Repair & Maintenance of Concrete Structures

Emmons, 1994

5. Repair of CorrosionCorrosion-Damaged Structures

Innovative Repair?

Corrosion

Cause
Chlorides at steel Carbonation Insufficient cover Poor quality concrete

Effect
Cracking Rust staining Spalling Delamination

Repair the Symptom

Replace delaminated concrete Fix cracks Overlay

Address the Cause

Remove chloride-contaminated concrete Remove chlorides (ECE)

Alter the Process

Cathodic protection

Do Nothing Else Future Prevention

Impermeable repair material Sealants/waterproofing Improved drainage Penetrating inhibitors

Surface Repairs

Durable repair material Crack Heavily corroded rebar Bonding new to old Reinforcing steel protection Reinforcing steel cleaning Concrete surface conditioning Removal of contaminated concrete & undercutting of exposed steel Edge conditioning

Spall

Contaminated concrete with chlorides or carbonation Delamination

Damage due to Corrosion

Removal of Damaged Concrete

Patch with New Concrete

Edited from ICRI Movie on Surface Repair

Simple Patch Configuration Wrong

Right

Patch Repairs Check List

Locate embedded electrical conduit or post-tensionning tendons using pachometer or other techniques (e.g. radiography). Conduct structural review before removal of significant amounts of concrete to determine if support (e.g. shoring) is required. Exposed corroded rebar should be undercut to ensure adequate coverage and bond with new concrete (minimum clearance of inch or inch more than max aggregate size in patching concrete) The full circumference of the exposed bar should be cleaned Care should be taken to avoid damaging the bond around any exposed uncorroded bar Loose rebar should be tied to other secure bars If more than 25% of the cross section of a bar has been lost (or more than 20% of the cross section of two bars in close proximity) a structural review should be conducted to determine if repair or replacement of the bars is necessary. Unless shotcrete repairs are anticipated, the edges of the patch should be cut straight and square with the surface to ensure maximum integrity of the patch (i.e. avoid feathered edges)

Repair/Substrate - Incompatibility

No chlorides High pH

Chloride & Lower pH

Creation of a New Galvanic Cell

Formation of incipient anode adjacent to the new patch

Cathode: O2 + 2H2O + 4e- 4OH-

Anode: 2Fe 2Fe2+ + 4e-

Spall in Slab

Patch Repair

Anodic Ring Ring Effect

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Improving the Performance of Patch Repairs Treating the Surface

H2O Membranes No chlorides High pH Chloride & Lower pH Cl

H2O vapour Reduces moisture content in the slab & prevents further chloride ingress.

But does it reduce corrosion?

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Improving the Performance of Patch Repairs Treating the Surface

H2O Dense overlay No chlorides High pH Chloride & Lower pH Cl

H2O vapour Reduces moisture content in the slab & prevents further chloride ingress.

But does it reduce corrosion?

Improving the Performance of Patch Repairs Treating the Surface

Penetrating Sealer

H2O No chlorides High pH

Cl Chloride & Lower pH

H2O vapour Reduces moisture content in the slab & prevents further chloride ingress.

But does it reduce corrosion?

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Improving the Performance of Patch Repairs Treating the Steel Rebar

EpoxyEpoxy-coating the exposed steel

Electrically isolates the steel in the patch and prevents it from becoming a cathode and reduces the risk of incipient anode formation.

But does it extend the time to the next repair?

Improving the Performance of Patch Repairs Treating the Steel Rebar

Coating the exposed steel with zinc paint

Zn Zn 2+ + 2e

The zinc coating will become a sacrificial anode and may prevent the formation of an incipient anode formation adjacent to the patch.

But does it extend the time to the next repair?

Improving the Performance of Patch Repairs Installing a Discrete Sacrificial Anode

Norcure System Courtesy of http://www.norcure.com

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Norcure Embedded Galvanic Anode

Sacrificial metal (zinc) core

Cementitious matrix Tie wires

Improving the Performance of Patch Repairs Installed Galvanic Anode

The zinc becomes a sacrificial anode and provides cathodic protection to the steel in the vicinity of the patch. Recent testing has demonstrated that this system does extend the time to the next repair? Courtesy of http://www.norcure.com

Courtesy of http://www.norcure.com

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Courtesy of http://www.norcure.com

Courtesy of http://www.norcure.com

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Courtesy of http://www.norcure.com

Courtesy of http://www.norcure.com

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Courtesy of http://www.norcure.com

Courtesy of http://www.norcure.com

Removing all the Chloride Contaminated Concrete

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Hydromilling

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Complete Slab Replacement

Cathodic Protection

Sacrificial Anode
Less noble metal (e.g. Zinc) connected to steel reinforcement and confers protection to the steel through sacrificial corrosion. Note: the anode is consumed by the process. Only suitable when the resistivity of the system is low and good electrolytic contact is maintained e.g. submerged or buried structures, particularly marine structures

O2 + H2O + 4e- 4OH-

Zn Zn 2+ + 2e

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Impressed Current

2e-

2 H 2O 2 H + + O2 + 2e Inert Anode 2 NaCl 2 Na + + Cl2 + 2e

2e-

1 O2 + H 2O + 2e 2OH 2

H 2O + e H + OH

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Requirements for Impressed Current CP

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Summary of CP Requirements

Direct current supply Impressed current anode Electrolyte (concrete) Cathode (rebar) Electrical and electrolytic conductivity

Control & Monitoring

Current Density Typically current densities are in the range of 10 to 20 mA per m2 steel although higher values (up to 50 mA/m2) may be required in the most severe environments (e.g. poor quality concrete, low cover, high chlorides, high O2 environment, fluctuating moisture, high temperatures, extensive active corrosion on the steel) Power Supply It is usual to provide a number of small power supply units to protect individual (isolated) zones - typically 50 to 100 m2 area. This usually translates to total current requirements of < 10 A and relatively low voltages of < 10 V (DC) to drive an individual zone (circuit). The actual voltage needed to deliver the required current will depend on the electrical resistivity of the concrete. Supplies are usually transformer rectifier units that run on standard AC mains voltage and provide full control of the DC output currents and voltage. Chess, 1998

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Cl-rich patch
Fe Fe 2+ + 2e

2eI I

2e-

Apply Cathodic Protection

Cl-rich patch
Fe Fe 2+ + 2e

2eI I

2e-

Apply Cathodic Protection

eI I

e-

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Macrocell Probes based on creating a local aggressive condition around an isolated piece of steel. An area of concrete is cut out and the steel bar isolated.

The isolated bar probe is then connected to the main reinforcement via a zero-resistance current meter. The hole is filled with chloride-rich concrete (Cl in patch > Cl in parent concrete)

Cl-rich patch

The current flow between the probe and main reinforcement is measured. Current should flow from the main reinforcement to the probe (electron flow in reverse direction)

Cl-rich patch
Fe Fe 2+ + 2e

2eI

2e-

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The CP system is then connected.

Fe Fe 2+ + 2e

2eI

2e-

As the system current is increased the current flow to the probe will be reduced as the system becomes more negative.

e-

1 O2 + H 2O + 2e 2OH 2

Fe Fe 2+ + 2e

eI

e-

As the system current is increased the current flow to the probe will be reduced as the system becomes more negative. When the current flow between the probe and main reinforcement passes through zero, this is considered to be a satisfactory level of protection.

2e-

1 O2 + H 2O + 2e 2OH 2

1 O2 + H 2O + 2e 2OH 2

eI

e-

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Measuring potential versus an embedded reference half-cell (e.g. Ag/AgCl, Mn/MnO2)

Criteria: Absolute potential Instant-off potential Polarization decay

CP Repair Strategy

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Electrochemical Chloride Extraction

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www.norcure.com

Cellulose fibres soaked in anolyte (e.g. sodium borate) sprayed on concrete surface www.norcure.com

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www.norcure.com

CP Repair Strategy

ECE Repair Strategy

Yes

Apply ECE Protect from further Cl ingress

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Repair of Carbonation-Induced Corrosion

Reinstate damaged concrete Electrochemical Realkalization Apply Coating (e.g.CO2 Barrier)
Na+

CO2-resistant Coating

Na+

CO2

CO2

K+

K+

Realkalization

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Before

After

Protecting the Repaired Structure

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?
No

REPAIR?

Yes

DESIGN REPAIR

EXECUTE REPAIR

We will look at the issues that affect these steps in the process later on in the course!
Adapted from Emmons, 1994

Broomfield, 1997

Broomfield, 1997

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Broomfield, 1997

Broomfield, 1997

REPAIR?

Yes

DESIGN/ SELECT REPAIR

EXECUTE REPAIR

Adapted from Emmons, 1994

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