to a cycle of compression and tension.
Years of sailing can accumulate a lot of these fatigue cycles. Shock
loads, groundings, competitive sailing and a rudder that may have
been under-engineered all contribute to rudder failure. Of all the parts
of a ship, rudder is one of the most important parts in a vessel for it is
use in maneuvering. After hull integrity, rudder integrity is the most vital
component of a seaworthy vessel.
Maintaining rudder integrity is quite hard because of its situated
position. It requires dry docking before proceeding to its maintenance.
As a result, there are already many reported cases of breakdown of
ships rudders.
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These caught the attention of the seafaring industry to solve this issue
because of the damages caused by ships rudder breakdown like
collision, grounding and worst, loss of lives. As a result, the researchers
have come up with the following cases of rudder failures but before
that, parts of the rudder, types of rudders and kinds of rudder will be
discussed first.
1.2 Parts of a Rudder
1.2.1 Rudder Stock
Rudder stock is the vertical member at the forward edge of a rudder,
hinged at the sternpost and attached to the helm or steering gear.
1.2.2 Rudder Framework
Rudder framework is made out of stainless steel, rather than mild steel,
and is firmly attached to the stock with long, strong welds.
1.2.3 Rudder Bearings
Rudder bearing is used to support rotating shaft against either
transverse or thrusts loads.
1.2.4 Rudder Shaft
Rudder shaft is the central shaft around which the rudder turns. This is
the shaft of the rudder to which the tiller or steering mechanism is
attached.
1.2.5 Rudder Brace
Rudder brace is the system of aligned gudgeons and pintles which
form a pivot for the rudder.
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1.3 Types of Rudders
The choice of the rudder type will depend on factors such as ship or
boat type and size, the shape of the stern, size of the rudder required
and whether there is a propeller upstream of the rudder.
1.3.1 Balanced Rudder
Open stern frame with a bottom pintle, which is a support bolt or pin
with a bearing. The upper bearing is inside the hull. It has been applied
to vessels such as tugs and trawler sand extensively to single-screw
merchant ships.
1.3.2 Spade Rudder
A balanced rudder. Both bearings are inside the hull. Bending moments
as well as torque are carried by the stock, leading to larger stock
diameters and rudder thickness. Applied extensively to single and twin-
screw vessel, including small power craft, yachts, ferries, warship and
some large merchant ship.
1.3.3 Full skeg rudder
An unbalanced rudder. The rudder is supported by a fix skeg with a
pintle at the bottom. Applied mainly to large sailing yathcts, but also
applied as hydroplanes on the underwater vehicles.
1.3.4 Semi-balanced skeg rudder
Also known as horn rudder or mariner rudder. The movable part of the
rudder is supported by a fixed skeg with a pintle at the bottom of the
skeg.
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1.3.5 Semi-balanced rudder, aft of skeg or deadwood
Typically applied to the twin-screw ship with the single rudder. Tends to
have been suspended by the use of twin rudder or type.
1.4 Types of Rudder Failures
There are many different causes of rudder breakdown. It has its own
unique characteristics which differ from the other. One can causedamage to the ship instantly and others can affect in a long duration
of time.
These damages require careful investigation for it will occur anytime if
neglected to be solved. Examples of rudder breakdown are as follows:
1.4.1 Stock Failure
Stocks can fail in several ways, all related to inadequate strength.
However, a rudder stock should not be so strong that it pries open the
bottom of a boat rather than bending in a collision or grounding.
1.4.2 Delamination
It is the separation of the layers of coating caused by stress and
dissolution of the adhesives.
1.4.3 Cavitation
Cavitation is caused by the flows from the motion of the propeller, the
cavities imploding on the propeller blades or being transported rapidly
back to implode on the rudder surface. The cavitation can also be
caused by the turbulence around the rudder itself, and the collapse of
the cavities can occur almost immediately after the cavity is created.
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Rudder stock is the vertical member at the forward edge of a rudder,
hinged at the sternpost and attached to the helm or steering gear.
Most rudders are constructed around a solid or hollow stainless steel or
aluminum stock. This tube or bar connects the rudder to the boats
steering mechanism.
Stocks can fail in several ways, all related to inadequate strength.
However, a rudder stock should not be so strong that it pries open the
bottom of a boat rather than bending in a collision or grounding. This
makes spade rudders on lightly built boats unavoidably more
vulnerable to a bent stockthe rudder is sacrificed to save the hull.
A bent metal stock can result in a rudder being jammed off-center,
which will stop any efforts to steer a boat with sails, a jury rudder or by
towing lines. Composite rudder stocks, meanwhile, will break rather
than bend.
Under normal operating conditions, a rudder stock is subject to
repeated and reversing torsional stress, which it can easily handle if it is
sized correctly.
Stainless steel, in particular, suffers when deprived of oxygen, which is
exactly what happens up inside a rudder tube full of stagnant
seawater. This effect is worsened when the shaft comes in contact with
a solid bearing surface, which rubs away the oxide film that protects
the steel.
Hidden from view, the stock begins to corrode. Over time, its strength is
compromised enough that an impact or strong twist snaps it like a
pretzel, and the rudder falls away.
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2.1.2 Delamination
Fig. 2 Delaminated Rudder Skin/Coating
Delamination is the peeling from undercoat or substrate. Delamination
can occur anywhere in the rudder but will most likely show up in this
same area where the metal mandrel inside the rudder ends. The stress
cracks and delamination can go unnoticed for a season or two and
the problem may not be identified until water begins weeping from the
rudder after the boat is pulled from the water.
In northern climates, delamination can be caused by freezing water. A
slight leak at the top of a fiberglass rudder will allow moisture to enter.
A drop or two of water per day adds up over time. Once inside, the
water will freeze during the winter. When it freezes, it expands and can
crush the foam core and, in some cases, cause the rudder to
delaminate and even split apart. It may take several seasons for a
problem like this to reveal itself.
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2.1.3 Cavitation
Fig. 3 Cavitation of a Rudder
A ships rudder, placed directly behind the propeller to give the ship
maximum maneuverability, is particularly prone to erosion followed by
corrosion. The erosion in this case is caused by hydrodynamic
cavitation.
Hydrodynamic cavitation is a phenomenon that accompanies
turbulent fluids. The turbulence in the fluid, in this case, is caused by the
ships motion through the water but more particularly by the action of
the ships propeller which results in areas of greatly reduced fluid
pressure.
Due to the low pressure, the water vaporizes. This causes small vapor-
filled cavities or bubbles in the fluid up to about 3 mm in diameter.
The cavities travel through the water and the pressure around them
increases, causing them to collapse suddenly. The implosion of the
cavities is accompanied by a complex set of physical processes.
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It is the collapse of the cavities which is accompanied by very high
pressure pulses, speeds and temperatures in the water, that cause the
damage.
The forces involved are very large. It is as if the surface affected has
been subjected to repeated, heavy blows from a hammer, as well as
high temperatures. This causes what is known as cavitation erosion as
the surface material, first paint and then steel, begins to flake away.
This process can be greatly magnified by the presence of gravel or
other hard particles in the water.
One need only examine a ships rudder that has been subjected to
cavitation damage to see that, whether one understands or subscribes
to the theory, in practice very real damage is caused by this
phenomenon.
Rudders become deeply pitted; paint coatings and hard steel simply
disappear; whole plates can fall off and the rudder practically
disintegrates altogether, all as a result of this cavitation damage.
So the rudder is subjected to cavitation damage from two main
sources: the turbulence caused by the propeller and that caused by
the water flowing over the rudder itself.
Cavitation damage is not limited to the ships rudder. The propeller is
also subject to the phenomenon, as are stabilizers, the vessels hull and
other parts of the underwater vessel where the water flows are
particularly swift or turbulent. But the rudder is particularly prone to this
phenomenon due to its position and form.
The process is gradual, but not necessarily slow. This process can occur
in a remarkably short period of time. Sometimes six months is all it takes
for serious rudder damage to be present.
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The first step is that the cavitation causes the paint coating on the steel
to erode, eventually exposing bare steel. The erosion of the steel is then
accompanied by the electro-chemical process of corrosion because
the steel is no longer protected.
The effect is multiplied as the cavitation continues and the erosion it
causes is added to by the natural corrosion of bare steel exposed to
water the electro-chemical process and the oxidation which this
brings about.
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3. CHAPTER III
CASE ANALYSIS
As any ship owner knows, a ships rudder is particularly prone to
damage caused by many factors such as erosion, corrosion, possible
near grounding incident and many more. These factors result in
frequent, costly repairs to or replacement of this vital part of the ships
underwater equipment.
So far, the bulk of efforts to relieve this problem have not been fully
effective. Symptoms of rudder failure are not easily detected, but the
ship can lower the risk of failure with a proper program of rudder care
and maintenance. The researchers have come up with the following
repairs taken from reliable sources.
3.1 Rudder Failure Repairs
3.1.1 Rudder Stock Repair
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Fig. 4 Rudder Stock Repair
According to Marketendia, a company expert in rudder failures, here
are the following procedures for repairing a damaged rudder stock:
1. View the stock:The best way to tell if your stock is sound is to get
a look at it where it is most likely to fail, in the area hidden by the
rudder tube. This is like examining through-the-deck chain plates
by extracting them. In the case of a rudder, dropping it a fewinches to expose the critical part of the stock should be
adequate. This applies equally to composite stocks, which can
suffer from hidden wear or damage just above where they enter
the hull.
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2. Check vertical alignment:Aside from its adverse effect on sailing
performance, a bent rudder stock will have been weakened,
and straightening it will weaken it more.
The force that bent the stock may also have damaged the
rudders bearings, internal frame, outer shell or even the structure
of the hull and rudder tube. A spade rudder that is not vertical or
does not rotate in place at the bottom of the blade requires a
careful and complete evaluation.
3.1.2 Delamination Repair
Accumulated stresses can lead to cracks in other locations on the
rudder. A common skin failure on an aging rudder occurs in the area
where the metal mandrel inside the rudder ends.
These stress cracks show up on the sides of the rudder about two thirds
of the length down from the top. The damage may be isolated to the
cracks in the fiberglass skin or problems may go deeper.
When delamination is discovered, drill a few small holes to drain any
water that may have accumulated inside the void. Tap on the outside
of the rudder to identify the extent of damage.
Delaminated areas will have a distinct dull sound compared to
undamaged sections. Use a pencil or permanent marker to identify the
boundaries of damage.
The researchers have come up with the following procedures for
repairing delamination of rudders:
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There are two approaches one can take to restore strength to the
delaminated area.
1. The first and easiest option is the drill and fillapproach.
2. The second option involves removing the fiberglass skin in the
delaminated area, repairing the core, gluing the skin back in
place and structurally repairing the original cracks in the skin if
any and the cuts made in the fiberglass skin to gain access to
the core.
Drilling and Filling Approach
Fig. 5 Drilling and Filling of Delaminated Area
The drill and fill method is the easiest of the two repairs. It involves fewer
steps but takes more time to complete the repair because of the
longer time required to dry out the wet core before the repair can be
attempted.
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The repair may not be as reliable as the second method because there
is no opportunity to inspect or prepare the delaminated areas inside
the rudder for optimum bonding. Even so, this method has worked well
when the damage is not too extensive.
1. Drill a series of 1/8" to 3/16" holes on a one inch grid pattern over
the debonded area. Drill deep enough to get to the center of the
core. You may hit the metal mandrel.
2. Dry the core. Wet cores can take weeks or months to dry even ifa multitude of holes have been drilled. Force drying with heaters or
heat lamps is recommended for speeding the process. A small fan
blowing over the surface will help.
Locate any heat source carefully to minimize the risks of fire. I have
been surprised to find how hot a surface can get after leaving a heat
lamp unattended for several hours.
3. Verify that the core is dry by drilling a few more holes when you
think the rudder has dried out. Squeeze the core drillings to see if they
are dry.
4. Inject a slow curing epoxy such as 105 Resin and 206 Hardener or
105 Resin with 209 Extra Slow Hardener. Use syringes to force the epoxy
into the delaminated areas. Lay the rudder on its side with the drilled
side facing up, so gravity works in your favor.
5. Refill the holes as necessary with unthicken epoxy until the holes
are filled flush with the surface. A light layer of fiberglass cloth can be
applied over the area to strengthen the area if desired.
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Removing the Skin and Repairing the Core Approach
Fig. 6 Removing the Skin and Repairing the Core
Most repair facilities use the second option and cut off the fiberglass
skin in the delaminated area. They remove and repair the voided core
before gluing the rudder skin back in place. This method allows the
rudder to be repaired over the period of days rather than weeks. It is
also a more reliable repair because you get to see what you are
bonding to. Surfaces can be dried quickly and thoroughly, and
damaged core can be removed and replaced with new core.
1. Cut through the fiberglass skin using the marked boundary of the
delaminated area as a guide. Use a rotary tool or a circular saw
with the blade set to cut just below the surface of the fiberglass.
2. Carefully pry off the fiberglass skin to expose the delaminated
core. Removing the skin may be difficult if the delamination is
within the core rather than between the skin and core.
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8. Press the fiberglass skin into the thickened epoxy and hold it in
position (flush with the surrounding skin), with weights, duct tape
or bungee cord.
9. Prepare the cuts in the fiberglass skin for repair by grinding a 12:1
bevel in both directions from the cut. An 1/8" thick fiberglass skin
will require a 1/2" wide bevel on either side of the cut.
10. Apply several layers of fiberglass tape over the joint. Use enough
layers to equal the thickness of the skin. (Several layers of 731 or732, 9 oz. fiberglass tape equals about 1/8".
11. Prepare the surface of the cured epoxy by washing with water
and an abrasive pad, and sanding thoroughly (or wet sanding).
Fair the fiberglass buildup with 407 Low-Density filled epoxy.
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3.1.3 Cavitation Repair
Fig. 7 Grid 2 Ft by 2 Ft Squares in Indexed Locations of Cavitated Rudder
Fig. 8 Critical Repairs to a Rudder that has Suffered Cavitation
Rudder cavitation damage is a well-known and extensively
documented phenomenon. There is a vast amount of literature on the
subject. High speed video has been used to capture the process of
cavitation in action so that it can be studied.
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Computer programs have been developed to model the effects of
cavitation and predict where the most damage will occur, depending
on the construction and shape of the rudder. Many scientists have
investigated the phenomenon and scientific papers on the subject
abound.
There have been many attempts to prevent the damage caused by
cavitation. In the main these attempts fall into the following categories:
1. Change the position of the rudder so that it is not behind the
propeller. This reduces cavitation on the rudder, but is
impractical since the ship loses its maneuverability. The ideal
placement of the rudder so that it provides maximum control of
the ship is directly behind and in the wake of the propeller. The
more rapidly moving water makes the rudder more effective.
In other words, positioning the rudder so that it carries out its
function in the best possible way renders it most liable to
cavitation damage.
2. Redesign the rudder so that it is less affected by the flows and
turbulence. Some inventors have developed a twisted rudder
which is marketed and in use.
The twist is an attempt to reduce the turbulence caused by the
flow of the water from the rotation of the propeller by changing
its angle of attack on the rudder. This has met with some success
but has not eliminated the problem.
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3. Strengthen the surface of the rudder to increase its resistance to
cavitation erosion, often with some other metal. This has only
partially relieved the problem, and can in fact be
counterproductive if the combination of metals increases the
electro-chemical/corrosion factor. The difference in potential
between metals can cause very rapid corrosion to occur.
Historically, the most dramatic example of this was perhaps the
attempt to put copper sheathing on steel hulls to protect them
from fouling. The proximity of the two metals resulted in very
rapid corrosion of the steel. There have been attempts to
reinforce the rudder with a stainless steel plate over the steel,
only to have the welds or fasteners holding the plates in place
corrode completely so that the plates simply dropped off.
4. Use cathodic protection systems to reduce the electro-
chemical/corrosive effects. Since the corrosion only sets in after
the protective coating has been eroded by cavitation, this is like
putting a lock on the barn door after the horse has been stolen.
It may reduce the corrosion, but it does not address the primary
cause, which is the erosion damage caused by the cavitation.
5. Develop better coatings and rudder protection.
Current Practices
The most common practice is to use a conventional type of rudder,
place it directly behind the propeller and coat it with a typical epoxy
coating or antifouling scheme consisting of primer, epoxy coats,
midcoat and biocidal AF paint; the rudder area is often also
surrounded by a number of sacrificial anodes for cathodic protection.
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Depending on the design of the rudder, the usual cruising speed of the
vessel and the presence or absence of abrasive particles in the water,
cavitation erosion sets in rapidly or not so rapidly; the paint is eroded
away leaving bare steel; the steel is then subjected to the combined
damaging effects of cavitation erosion plus corrosion; the rudder
becomes pitted and damaged, usually in a specific pattern; inspection
reveals the damage, hopefully before it is too late, and the rudder
must be repaired or replaced before it disappears completely.
The repair usually consists of welding to restore and build up the surface
where the metal has eroded or corroded away, followed by
repainting. Plates may need to be entirely replaced.
This usually takes the form of lengthy and expensive hot work
performed in dry dock.
Alternatively, it can involve expensive, drawn out underwater repairs to
the rudder to keep it functioning until the next opportunity to drydock
the ship. Repairs done under water can only be considered a
temporary measure since the steel and the welds must of necessity be
left bare.
There have been many attempts to devise a better protection system
for the hull. Most of these have been ineffective but not all of them. The
vessel sails and the repaired rudder is subjected to further cavitation.
Weaker now, the damage occurs more rapidly. Before too long the
rudder must be replaced entirely. This all adds up to a continuing
economic nightmare for the ship owner/operator.
Dry docking is expensive in many ways, not the least of which is the off-
hire time it entails.
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Successful Approach
One particular coating, a specially formulated glass flake vinylester
surface treated composite (STC) has been found to be extremely
effective in completely preventing rudder cavitation erosion from
occurring in the first place, thus breaking this vicious circle.
This was an entirely practical solution, stumbled upon almost by
accident by the manufacturer, since the coating system was designed
for protection of the underwater ship hull and fouling control, notdeveloped specifically for rudder protection. Observation of the
coating system in action demonstrated that hull areas which are
normally prone to cavitation erosion were successfully protected with
this STC. There was no cavitation erosion where it normally would be
expected to occur. This then led to its experimental application to
rudders.
So far in the eight years that this system has been in use on many
different rudders not one has suffered any cavitation erosion damage.
The rudders so treated have not even needed to be recoated with the
STC, let alone repaired or replaced. The STC not only offers protection
against rudder cavitation damage, it has also been used to repair
rudder damage where it has occurred due to an ineffective paint
scheme. In cases where the steel was pitted but not completely wornaway, the STC was used to build up and repair the pitting, before
being applied to entire rudder to protect it against future damage. This
has also proved to be 100% effective.
Due to its high glass content, this coating is extremely tough and
resilient and has the added advantage of being an electrical insulator
which successfully prevents electro-chemical corrosion from taking
place.
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While the experiment with the STC has not yet been attempted on
every type of vesselsrudder, and it remains to be tried on some of the
really high speed ships, results to date show a potential final solution to
all rudder cavitation problems.
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4. CHAPTER IV
CONCLUSION
During the duration of the case study the researchers had able to
come up with the following conclusions:
1. Rudder breakdown is a constant expense and interruption to
ship owners and operators. Increasing numbers of high speedcontainer carriers and other vessels have magnified the problem
since they suffer from different rudder failures more than lower
rev, slower ships.
2. Most attempts to solve the problem have proved unsuccessful,
as evidenced by the continuing need for frequent repair or
replacement of rudders. Rudder design has mitigated the
problem somewhat but far from solved it.
3. For rudder stock, failure usually occurs because of repeated and
reversing torsional stress or even corrosion.
4. For delamination, the failure is due to crack formations in the
rudder. These cracks serve as a pathway for fluid to enter the
coating down the core/substrate. As a result, the rudder coating
tends to debond from the core.
5. For cavitation, most coatings generally fail to provide adequate
protection and usually erode. Cavitation usually occurs
electrochemical processes and even hydrodynamic drag.
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5. CHAPTER V
RECOMMENDATIONS
After analyzing the case, the researchers had come up with the
following recommendations:
1.
To avoid further accident caused by ships rudder breakdown,
scheduled dry docking maintenance must be observed.
2. Ships should also choose the right type of rudder that would suit the
ships speed and even the route itself.
3. For rudder stock, repair and maintenance should be observed at
any cost. Checking the alignment and ensuring it free of cavitation
could also help.
4. For delaminated area, the second approach stated in the Chapter
III, removing the skin and repairing the core approachis the best
way to repair a delaminated rudder area. It is a more reliable repair
because one can see what he is bonding to. Surfaces can be dried
quickly and thoroughly, and damaged core can be removed and
replaced with new core.
5. For cavitation, cathodic protection is not really a solution for this. It
will only slower down the process. To maintain rudder for cavitation,
dry docking must be observed. Choosing the right paint coating,
choice of rudder material and type of rudder are big factors that
should be observed by ship owners.
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