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FINDINGS LIBRARY · RIG

Mast step corrosion: keel-stepped mast heels and how surveyors write it up

UPDATED 6 NOVEMBER 2026 · 3 EXAMPLE FINDINGS · 1 SOURCES

Why the heel of a keel-stepped aluminium mast corrodes, what white powder and pitting mean, what a surveyor checks at the step, what repair involves and three example findings graded A, B and C.

AT A GLANCE
Mast step corrosion
USUAL GRADE
A for a mast heel or step corroded through or cracked, or a heel no longer sitting on the step. B for heavy pitting and white powder at the heel or step, or a step sitting in water. C for light corrosion and blocked drain holes
FOUND WITH
Lifting the sole to see the heel and step, looking for white powder, pitting, cracks and bulging, probing soft areas, checking the heel sits square, and looking for standing water
JUDGED AGAINST
Condition. Practical Sailor calls corrosion at the heel probably the most common problem with keel-stepped aluminium spars, with a powdery white deposit the first clue
REPAIR COST
A new step is a part and fitting. Cutting back a corroded heel and adding a spacer or new base means unstepping the mast. Priced per boat

On a keel-stepped boat, the mast goes through the deck and stands on a step at the bottom of the boat, usually right above the bilge. Salt water drips down the mast, collects round the step and sits against aluminium, often next to a stainless or steel fitting. The heel corrodes quietly where nobody looks.

How a surveyor checks it

Lift the sole and look at the heel and step. Practical Sailor says corrosion at the heel is probably the most common problem with keel-stepped aluminium spars, and the first clue is a powdery white deposit round the edge of a fitting. Look for pitting, bubbling paint, cracks and swelling where the heel meets the step. Probe anything suspicious.

Check the heel sits square on the step without gaps, the drain holes are clear, and the step isn't standing in water. Note what the step is made of and what it's bolted to.

What decides the grade

Remaining metal and how the mast sits. Corrosion through the wall, cracks or a heel that's settled off the step is an A. Heavy pitting on sound metal is a B. Light powder on a dry step is a C.

Mast step corrosion: example findings

The same defect written up at each grade, the way Axsail writes it from what the surveyor says on board. The grade follows what was found, so use these as wording, then grade what you see.

RIGA
Mast heel and step, keel-stepped mast

Mast heel corroded through on the aft side for about 60 mm. Heel no longer sits square on the step. Step sitting in bilge water.

Recommendation: Do not sail until the mast has been unstepped, the heel cut back and repaired or a new base fitted, and the step replaced.

RIGB
Mast heel and step

Heavy white powder and pitting round the bottom 100 mm of the mast and on the step. Metal sound on probing. Drain holes blocked.

Recommendation: Have a rigger inspect the heel at the next unstepping, within 12 months, clean and treat the corrosion, and clear the drains so the step stays dry.

RIGC
Mast step

Light white powder on the step. Heel sits square, metal sound. Step dry.

Recommendation: Clean and protect the step and keep the bilge dry. Recheck at the next survey.

ASafety. Safety or compliance deficiency. Fix before the vessel is next underway.
B12 months. Deficiency that needs timely attention. Fix within about 12 months.
CRoutine. Note or observation, cosmetic or maintenance. Routine maintenance at the owner's convenience.

What repair involves

Job Reported cost
Clean, treat and clear drains Owner's time
New mast step Part and fitting
Cut back the heel and fit a spacer or new base Rigger, mast unstepped
Unstep and restep the mast Crane and rigger time

Photos to take

The heel and step from each side, the white powder and pitting close up, the drain holes, and any water. With Axsail, say what you see at the heel as you take each photo and they go on the rig finding.

Writing it up

Describe the heel and step, how far up the corrosion goes, whether the metal is sound on probing, how the heel sits, and whether the step is dry. With an A, say "do not sail".

Frequently asked

Why do keel-stepped masts corrode at the heel?

The heel sits in or near the bilge, often wet with salt water, and often on a step of a different metal. Practical Sailor calls heel corrosion probably the most common problem with keel-stepped aluminium spars.

What does mast corrosion look like?

Practical Sailor says the first clue is likely a powdery white deposit round the edge of a fitting. Pitting, bubbling paint and swelling under fittings follow. Probe anything that looks bad.

How do you stop mast step corrosion?

Keep it dry and avoid dissimilar metals. Drain holes in the heel and step should be clear, the bilge under the step dry, and stainless fittings isolated from the aluminium.

Can a corroded mast heel be repaired?

Often. A rigger can cut back the corroded section and restore the height with a new base or spacer, with the mast unstepped. A heel that's corroded far up the section may need more.

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Standards it's judged against

ISO 12215

Small craft, Hull construction and scantlings (ISO 12215, in several parts)

What ISO 12215 covers for small craft hull construction, the parts on design pressures, structural details, rudders, keels and rig attachments, how surveyors use it on structural findings, and how to cite ISO 12215 in a finding.

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