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FINDINGS LIBRARY · HULL AND STRUCTURE

Steel hull wastage: ultrasonic thickness readings and how much loss is too much

UPDATED 10 NOVEMBER 2026 · 3 EXAMPLE FINDINGS · 1 SOURCES

How a surveyor gauges a steel hull with an ultrasonic thickness meter, the 25 percent wastage limit used in US Coast Guard guidance, where steel boats corrode, and three example findings graded A, B and C.

AT A GLANCE
Steel hull wastage
USUAL GRADE
A for plate below the wastage limit, or pitting near through-thickness below the waterline. B for plate approaching the limit, or active corrosion with no readings yet. C for coating breakdown and surface rust on sound plate
FOUND WITH
An ultrasonic thickness gauge on a grid across the bottom and keel, extra readings round pits and thin edges, a hammer, and a close look at the bilges and under fixtures
JUDGED AGAINST
The builder's plate thickness. A surveyor's write-up of a hull gauging uses the US Coast Guard's NVIC 8-68 guidance of no more than 25 percent wastage of original thickness
REPAIR COST
Plate is cut out and new steel welded in, priced by the yard for each area. No published per-plate figure to quote

A steel hull rusts from both sides: from the sea outside, and from the bilge water, condensation and trapped damp inside. Coatings slow it down. Where they fail, plate gets thinner, and the outside of the hull can look sound while the plate behind is wasting.

How a surveyor checks it

Gauging. An ultrasonic thickness gauge reads the plate from one side. The surveyor in this gauging report calibrated a 5 MHz gauge on a known 5 mm plate and took readings on a 12 by 24 inch grid across the underbody and keel, with extra readings wherever there was deep pitting, holes, fractures or thin edges on structural members.

The limit. That report applied the US Coast Guard's NVIC 8-68 guidance: no more than 25 percent wastage of original thickness. On the 5 mm hull plate in the report, that put the limit at about 3.75 mm. Class societies and flag states set their own limits for the vessels they cover. Pitting is judged on its own: one deep pit near through-thickness needs repair whatever the plate around it reads.

Where to look. The inside is where steel boats usually go: bilges that stay wet, under tanks and engines, behind linings and insulation, round deck drains and at the turn of the bilge. Outside, look at the waterline, round anodes and fittings, and anywhere coating has broken down. Dissimilar metal at fittings such as a mast step needs isolating from the steel; see stray current corrosion.

What you can't gauge. Filled and faired topsides can't be read reliably. The report in the source gauged only the underbody and keel for that reason. Say so in your report.

What decides the grade

Thickness against the original and the limit. Plate below the limit, or pitting near through-thickness below the waterline, is an A. Plate approaching the limit is a B: regauge to measure how fast it's going. Coating breakdown on sound plate is a C.

Steel hull wastage: 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.

HULL AND STRUCTUREA
Bottom plating, port side under the engine room

Ultrasonic readings of 3.4 to 3.6 mm over about 0.5 m² against 5.0 mm original plate, below the 25 percent wastage limit. Deep pitting under a bilge fixture, one pit near through-thickness.

Recommendation: Cut out and replace the plate in the area before the vessel is next afloat for any length of time. Gauge the surrounding plate to find the edge of the wasted area.

HULL AND STRUCTUREB
Keel plate and bottom plating aft

Readings of 4.0 to 4.2 mm against 5.0 mm original, about 16 to 20 percent wastage. Coating broken down with rust scale in the aft bilge.

Recommendation: Clean and recoat the aft bilge within 12 months and regauge at the next haul-out to measure the rate of loss.

HULL AND STRUCTUREC
Topsides, starboard bow

Coating breakdown and surface rust round the anchor locker drain. Readings within 5 percent of original.

Recommendation: Treat and recoat at the next maintenance period.

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

Wasted plate is cut out and new plate welded in, then coated. Yards price each area. The cost depends on access: plate behind tanks, engines or fitted joinery means taking those out first, which often costs more than the steel.

Photos to take

The gauge on the plate with its reading visible, a sketch or photo of the grid with readings marked, pitting with a scale, and the inside of the bilge. With Axsail, read each thickness out loud as you take it and the readings go into the finding.

Writing it up

Give the original thickness and where it came from, the limit you applied and its source, the readings by area, the worst reading and its location, and what you couldn't gauge. A table of readings by frame or position helps the yard and the next surveyor.

Frequently asked

How much wastage is acceptable on a steel hull?

A common limit is no more than 25 percent of the original plate thickness, from the US Coast Guard's NVIC 8-68 guidance, as one surveyor's gauging report applies it. Class societies and flag states set their own limits for the vessels they cover, and deep pitting can need repair before average thickness reaches the limit.

How is steel hull thickness measured?

With an ultrasonic thickness gauge, which reads plate thickness from one side. The surveyor in the source calibrated on a known 5 mm plate and took readings on a 12 by 24 inch grid, adding more round pitting, holes and thin edges.

What original thickness do you compare against?

The builder's scantlings, from the plans or the builder. Without them, compare against readings from protected areas of the same plate, and say in the report that the original thickness is assumed.

Why gauge a steel hull that looks sound?

Corrosion inside a steel hull is often hidden behind linings, tanks and fillers, so the outside can look sound. Gauging is the only way to know how much steel is left.

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