Evaluation of Accelerated Rail Corrosion at Bulk Terminal, Port of Long Beach Pier G Berths 212–214 Terminal

The Pier G Berths 212–214 terminal handles dry bulk material products, including coal, petroleum coke, soda ash, and sulfur, which are imported and exported primarily by rail. During a project to construct rail, paving, and wharf improvements at this terminal, significant corrosion was observed of the crane rails used by two ship loaders, railroad tracks, fastening clips, and other metal materials, which were embedded in the existing asphalt pavement. A quick initial corrosion study was performed while the construction was being performed. This initial study determined that a corrosive mix of water and dry bulk materials collecting below the pavement surface was the primary cause of the rapid rate of the pavement embedded metal component corrosion encountered. This paper will detail the more extensive subsequent rail corrosion investigation study that was performed to investigate the cause of extensive embedded railroad track and crane rail corrosion that was presumed to be occurring at the terminal, as well as to recommend corrosion monitoring applications to prevent undue failing of the embedded rail components and potential rail operation risks. The estimated service life of existing rails, recommended schedule for replacement, and recommended corrective measures to mitigate future rail corrosion are included in the study.