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For Official Use Only: Technical Literature On Corrosion/Carbonisation Protection in Concrete Structures
For Official Use Only: Technical Literature On Corrosion/Carbonisation Protection in Concrete Structures
For Official Use Only: Technical Literature On Corrosion/Carbonisation Protection in Concrete Structures
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(Railway Board)
MARCH 2008
BS-88
ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW - 226011
ii
CONTENTS
INTRODUCTION
1.0
CARBONATION OF CONCRETE
2.0
4
CHLORIDE ATTACK
3.0
CORROSION CONTROL
3.1
9
METLLURGICAL METHOD
3.2
CORROSION INHIBITORS
3.3
12
COATINGS TO REINFORCEMENT
3.4
METALLIC COATINGS
3.5
17
RE-ALKALIZATION
3.6
CHLORIDE REMOVAL
18
3.7
CATHODIC PROTECTION
18
3.8
21
COATINGS TO CONCRETE
4.0
REFERENCES
15
29
iii
0. Introductions
Corrosion of steel in concrete is a complex phenomenon. There are different
factors affecting the process of corrosion in concrete. The increase in volume of
reinforcement after corrosion is one of the adverse effects on the structure apart from
reduction in cross section area of reinforcement. Corrosion has been found one of the
important reason causing weakness to concrete structures. Lot of research has been done
on this subject in India and abroad to prevent the process of corrosion in concrete
structures. Before discussing the methods to avoid or reduce corrosion, it will be more
appropriate to understand some of the fundamentals of process of corrosion of
reinforcement in concrete. The ingress of water and oxygen is must to start process of
corrosion. The excess of Ca (OH) 2 as a result of hydration process of cement in concrete
provides a passive environment around reinforcement to prevent corrosion. The pH value
of normal concrete with OPC remains in the range of 13 to 17. Any chemical reaction
with in concrete to reduce this pH value poses a potential threat for start of corrosion of
reinforcement apart from other damages to concrete microstructures. Following are few
commonly known processes causing deterioration to concrete.
1.
Carbonation of concrete
The microstructure of concrete is such that it has capillary pores to the extent of
28%. The extent of pores depends upon quality of concrete and the presence of water at
the time of mixing of concrete. Making more dense concrete with less w/c ration reduces
the amount of pores. These pores are created due to evaporation of excess free water
during strengthening of concrete mass. These pores are inter connected and goes inside
the concrete mass from surface of concrete structures.
Carbonation of concrete is a process by which carbon dioxide from the air
penetrates into concrete through pores and reacts with calcium hydroxide to form calcium
carbonates. It has seen that the conversion of Ca(OH)2 into CaCO3 by the action of CO2
results in a small shrinkage.
We shall see another aspect of carbonation, as CO2 by itself is not reactive. In the
presence of moisture, CO2 changes into dilute carbonic acid, which attacks the concrete
and also reduces alkalinity of concrete (i.e. ph value reduces).
Air contains CO2. The concentration of CO2 in rural air may be about 0.03 percent
by volume. In large cities the content may go up to 0.3 percent or exceptionally it may go
up to even 1.0 per cent. In the tunnel, if not well ventilated the intensity may be much
higher.
The pH value of pore water in the hardened concrete is generally between 12.5 to
13.5 depending upon the alkali content of cement. The high alkalinity forms a thin
passivating layer around steel reinforcement and protect it from action of oxygen and
water. As long as steel is placed in a highly alkaline condition, it is not going to corrode.
Such condition is known as passivation.
1
Grade of concrete
Permeability of concrete
Depth of cover
Time
Table 1
Age-years
2
5
10
50
15
100+
56
20
100+
99
3
25
100+
100+
30
100+
100+
0.55
0.60
0.65
0.70
27
49
76
16
29
45
13
23
36
11
19
30
Time in years for carbonation
100
65
52
43
CO2
SO2
H2O
Fig 3 Concrete is under continuous attack by aggressive envoi mental agencies. Good
concrete and sufficient cover is the answer for durability
Measurement of depth of carbonation:
A common and simple method for establishing the extent of carbonation is to treat
the freshly broken surface of concrete with a solution of phenolphthalein in diluted
alcohol. If the Ca(OH) 2 is unaffected to CO2 the colour turns out to be pink. If the
concrete is carbonated it will remain uncoloured. It should be noted that the pink colour
indicates that enough Ca(OH) 2 is present but it may have been carbonated to a lesser
extent. The colour pink will show even up to a pH value of about 9.5.
2. Chloride Attack:
Chloride attack is one of the most important aspects for consideration when we
deal with the durability of concrete. Chloride attack is particularly important because it
primarily causes corrosion of reinforcement. Statistics have indicated that over 40 per
cent of failure of structures is due to corrosion of reinforcement.
We have already discussed that due to high alkalinity of concrete a protective
oxide film is present on the surface of steel reinforcement. The protective passivity layer
can be lost due to carbonation. This protective layer also can be lost due to the presence
of chloride in the presence of water and oxygen. In reality the action of chloride in
inducing corrosion of reinforcement is more serious than any other reasons. One may
understand that Sulphates attack the concrete whereas the chloride attacks steel
reinforcements.
Chloride enters the concrete from cement, water, and aggregate and sometimes
from admixtures. The present day admixtures are generally containing negligible quantity
of chloride or what they call chloride free. Chloride can enter the concrete by diffusion
from environment. The Bureau of Indian Standard earlier specified the maximum
chloride content in cement as 0.05 percent. But it is now increased the allowable chloride
content in cement to 0.1 per cent. I S 456 of 2000 limits the chloride content as (Cl) in the
concrete at the time of placing is shown in table 3.
1.
2.
3.
Maximum Total
acid
soluble
chloride content.
Expressed
as
kg/m3 of concrete
Concrete containing metal and steam cured 0.4
at elevated temperature and prestressed
concrete
Reinforced concrete or plain concrete 0.6
containing embedded metal
Concrete not containing embedded metal or 3.0
any material requiring protection from
chloride
The amount of chloride required for initiating corrosion is partly dependent on the
pH value of the pore water in concrete. At a pH value less than 11.5 corrosion may occur
without the presence of chloride. At pH value greater than 11.5 a good amount of
chloride is required.
Limiting values of chloride contents, above which corrosion may be imminent, for
various values of pH are indicated in table 4. The total chloride in concrete is present
partly as insoluble chlorialuminates and partly in soluble form. It is the soluble chloride,
which is responsible for corrosion of reinforcement.
Table 4 Limiting Chloride Content Corresponding to pH of concrete
PH
13.5
13.0
ppm
6740
2130
12.5
12.0
11.5
11.0
10.0
9.02
0.6720
0.2130
0.0670
0.0213
0.0021
0.0002
672
213
67
21
2
0.2
Charges passed
(Coulombs)
4000
2000 to 4000
1000 to 2000
100 to 1000
100
Type of Concrete
High water-cement ratio 0.6
Moderate W/C ratio (0.4 to 0.5)
Water-cement ratio 0.4
Latex modified concrete
Polymer Impregnated concrete
Fig 6 Shows that, depending on the oxidation state, metallic iron can increase
more than six times in volume.
choosing constituents material and good rules to be followed during various stages or
production of concrete, in particular the use of lowest possible water/cement ratio having
regard to workability. In view of the general availability of superplasticizers, it should be
used to cut down the W/C ratio to make dense concrete.
Fig 8
Proper mix design, use of right quality and quantity of cement for different
exposure conditions is to be adopted. Recently it has been realized that lower W/C ratio
which has been always associated with lower permeability is not enough to make
impermeable concrete contributing to high durability. Use of supplementary cementitious
materials such as fly ash, ground granulated blast furnace slag (ggbs), silica fume etc. are
required to be used as admixtures or in the form of blended cement in addition to lowest
possible W/C ratio to make concrete dense. These materials improve more than one
properties of concrete, which will eventually reduce corrosion of reinforcement. Tests on
mortar containing ggbs have shown that water permeability is reduced by a factor up to
100. It is also reported that 60 per cent ggbs educed the diffusion of chloride ions into the
concrete by as much as 10 times. Silica fume contributes to the all-round improvements
in the quality of concrete, which are responsible for reducing corrosion of steel
reinforcement. The improvement in the microstructure of hydrated cement paste is
ultimately responsible for protecting the steel reinforcement from corrosion.
In short it can be said that if we make good concrete with low permeability and
improved microstructure, it will be durable by itself and also it can take care of the
reinforcement contained in it o a great extent. It is always not possible to make such ideal
concrete, particularly, in view of the complex environmental and exposure conditions.
Further the inherent long term drying shrinkage and micro cracks in concrete, the
problems become more serious. This demands certain other measures to control the
corrosion of steel reinforcement. They are listed and briefly explained.
Metallurgical methods
Corrosion inhibitors
Coatings to reinforcement
Re-alkalization
Chloride removal
Cathodic protection
Coatings to concrete
3.1 Metallurgical Methods:
Steel can made more corrosion resistant by altering its structure through
metallurgical processes. Different methods such as rapid quenching of the hog bars by
series of water jets, or by keeping the hot steel bars for a short time in a water bath, and
by such other process the mechanical properties and corrosion resistance property of steel
can be improved. There are many situations where stainless steel reinforcements are used
for long term durability of concrete structures.
3.2 Corrosion inhibitors:
Corrosion inhibitors, which come in powder, gel and liquid form, retard the rate
of the corrosion reaction. They are widely used in many industries to effectively reduce
the corrosion rate of steel and other metals. Commercial products for the control of
corrosion of steel reinforcement in atmospherically exposed concrete were first produced
in the 1970's. They increase the time to the onset of corrosion and then act to reduce
the rate of corrosion. They can be introduced into the concrete mix at the time of
construction/ repair or (in a suitable formulation) applied to the surface of an existing
concrete structure. There are three main types of inhibitors:
3.2.1 Anodic inhibitors, which retard the corrosion reaction at the anode: Corrosion
can be prevented or delayed by chemical method by using certain corrosion inhibiting
chemicals such as nitrites, phosphates, benzoates etc. At low dosage there is concern that
they will suppress generalized corrosion but may fail to eliminate all anodic sites. Of the
available materials, the most widely used admixture is based on calcium nitrite but have
proved to be deleterious at high chloride concentrations. It is added to the concrete during
mixing of concrete. The typical dosage is of the order of 10-30 litres per m3 of concrete
depending on chloride levels in concrete.
cathodic sites of the steel. By virtue of its high vapour pressure, very high affinity and
virtue of diffusion these inhibitors migrate towards the steel in concrete and get deposited
in a monomolecular layer. This is true even in dense concrete. This barrier coating then
raises the chloride threshold concentration for corrosion. Further more the inhibitor
within the concrete matrix reduces the rate of chloride ion migration towards steel. It also
dislodges previously absorbed chloride ions and water molecules on the steel surface.
The basic advantage of the product lies in the ease of use. Studies have proved
that addition of these types of corrosion inhibitors has no deleterious effect on the
properties of concrete. Concrete penetrating corrosion inhibiting admixture upon addition
into the concrete matrix plays a major role in inhibiting the corrosion process. The
European Committee for standardization (CEN) pr. ENV 1504-9 recommends application
of Concrete penetrating corrosion inhibitors as a proven corrosion control strategy.
SHRP-S-666 (Strategic Highway Research Programme) has recommended these types of
corrosion inhibitors for concrete structures subjected to chloride-induced corrosion.
General Building Corporation of Japan has evaluated this product in concrete extensively
and has reported rebar life extension by six times. Two codes available internationally for
testing these types of inhibitors are ASTM G 109 & JIS A 6205.
They are available, both as surface applied inhibitors and as admixed inhibitors.
Surface applied inhibitors are used by spraying on the complete surface of the structure
being repaired so that protection to the unexposed reinforcement is taken care of.
Admixed inhibitors are used in the fresh mortar/concrete being placed for strengthening
the structure.
Specification for surface applied Corrosion inhibitor
Base
Colour
Specific Gravity
Viscosity at 250C
pH
Dosage
Toxicity
Evaluation
Base
Colour
Specific Gravity
Viscosity at 250C
pH
Dosage
Toxicity
Effect on concrete
properties
Compatibility for
Thermal Cycles
Evaluation
Acceptance Criteria:
Migratory Bipolar Corrosion Inhibitor should be tested as per ASTM-G-109/ JIS - 6205
from reputed laboratories like CSIR & I.I.T.
Tropical Compatibility:
Material shall have evaluated test reports indicating significant reduction in corrosion rate
after minimum of 90 thermal cycles at 60oC followed by 8 weeks of accelerated
corrosion. (Linear polarization method)
The inhibitor shall be non-toxic & safe to plant and human life.
The principle of most inhibitors is to develop a very thin chemical layer on the
surface of the reinforcement. There is a very wide range of corrosion protection
performance from different inhibitor formulations, even with generic classifications.
Independent evaluation and certification of performance is desirable. However,
such evaluations need to be representative of field concretes and conditions. As the
true effect of an inhibitor can only be evaluated from corrosion rate measurements
before and after application and by reference to a control area, such systematic
evaluations are lengthy processes and are in their early stages.
3.3 Coatings to Reinforcement:
3.3.1 Cement Polymer Composite coating system (CECRI Karaikudi):
Central Electro-Chemical Research Institute, Karaikudi, developed the system
after years of research on cement-based coatings. Rebars embedded in concrete are
surrounded by an alkaline medium and as such cement based coating is more compatible.
Basically two coats are applied - Primer coat and Sealer coat. The primer and sealer
products: have thereto-plastic acrylic resin as basic raw material. The sealer product is
formulated with resin mixed with cement as a pigment. The principle of the system is
that the base metal contains 'p' electrons, which get released in corrosive environment
leading to formation of Iron Oxide (Fe203). To prevent oxidation, a surface coating
capable of nullifying the released electrons is provided. The sealer coat is compatible with
primer and alkaline environment.
12
System at a Glance:
No. Parameter
Requirement
1.
2.
Pre-treatment
(Surface reparation)
Primer coat
3.
Sealer coat
4.
Air curing
5.
Continuity of coating
7.
8.
6.
Codal
Reference
13
Fig 11
Pros and Cons of the System:
Though this system is being used in India for more than a decade and in USA for
more than 3 decades, there are opinions expressed in favour and against this system..
Briefly, some points are highlighted here for the benefit of decision makers.
Points in favour of the system:
Research carried out by The National Bureau of Standards (NBS) for Federal
Highway Administration, USA concluded that epoxy coated reinforcement by
fusion bonding process in excess of 102 microns in thickness would be capable
of protecting steel from corrosion. Similarly, research done in other countries
(Canada, Japan, UK) has shown that FBEC bars performed better compared to
uncoated bars.
In India, Central Road Research Institute conducted the test on coated bars in the
laboratory and in field for 3 years and evaluated that the performance of FBECR
bars is satisfactory.
It is possible to repair cut ends and damages to the fusion bonded epoxy coated
bard by touch-up methods. Within few hours, it can be used.
Points against the system:
Investigation carried out on 40 bridges in Florida Key in USA has revealed that
disbandment can occur easily in the FBEC rebars which lacked passivation layer
of Fe 2 O 3 and is a precursor to corrosion.
Lot of precautions and care is required in transportation, handling and placement of these
coated bars failing which there will be damages, cuts and abrasions which may lead
to corrosion.
3.3.3 IP Net Rebar Coating System (CBRI Roorkee)
CENTRAL BUILDING RESEARCH INSTITUTE [CBRI/CSIR] ROORKEE
LICENCED SYSTEM
It is Interpenetrating Polymer Network Coating System for Corrosion Protection of
Reinforcing Steel.System Composition. The coating system consists of a primer coat and
a topcoat of the same system. The Primer and Topcoat (both coats) have Epoxy phenolic
base with mixing proportion of 1: 1 of resin and hardener by volume.
METHOD OF APPLICATION OF COATING SYSTEM:
The application of the IPNet-RB coating system comprises the following sequence.
Properties: System shall conforms to
14
S. No.
Environment
1.
Aggressive
surrounding 915 (125 microns)
such as marine areas,
chemical plants
16
2.
Normal
- do -
Zinc coating covers up any scratches/holidays that may occur in the coating due to electrochemical property of zinc. Galvanized bars can be bent without cracking or peeling up of
coating due to ductility of zinc. Bond characteristics and weld-ability of zinc coated bars
remain unaffected.
Testing of Galvanized Bars:
Following tests shall be carried out to determine suitability of galvanized bars and before using
them in concrete:
S.No.
Test
1.
2.
3.
4.
5.
6.
Criteria
for Reference
Acceptance
Should not peel off
IS 2629
3.5 Re-alkalization:
This electro-chemical technique provides a means of restoring the alkalinity to
carbonated but otherwise sound concrete. It involves the passage of a direct current
between the reinforcement (the cathode) and an anode applied temporarily to the
surface of the concrete. This process generates hydroxyl ions at the steel surface,
which locally regenerates the alkalinity of the concrete raising its pH upto about 12.
This helps restore the passivating surface oxide layer to the reinforcement.
Under the applied voltage, alkali ions are drawn from the anode into the
concrete. The use of sodium or potassium carbonate electrolyte is claimed to make the
treatment more resistant to further carbonation. Several forms of anode may be
employed. These are commonly either some form of mesh (titanium or steel) or
electrolytic tanks (for vertical surfaces)/baths (for deck slab applications). Sprayed
cellulose impregnated with the electrolyte is used with the mesh anode system.
The introduction of sodium ions, when using sodium carbonate as an
electrolyte, may exacerbate any potential the concrete has for ASR. In these cases,
plain water has been used as an electrolyte. It is understood that a lithium electrolyte has
been proposed and tested but is still a subject of research. The process typically takes
17
Remarks
between three and five days but sometimes may take several weeks. Successful
treatment can be established by means of an acid/alkaline indicating solution. However,
it should be noted that phenolphthalein changes colour at a pH of about 9.5 (unless a
modified solution of phenolphthalein is used). This is not a passivating condition
and an indicator (Universal indicator) with a colour change closer to pH 12 may
be required to demonstrate that a passivating condition has been achieved.
As with cathodic protection and desalination, consideration must be given to
hydrogen evolution at the reinforcement. The re-alkalization process applies some 20
- 50 VDC between the anode and the steel that must be expected to achieve steel
potentials at which hydrogen evolution could take place. It seems unlikely that realkalization would need to be applied to pre-stressed concrete structures.
Re-alkalization requires electrical continuity of the steel in the areas to be
treated, a reasonable level and uniformity in the conductivity of the concrete, no
short circuits between the cathode and the anode and no electrically insulating layers
in he cover zone/bar surrounds. The process requires fewer concrete repairs than the
patch repair alternative. It is also able to treat the whole surface of the zone in
question. There has been strong growth in the use of re-alkalization in recent years
(since the late 1980's) presumably because of its greater convenience and cost
advantage over patch repairs.
3.6 Chloride removal:
Negatively charged chloride ions (Cl-) can be repelled from reinforcement and
move towards an external anode by making the steel cathodic and passing a direct
current through the concrete. This process is known by various names such as electrochemical chloride extraction, desalination and chloride removal. It is similar in
operation to cathodic protection by utilizes a temporary anode and a much higher
electrical power density. The cathode reaction generates hydroxyl ions that locally
enhance the alkalinity of the concrete in the vicinity of the reinforcing bars and
encourages their re-passivation. Treatment periods are in the order of 3 to 6 weeks.
Electrolytes employed include water and saturated calcium hydroxide.
The anode types employed are essentially the same as those used for
Realkalisation protection, namely either mesh systems or liquid electrolyte systems
contained within tanks. Sprayed cellulose impregnated with the electrolyte is used with
the mesh anode system. These use either titanium or a steel mesh (which is consumed
during the treatment).
As with other electro-chemical systems, it is necessary to have electrical
continuity across the zone to be treated, no electrical short circuits between anode
and cathode together with a reasonable level and uniformity in the conductivity of
the concrete. The approach minimizes the amount of concrete repair work necessary. It is
claimed hat the technique can be used to treat the whole of the concrete surface and, on
the basis of life cycle costs, that it should be applicable to a wide range of structures. Care
needs to be exercised in relation to potential problems (as with the other electro-chemical
methods, namely hydrogen evolution in the member concerned).
3.7 CATHODIC PROTECTION:
The chloride extraction and re-alkalization repair techniques are temporary
18
the application of 99.9% pure zinc by arc-spray method at a total thickness of about 400
microns. It is a sacrificial system, which has a life expectancy of 12 to 15 years that can
be extended by whip blasting and re-spraying additional zinc material. It can also
be installed as an impressed current system and a protective coating may be applied
over it to further extend the useful life of the system. Sacrificial zinc anodes are also
use din combination with these systems, which protect the submerged/ tidal zones and
minimize current dumping.
3.7.9 Impressed current systems:
These require electrical connections to distribute the impressed current across
the anode, a DC power supply and an associated control system together with
embedded monitoring probes providing data by which adjustments can be made to
the voltage and currents applied. An installation will normally be divided into a number
of zones, each with its own power supply. The design of the zones needs to take
account of a number of factors such as the Variation in moisture and chloride contents (and hence the conductivity, of
the concrete) across the structure.
Continuity of reinforcement in different areas,
Presence of joints in the structure,
Requirements for different anode types
Variation in reinforcement provision.
Commissioning is a very important stage in achieving an effective and
durable CP system. It provides the opportunity to perform a variety of tests and trials
establishing the initial behaviour of the CP system, make adjustments to current and
voltage supplies and to verify control criteria. Once it has been established that an
impressed current CP system is providing protection to all reinforcement, it is
essential that the operation of the system be monitored and that it be properly
maintained. Changes occur in the concrete over the first few months of operation
(increase in resistivity due to removal of chloride ions and drying out of concrete).
The objective of the monitoring is to ensure that all reinforcement remains effectively
protected. For concrete structures with old types of pre-stressing steel, the risk of
hydrogen-embitterment shall be analyzed when considered the implementation of
impressed current CP systems.
3.8 Coatings to Concrete:
In the past it was believed that concrete by itself is a durable material, which
needs no protection or maintenance. This belief is no more hold good particularly on
account of environmental pollution, industrial fumes and contamination of ground water.
In addition to the coating of reinforcement by appropriate material, a surface coating to
the concrete member is given to increase the durability further. The coatings serve the
dual purpose of protection and decoration. Fig2 shows the reduction in depth of
carbonation of the protected concrete.
Giving protective coatings to major concrete structures such as bridges, flyovers,
industrial buildings and chimneys have become a common specification in India as in
21
other countries. Four km long bridge on national highway at Cochin was recently coated.
Almost all the flyovers at Mumbai are being coated for additional durability.
There are number of approved coating systems available in the country however
selection of coating depends on the severity of environment and the component of the
bridge.
3.8.1 Epoxy Painting System by CECRI System:
Central Electro-chemical Research Institute at Karaikudi has developed a coating
system for controlling corrosion. This system is applied on the concrete surface and
helps in controlling carbonation and weathering effects. The system comprises of 4
coats such as primer coat, middle coat and top coat all these are epoxy based. The fourth
coat is finish coat of polyurethane and is recommended wherever the surface or part
of the structure is exposed to ultra violet radiation.
Before application, the substrata is thoroughly cleaned to remove the dust,
hardened cement slurry, oily residues etc., by scrubbing with coarse wire brushes,
grinding or sweep blasting methods depending on site requirements. Residual
amounts of de-moulding agents, curing agents should be completely removed. Any
cracks, crevices or surface blemishes should be treated with sealant prior to primer
application. The subsequent coats shall be applied by brush or spray with an interval of
24 hours between the two coats.
Application:
Concrete surface to be painted shall be allowed maturation time of minimum
28 days before applying primer coating. Primer coating shall be applied to the cleaned
surface after surface preparation within the pot life. After air-curing, intermediate and
top coatings should be applied with time lag as per manufacturer's specifications. The
coating shall be applied by brush or air-less spray gun.
The paint application should aim to achieve minimum dry film thickness as
specified by CECRI. Some typical thickness used are as under:
The DFT (Dry film thickness) shall be measured on 100x100mm steel plate
attached with epoxy on the concrete surface at the rate one per l0m2.
3.8.2 Epoxy Phenolic IP Net (Inter-Penetrating
Protective Coating system (CBRI Roorkee):
Polymer
Network)
MATERIALS
1. The coating materials shall meet the standards specified by various codes and
formulation set forth by the patenter.
22
2. A written certification shall be furnished to the Department that properly identifies the
number of each batch of coating material used in the work, material, quantity represented,
date of manufacture, name and address of manufacturer and a statement that the coating
material used must meet the requirements specified by CBRI-Roorkee.
3. The coating material shall be stored in the manner as per recommendations of the
manufacturer until ready for use. The coating material shall be used within the
manufacturers written recommended shelf life.
4. When a representative sample of the material is to be sent to outside laboratory, then
the sample shall be packaged in an airtight container and identified by batch number. The
sample will be got tested at Tenderer/ Contractors cost.
SPECIFICATION OF COATING MATERIAL
S. No.
Description
Primer coat
Middle coat
1.
Base
Interpenetrating
Polymer
(Epoxy phenolic)
Interpenetrating
Polymer
(Epoxy phenolic)
2.
Pot life
Top coat
Interpenetrating
Polymer
(Aliphatic
Polyurethane)
1 Hour for 2 lt.mix
3.
Curing
Air curing
Air curing
Air curing
4.
Colour
5.
Shelf Life
Clear
Yellow/Grey
Yellow/Grey
One year in tightly One year in tightly One year in tightly
sealed container One
sealed container
sealed container
6.
7.
8.
Dry
film
thickness
55-65 per coat
(Microns)
Coverage
5-6 sq.mt/lt.
Recommended
One
No. of coats
9.
Recoatibility
10.
Mix proportion
4-5 sq.mt/lt
6-7 sq.mt/lt
One
One
4 hours to 7 days.
Subsequent coat shall
Ensure the surface is
be applied after 6
dust and deposit free N. A.
hours to 7 days
prior to application.
Base:1 PBV*/
Base:1 PBV*/
Base:1 PBV*/
Curing Agent:1 PBV* Curing Agent: 1PBV* Curing Agent: 1PBV*
*PBV-parts
volume
by *PBV-parts
volume
by *PBV-parts
volume
by
SURFACE PREPARATIONS
In order to have better bonding, the concrete surface should be clean, dry and
mechanically sound. The surface of the concrete structure to be coated shall be cleaned of
all traces of mould oil, laitance, salt deposits by mechanized means. The surface should
be thoroughly scrubbed using power tools/sweep blasting. Finally, the surface should be
washed with clean water jet to remove any salt deposits. The surface should be dried. All
the protrusions should be removed and cracks, joints should be sealed with sealant.
APPLICATION OF COATING
1. Mix the base and curing agent in prescribed proportion by volume thoroughly and
allow it to remain in a container for ten minutes.
2. A primer coating of IPN polymer shall be applied to the cleaned surface after surface
preparation within the pot life.
3. After air curing, intermediate and top coating should be applied with time lag as per
manufacturers specification.
4. The coating shall be applied by airless spray or other approved means.
COATING THICKNESS
During the application of IPNet systems clean, abraded steel plates of
approximately 10cm x 8cm shall be adhered to the concrete surface by means of putty/
adhesive in such a way that these can be detached. IPNet system can be applied over the
plates in the course of application over the concrete surface. Dry film thickness (DFT)
can be measured using magnetic electrometer. DFT measurement should be done at every
500-to 600-sqm areas or as per the direction of Engineer-in-charge.
For acceptance purpose, at least 60% of all recorded total thickness measurement
of the coating after curing shall be 200 10 microns (minimum). Thickness measurement
below 200 10 microns shall be considered cause for rejection. The upper thickness limit
does not apply to repaired areas of damaged coating.
PERMISSIBLE COATING DAMAGE AND REPAIR OF DAMAGED COATING
1. All coating damage shall be repaired with patching material by the contractor at his
own cost.
2. Repaired areas shall have a minimum coating thickness of 200 10 microns
3. Repair of damaged coating shall be done in accordance with the patching material
manufacturers written recommendations within the accepted rates.
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Base
2 hours
Chemical resistance
Adhesion
Resistance (Impedance)
108 ohms
Surface preparation
SURFACE PREPARATIONS
In order to have better bonding, the concrete surface should be clean, dry and
mechanically sound. The surface of the concrete structure to be coated shall be
cleaned of all traces of mould oil, laitance, salt deposits by mechanized means. The
surface should be thoroughly scrubbed using power tools/sweep blasting. Finally, the
surface should be washed with clean water jet to remove any salt deposits. All the
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protrusions should be removed and cracks, joints should be sealed with sealant as per
Central Electrochemical Research Institute, Karaikudi (CECRI).
APPLICATION OF COATING
1. Mix the base and curing agent in prescribed proportion by volume thoroughly and
allows it to remain in a container for ten minutes.
2. First and Top Coat should be applied with time lag as per manufacturers
specification.
3. Repair of damaged coating shall be done in accordance with the patching material
manufacturers written recommendations within the accepted rates.
COATING THICKNESS
1. Measurement of coating thickness shall be made using thickness measuring gauge
and Elcometer. The minimum total thickness of coating (1st& Top coat) must be 300350 microns
2. For acceptance purpose, at least 60% of all recorded total thickness measurement of
the coating after curing shall be 300-350 microns (minimum). Thickness
measurement below 300 microns shall be considered cause for rejection. The upper
thickness limit does not apply to repaired areas of damaged coating.
PERMISSIBLE COATING DAMAGE AND REPAIR OF DAMAGED COATING
1. All coating damage shall be repaired with patching material by the contractor at his
own cost.
2. Repaired areas shall have a minimum coating thickness of 300-350 microns
3. Repair of damaged coating shall be done in accordance with the patching material
manufacturers written recommendations within the accepted rates.
3.8.4 Solvent/Water based Acrylic Elastomeric Coating
3.8.5 MATERIALS
a. The coating materials shall meet the standards specified by various codes and
formulation set forth by the patenter.
b. A written certification shall be furnished to the Department that properly identifies the
number of each batch of coating material used in the work, material, quantity represented,
date of manufacture, name and address of manufacturer
c. The coating material shall be stored in the manner as per recommendations of the
manufacturer until ready for use. The coating material shall be used within the
manufacturers written recommended shelf life.
d. When a representative sample of the material is to be sent to outside laboratory, then
the sample shall be packaged in an airtight container and identified by batch number. The
sample will be got tested at Tenderer/ Contractors cost.
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Top coat
based Aqueous
Acrylic
based
2.
Curing
Air curing
Air curing
Air curing
3.
Colour
Clear
Pigmented
Pigmented
4.
Shelf Life
5.
Coverage
7-8 sq.mt/lt.
4-5 sq.mt/lt
4-5 sq.mt/lt
6.
Recommended
No. of coats
One
One
One
Recoatibility
24 hours to 7 days.
Subsequent coat shall
Ensure the surface is
be applied after 24
dust and deposit free N. A.
hours to 7 days
prior to application.
7.
Dry
Film
Total DFT in Three Coats 22520 microns
Thickness
Material should conform to following properties:
8.
1.
Specific Gravity
IS-345
1.32 to 1.40
2.
Solid Content
IS-345
70% 3
3.
UV Resistance
ASTM-G-53
Should Pass
4.
Adhesion
ASTM-D-4541-02
Should Pass
5.
ISO-6860
Should Pass
6.
Difusion
Dioxide
Should Pass
7.
ISO-2812-2
Should Pass
Against
Carbon
Electrochemical
Polarisation
Tafel Extrapolation
Should Pass
Test
SURFACE PREPARATIONS
In order to have better bonding, the concrete surface should be clean, dry and
mechanically sound. The surface of the concrete structure to be coated shall be cleaned of
all traces of mould oil, laitance, salt deposits by mechanized means. The surface should
be thoroughly scrubbed using power tools/sweep blasting. Finally, the surface should be
washed with clean water jet to remove any salt deposits. The surface should be dried. All
8.
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the protrusions should be removed and cracks, joints should be sealed with sealant as per
manufacturers recommendation.
APPLICATION OF COATING
1. Thoroughly mix the entire contents of the packaged tin prior to use.
2. A primer coating of the coating shall be applied to the cleaned surface after surface
preparation.
3. After air curing, intermediate and top coating should be applied with time lag as per
manufacturers specification.
4. The coating shall be applied by airless spray or other approved means.
COATING THICKNESS
During the application of the coating, clean abraded steel plates of approximately
10cm x 8cm shall be adhered to the concrete surface by means of putty/ adhesive in such
a way that these can be detached. The coating can be applied over the plates in the course
of application over the concrete surface. Dry film thickness (DFT) can be measured using
magnetic electrometer. DFT measurement should be done at every 500-to 600-sqm areas
or as per the direction of Engineer-in-charge.
For acceptance purpose, at least 60% of all recorded total thickness measurement
of the coating after curing shall be 225 20 microns (minimum). Thickness measurement
below 225 20 microns shall be considered cause for rejection. The upper thickness limit
does not apply to repaired areas of damaged coating.
COATING CONTINUITY
The coating shall be visually inspected after curing for continuity of the coating
and shall be free from holes, voids, contamination, cracks and damaged areas discernible
to the unaided eye.
PERMISSIBLE COATING DAMAGE AND REPAIR OF DAMAGED COATING
1. All coating damage shall be repaired with patching material by the contractor at his
own cost.
2. Repaired areas shall have a minimum coating thickness of 225 20 microns
3. Repair of damaged coating shall be done in accordance with the patching material
manufacturers written recommendations within the accepted rates.
Bridge piers and girders are of considerable dimensions. Freshly made concrete
members contain plenty of water in the pore structures. It takes long time to dry. Such
freshly made concrete structures should not be coated with epoxy or other materials,
which will seal off and prevent the internal moisture from going out in consonance with
atmospheric conditions. The moisture trapped inside the concrete can do untold harm to
the durability of concrete in addition to damaging the protective coating itself. For better
durability, the concrete should be able to breathe i.e. water vapour should be able to
migrate from inside to outside and from outside to inside. But water as it is, should not be
able to enter from outside to inside. The protective coating given to the concrete should
be of the above characteristics.
Therefore, it is pointed out that the epoxy coating, which does not allow the
concrete to breathe, should not be used for coating concrete members.
Instead, the protective coating should be based on acrylics which retains the
breathing property of concrete, while protecting the concrete from other harmful
environmental agencies, in particular entry of water and carbonation.
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In addition, epoxy based coating material is not resistant to ultra violet rays when
exposed to sunlight and also it is not flexible. Whereas the coating material based on
acrylic polymer is resistant to ultra violet rays of sun and is flexible.
Coating is not only required for bridges, flyovers and industrial structures, it is
also required for very thin members like fins, faade, sun breakers and other delicate
concrete structures where specified amount of cover can not be given. Therefore, acrylic
based protective cum decorative coatings can be given for additional durability of such
concrete members.
REFERENCE :-
Specifications for Road & Bridge Works issued by MORT & H and
published by Indian Road Congress.
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IS 12594 : 1988 HOT DIP Zinc Coating on Structural Steel Bars for
Concrete Reinforcement.
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