DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 8

Coatings For Steel And Concrete

8.1 Concrete structures in aggressive environment (Marine / Industrial area)
are subjected to chloride attack . In order to protect concrete structures from
chloride attack in aggressive environment, it is necessary that protective
coatings are applied to concrete and steel both to prevent ingress of
chlorides.

8.2 Selection and coating for steel: The metallurgists and electrochemical
engineers have developed several methods for protection of steel from
corrosion in concrete. The most commonly known systems of protection of
steel from corrosion in concrete are :

i) Use of Corrosion Resistance Steel Reinforcement Bars
ii) Methods developed by Central Electro-Chemical Research Institute
(CECRI), Karaikudi - Tamilnadu.
Inhibited Cement Slurry Coating System (Old Method)
Cement-Polymer-Composite Coating System(New Method)
i Fusion Bonded Epoxy Coated Rebars (FBECR)
ii Hot dip Galvanizing
iii Epoxy Phenolic Interpenetrating Polymer Network (IPN) Coating
for reinforcing steel developed by CBRI, Roorkee.
iv Truncated inhabited slurry cement base coating as used in
Konkan Railway

8.2.1 Corrosion Resistant Steel Reinforcement Bars: A number of
manufacturers have come up with a new type of higher strength re-bars which
are claimed to be corrosion resistant. These products are as given in table
8.1
Table 8.1

Manufacturer Product

SAIL

HCR Rebars
Grade A and Grade M
TISCO

TISCON- CRS
TISCON- 50 CRS
TISCON- 50 TMT
Rashtriya Ispat Nigam Ltd. TEMP CORE REBARS
Vizag Steel High Strength Corrosion Resistant A-1
Rebar

These bars have dual micro structures i.e. the surface layer is tempered
martensite while the inner shell is ductile ferrite-pearlite. To increase
corrosion resistance of these bars certain elements like nickel, chromium,
copper and phosphorus are also added. These bars form a protective layers

DURABILITY OF CONCRETE STRUCTURES


on the surface when they come in contact with atmospheric oxygen and
moisture. This layer is formed over a period of time. In concrete oxygen is
not available. Hence, the protective coating may not form when such bars
are used as reinforcement in concrete. Obviously, there appears to be no
advantage in using such bars in place of mild steel. Even, when exposed to
atmosphere in marine environment the chlorides present in the air break the
protective layer thereby reducing corrosion resistance. Therefore, in marine
atmosphere these bars do not give good resistance to corrosion as in normal
atmosphere. Secondly, their chemical composition is such that it may lead to
pitting corrosion which is highly undesirable. In mild steel bars conforming to
IS:1786, although is less corrosion resistance, but corrosion occurs all over
the surface without pitting.

8.2.2 Inhibited Cement Slurry Coating System:-

8.2.2.1 This method was developed by CECRI, Karaikudi. This is their
older system. It consists of application of cement based inhibited and sealed
reinforcement bars. The entire process of coating is based on following
system :
i De-rusting : Removal of rust, dirt and oil from steel surface
ii Phosphating: Phosphatisation of steel surface(by Phosphating
Jelly) offers temporary protection during time lag between
derusting and application of first coat of inhibited cement slurry.
iii Cement slurry: Two coats of cement slurry made by OPC
cement and Inhibitor solution to protect steel surface from the
attack of Sulphate and Chloride ions and to keep the steel surface
in high pH environment.
iv Sealing: Two coats of Sealing solution to increase the adhesion
between steel and cement coating and to seal the surface and
make it impermeable for gaseous and water molecules.

8.2.2.2 Briefly following steps are involved in this process

i Derusting by dipping the rebars in pickling solution (patent
no.465/CAL/75) for 30 minutes (pH of the solution is 1.04)
ii Removal from acid tank and dipping in alkaline tank to neutralize
and cleaning with potable water for 2 minutes.
iii Application of phosphate jelly coat (Patent no.109897) and drying
for 45-60 minutes (pH of the jelly is 2.5).
iv Application of inhibitor solution A (patent no.109784/67) for 2
minutes.
v Application of first coat of cement slurry coating with inhibitor
solution A
vi Air drying for 24 hours.
vii Application of first coat of sealing solution B (Patent no.112440/67)
for 2 minutes.
viii Application of 2
nd
coat of cement slurry solution A for 2 minutes.
ix Air drying for 24 hours
x Another coat of sealing solution B and drying for 4 hours.

DURABILITY OF CONCRETE STRUCTURES



xi Application of 3
rd
coat of sealing solution B for 2 minutes
xii Air drying for 4 hours.

Detailed specification regarding quality control aspect and
chemicals/solution used in the process may be obtained from Central Electro-
chemical Research Institute (CECRI) Karaikudi-623 006 (Tamilnadu). Code of
Practice for this system, as received from CECRI is annexed with the report
as Appendix-I.

8.2.2.3 Merits & demerits of system:

Merits

This is an in situ process
Easy to patch repair
There is adequate tolerance to defects
This is passivating type of system
It is cost effective and
It is based on logical sequences

Demerits:

This is a multi step field process
Bending operations have to be completed prior to coating.
No well-established criteria/specifications
The process is labour intensive and needs close monitoring

8.2.2.4 Performance : This coating has been used in many prestigious
structures, built in the East and the West coast of India as enumerated below.
Nothing adverse has been noticed so far from these structures.

i New thane Creek Railway bridge, Mumbai-The work started in
1987 and there is not a trace of any corrosion, upto 1998.
ii New Thane Creek Road bridge, Mumbai
iii Kalwa and Kasheli bridges, Mumbai
iv Konkan Railway bridges, West Coast
v New and old Mandavi bridges, Goa
vi Pamban bridge, Tamilnadu and
vii Television tower, Rameshwaram
viii Dr.M.G.Ramachandran Memorial, Chennai

8.2.2.5 The cost of the coating system is about Rs.2000 to 3000/MT.

8.2.3 Cement-polymer composite coating system (CPCC):

8.2.3.1 This is a new method developed by CECRI. This system has been
developed to overcome demerits of inhibited cement slurry coating system.

DURABILITY OF CONCRETE STRUCTURES


8.2.3.2 This system consists application of one coat of rapid setting primer
followed by a coat of cement polymer sealing product. The primer and
sealing products have thermoplastic acrylic resin as basic raw material.
Sealing product is formulated with resin mixed with cement as a pigments.
Rapid setting primer and sealing coats both are patented item. This system
has been developed mainly as a factory / shop process. The approach
behind development of this system is that the base metal of rebars, contains
electrons which get readily released in corrosive environment leading to
oxidation of iron and thereby formation of Fe
2
O
3
(rust) as principal deterrent.
In order to prevent this oxidation a surface coating capable of
interacting/nullifying the released electrons is provided. Further prestressing
and reinforcing steel, in concrete during service life, are exposed to an
alkaline environment and this necessitates introductions of a top coat which
should be compatible to primer and alkaline environment. To meet these two
contingencies, suitable polymers are carefully tailored through the formation
of a single phase in the polyblend which provides the necessary mechanical
and physical properties.

8.2.3.3 Briefly the following steps are involved in the process:

a Surface preparation : The surface of the steel reinforcing bars to be
coated is cleaned by abrasive (dry sand) blast cleaning to the near white
metal in accordance with SSPC-SP10/NAC No.2-1994. It includes the
following procedures.

i Prior to blast cleaning visible deposits of oil or grease are removed
by suitable cleaning method.
ii Clean dry compressed air is used for nozzle blasting.
iii Dry uniformly graded silica sand is used for blast cleaning which
should be free from contaminants.
iv Dust and residues are removed from prepared surface by brushing,
blowing off with clean, dry air, vacuum cleaning.
v The prepared surface shall meet the visual standards of
comparisons as in SSPC-VIS 1 of SSPC-VIS 2.

b Application of the coating:

i The coating is applied to the cleaned surface as soon as after
cleaning and before oxidation of the surface discernible to the
unaided eye occurs. However, the application of the coating
should not be delayed more than 4 hr. after cleaning.
ii A rapid setting primer shall be applied over the prepared surface of
the reinforcing steel either by brushing or dipping.
iii After 30 minutes of application of the primer a cement polymer
sealing coat shall be applied either by brushing or dipping.
iv The coated rods shall be handled after 6 hours.

c) Inspection and testing : Coated rebars shall be checked for minimum
average dry film thickness, uniformity of thickness, defects such as cracks,
peeling, bulging and uncoated areas etc. Coating shall be tested for adhesion,
DURABILITY OF CONCRETE STRUCTURES


bond strength, abrasion resistance, chemical resistance . as per specifications
laid down by the manufacturer.

d) Detailed specification of chemicals/solutions and quality control
aspects, if required, may be obtained from CECRI, Karaikudi. Code of
Practice for this system, as received from CECRI is annexed with the report
as Appendix-II.

8.2.3.4 Merits & Demerits of the System:

Merits :

The composition has corrosion resistance, making it suitable for
corrosion protection of steel in concrete structures in marine and
industrial environments.
Being cement based composition, it is more compatible in concrete
medium.
It is a passivating-cum-barrier type of coating and hence any
localized defect in the coating may not lead to severe undercutting.
It can be brush applied or sprayed and hence defects in the coating
can be easily patch repaired.
It has good bond strength and hence bond between coated rod and
concrete is not affected.
This system is suitable for the protection of prestressing steel
strands also.
The system can be adopted as in situ process also. The shelf life of
treated bars is 6 months.
Considerable reduction in process time as compared to inhibited
cement slurry system.

Demerits :

This system is newly developed system and the long term results
are not known.

8.2.3.5 Performance : This system is now being used on three fly over
bridges in Mumbai at Goregaon, Andheri and Mankhurd. As the system is a
newly developed system, hence field performance is not known. However
laboratory performance of the system, as reported by CECRI, is very good.
The system has passed bondability test, chemical resistance test, salt spray
test, impressed voltage test and abrasion resistance test as per test
procedure described in ASTM A77/775M-94. From structural point of view,
the coated bars have shown greater bond strength as compared to uncoated
bars.. This coating is superior to old CECRI coating and can be used
effectively in marine structures in future.

8.2.3.6 The cost of the coating is about 3200-8000/MT.



DURABILITY OF CONCRETE STRUCTURES


8.2.4 Fusion bonded epoxy coating (FBEC):

8.2.4.1 The Fusion Bonded Epoxy Coating is a process where epoxy
powder is applied by electrostatic spray on hot steel at pre-set temperature
level. The powder, when in contact with the hot bar, melts, flows, gels, cures
cools and produces a well-adhered continuous corrosion resistant protective
coating. This thermosetting is an irreversible process and provides the best
protection to rebar against corrosion. It prevents attack of chloride ion on the
metallic surface and occurrence of electro-chemical reaction initiating
corrosion of steel. The epoxy coated rebars were first tried in Pennsylvania
State in 1973 and commercially produced in the USA since 1976.
Subsequently this system is introduced in Western Europe and Japan. In
India M/s PSL Holdings Ltd, 386, Veer Savarkar Marg, Prabhadevi, Mumbai-
400 025, are producing Fusion Bonded Epoxy Coated Rebar (FBECR) at their
plant at Wapi ( Daman ) near Mumbai .

8.2.4.2 The process involves following steps to be performed in a plant
controlled by automatic quality control system.

i Degreasing : Bars are first cleaned from surface contamination
such as oil, grease etc. by chemical process before shot blasting.
ii Cleaning : The reinforcement bars are cleaned by shot blasting or
grit blasting to white or near white stage.
iii Heating : The blast cleaned bars are then heated through
induction heaters at preset temperature level around 230
0
C.
iv Coating : Hot bars are then fed to the coating booth, where the
epoxy powder is sprayed electrostatically.
v Curing and cooling : Coated bars are then cured and forced
cooled by water spraying to enable handling and testing.

8.2.4.3 Inspection and testing : Fusion Bonded Epoxy Coated Rebars are
tested at the coating plant to the codal requirements as specified in IS:13620-
1993. On line and off line holiday checks, thickness checks are carried out.
The adhesion of the coated bars are also tested frequently by bending of the
bar. Beside this, various other tests are performed in laboratory like chemical
resistance, short spray, resistance in continuance boiling water, abrasion
resistance and impact resistance etc. These are conducted on every batch
of production.

8.2.4.4 Handling transportation and working : FBECR bars are required
to be handled with extreme care so that coating is not damaged during
transportation. handling/concreting. Thus, Fusion Bonded Epoxy Coated Bars
require padded contacts during transportation, stacking, handling and till the
concreting is done. The cut ends, welded spots and handling damages are
required to be repaired with special liquid epoxy compatible with the coating
material as per specification of the coating agency.




DURABILITY OF CONCRETE STRUCTURES


8.2.4.5 Merits & demerits :

Merits :

As the technique is factory based, better quality control is
achieved. It gives uniform thickness of coating.
The bonding of coating with steel rebars is high as it has excellent
adhesives property.
It is flexible to allow straight bars to be bend during fabrication on a
special mandrill to protect the coating from damage.
The Fusion Bonded Epoxy Coating acts as insulator for electro-
chemical cells and offer barrier protection to steel which prevents
entry of chloride ions through it.
There are well established criteria for acceptance for this coating
(IS :13620-1993 and ASTM 775/A 775M-1992)

Demerits :

There is a reduction in bond strength between coated rebars &
concrete (Clause A.5 of IS:13620).
As the technique is plant based, double transportation/handling is
involved.
It requires careful handling as coating may get damaged.
Performance of the system depends upon least defect in the
coating.
Patching may not always be effective.
Even the smallest damage in coating can initiate corrosion in
severe environment.

8.2.4.6 Performance:

8.2.4.6.1 In US Pennsylvania Department of Transportation had
undertaken a project to evaluate and compare the effectiveness and cost of
various bridge deck protective systems. Evaluation was done by conducting
field survey. The protective systems evaluated in this study included epoxy
coated reinforcing steel, galvanized reinforcing steel, water proofing
membranes, latex modified concrete of salt contaminated decks and low
slump dense concrete. This field evaluation was carried out after 9 years of
construction. Field survey revealed that :-

i Rebar coating provide the most effective corrosion protection to the
rebar.
ii Epoxy coated rebar has been generally rated in excellent condition,
despite high chloride contents in surrounding concrete.
iii Based on the deterioration rate and life expectancy, epoxy coated
rebar decks have performed better than calculated rates.




DURABILITY OF CONCRETE STRUCTURES


8.2.4.6.2 However, during 1986 to 1990 in Florida severe corrosion of epoxy
coated reinforcing bars has been recorded at major construction project in
subtropical marine environments. The Florida key bridge has been put out of
commission.

8.2.4.6.3 A study has been conducted by the Canadian Strategic Highway
Research Programme (C-SHRP). It included extensive testing of epoxy
coated rebar (ECR) from coaters as well as from 19 field structures in
Canada and the United States. This study showed that epoxy-coated rebar
technology is flawed (as practiced in North America) and, as a result, epoxy
coated rebar will not provide long-term protection to reinforcement in salt
contaminated concrete. The study found that this was the case even in
perfect-coated rebars, namely coated bars which have zero holidays, zero
bare areas and comply with all other aspects of specifications. The reason for
these failures are not understood.

8.2.4.6.4 As far as lab performance is concerned, this coating has performed
well in all the test. But patching is found not always effective.

8.2.4.6.5 The cost of treatment is about Rs.4500 to Rs 13,000/MT.

8.2.5 Hot Dip Galvanizing:

8.2.5.1 Galvanizing is the process of deposition of zinc over the surface of
rebars. One of the methods to prevent the steel from under going corrosion is
to galvanized rebars as reinforcement material.. Zinc coating offers protection
in more than one way. Firstly, intermetallic and metallic layers of zinc act as
a physical barrier between the steel material and corrosion environment. In
this case, corrosion resistance of the steel owes to the corrosion resistance of
zinc. Further, wherever steel is exposed to the corrosive environment due to
the break down of the protective coating, steel is still protected by the
selective dissolution of zinc. Further investigations carried out by various
researchers have shown that normally zinc is able to absorb hydrogen within
its interstitial space and therefore prevents steel from undergoing hydrogen
embrittlement. Galvanizing or the method of zinc coating can be achieved
principally by electro-galvanizing and hot dip galvanizing method. Hot dip
galvanizing process is most widely used.

8.2.5.2 Hot dip galvanizing method involves the following steps :

i Organic contaminates such as dirt, paint markings, grease and oil
on the surface of rebars are removed in a shed by dipping in
caustic solution and cleans by water rinsing.
ii After caustic cleanings, scale and rust on rebars, are removed by
pickling in hot sulphuric acid on hydrochloric acid at room
temperature and then cleansed by rinsing in water.
iii In conjunction with chemical cleaning or alternative to it sand
blasting/shot blasting can also be undertaken for surface
preparation.

DURABILITY OF CONCRETE STRUCTURES



iv The cleaned rebars are the fluxed to protect from surface
degradation. This is achieved by dipping the rebars in zinc
ammonium chloride solution and thoroughly dried.
v Then the rebars are immersed in a bath of molten zinc (98.5%pure)
at specified temperature of about 45
0
C.
vi The time of immersion which is variable with the size and chemical
composition of rebars should be such that the thickness of coating
achieved should be at least 610 gm/m
2
(84 micron)
vii Then the rebars are air dried completely to be ready for use.

8.2.5.3 Merits & demerits

Merits:

Galvanized bars are successfully used in structure where
carbonation is a risk.
Galvanized rebars have no problems in rough handling,
transportation and in concreting.
Galvanizing can be easily done.

Demerits:

If galvanized bars are mixed with ungalvanized bars for use in the
same structure, accelerated depletion of the galvanizing occurs.
Electrochemical treatment to galvanized bar is fraught with danger
as it can result in severe pitting due to formation of galvanic cells.
It is not suitable for protection against chloride attack.

8.2.5.4 Performance :

In USA, observations of performance by different construction
authorities are as follows.
Galvanizing does not provide long term protection
Galvanizing delays the onset of corrosion process but does not
prevent it.
Service life of rebars does not extend more than 5 years.
Galvanized rebars show better performance in sub-tropical marine
environment when compared to uncoated bars.
In Japan, from long-term field performance the galvanized rebars have
performed well in comparatively low chloride content.
In UK, as a result of extensive field studies it is concluded that
chromated galvanized rebars have excellent corrosion resistance.
In Germany, the use of hot dip galvanized rebars has shown protection
of rebars in uncracked carbonated concrete. Sufficient protection is achieved
if the concrete cover is 50 mm and a crack width upto 0.5 mm.
In India, there is no feed back on performance. In the late eighties, the
Bahai temple in New Delhi was constructed with galvanized rebars and still
the temple is reported to be in sound condition.
DURABILITY OF CONCRETE STRUCTURES


8.2.6 Epoxy-phenolic IPN coating :

8.2.6.1 Central Building Research Institute (CBRI), Roorkee has developed
an Epoxy-Phenolic Interpenetrating Polymer Network (IPN) system for
protection of structural steels and now extended to rebar. It is a polymer
formulation consisting of more than two polymer crosslinked in the network
form by synthesis. Polymer are interwoven to each other and continue to link
together by permanent entanglements devoid of chemical linking.

8.2.6.2 The method of application is as follows :

i For cleansing the surfaces of rebars sand blasting/shot blasting is
done to remove rust and other deleterious material in a shed
provided with proper ventilation.
ii The first coat of Epoxy phenolic-IPN is applied by means of
brush/spray within 4 hours of sand blasting/shot blasting.
iii The application of coat should be done on a high platform of wood
or steel where the rebars can be kept at ease.
iv For effective polymerisation within 4 to 8 hours after the
application of first coat. Part A (Resin component) and part B
(Hardner component) of Epoxy phenolic IPN coating are mixed in
plastic container in 1:1 proportion by volume and vigorously stirred
for 5-10 minutes and then the mixture is allowed to remain in the
container for another 5-10 minutes. Then, it is ready for use the
plastic container should be clean and free from moisture, grease
oil, etc.
v The mixture is applied by means of brush/spray.
vi The treated rebar should be cured for 48 hours after the application
of first coat.

Detailed specifications of chemicals and quality control aspect if
required may be obtained from CBRI, Roorkee.

8.2.6.3 Merits & demerits :

Merits :

The method is very simple.
The method is site based hence chances of damage during
transportation are reduced.
Rebars have excellent corrosion resistance.
No pitting, spalling, scaling are formed.

Demerits:

Field performance is not known.
No well laid acceptance criteria/specification.
System is under development stage.


DURABILITY OF CONCRETE STRUCTURES


8.2.6.4 Performance : As the system is under developmental stage, field
performance is not known. However the coating has passed through
adhesion test, pull out test, search resistance test, salt spray test, elongation
test, scanning electron microscopy and differential scanning calorimetric test.

8.2.7 Truncated inhibited cement slurry coating for dry climate as used
for Konkan Railway bridges and structures: In dry climate, it is not
necessary to use the full CECRI system. The following procedure was
adopted in Konkan Railway for structures away from coastal area.

i Cleaning of steel by wire brush, for removal of dust and rust.
ii Apply one coat of cement slurry {1 kg cement + 600 c.c of inhibitor
solution (Patent No.109784/67)} by dipping or brushing. The cost
of inhibitor for solution is Rs.6.0 per litre. Allow it to dry for 24
hours in shade. The water is not to be used. The inhibitor solution
is prepared in ionised water.
iii Apply second coat of cement slurry (same as above). Allow it to
dry in shade.

The coating is purely cement based with inhibitor solution and is
passivating in nature. The cost of the application is negligible and shall be
about Rs.500/MT. The coating has been used in all the bridges and buildings
in Konkan Railway very effectively where bridges are more than 1 km away
from the coast line.

8.2.8 Cathodic protection : This subject is dealt with in the chapter 9.

8.2.9 Selection of coating for steel Recommendation: The following is
recommended.

Aggressive environment
( Severe, Very severe & Extreme )
Non-aggressive
environment
(Mild and Moderate)
Important and major
bridges and buildings
Minor bridges and
structures
All structures
Cement Polymer
Composite coating
or
Fusion Bonded Epoxy
coating
Cement Polymer
Composite coating
or
Inhibited cement slurry
coating
Truncated Inhibited
cement slurry coating

8.3 Coatings for concrete : The protective surface coating, as the name
implies, protects the concrete surface from aggressive chemical attack.
Surface coating of the concrete reduces the ingress of oxygen, water gases
and chemicals present in the industrial and other aggressive environment. So
surface coating for concrete is an effective method of protecting life of
reinforcement steel. The coating on concrete should be breathing type.



DURABILITY OF CONCRETE STRUCTURES


8.3.1 Epoxy-phenolic IPN coating:

8.3.1.1 Central Building Research Institute (CBRI), Roorkee has developed
an Interpenetrating Polymer Network System (IPN Polymer) as coating for
concrete for the protection of concrete structures exposed to aggressive
environments. The corrosion protection efficacy for protection of concrete is
the hall mark of this two component coating system.

8.3.1.2 Preparation of IPN polymers: Two different resins a medium -
viscosity epoxy resin based on epichlorohydrin and bisphenol as base and an
aromatic amine adduct as the crosslinker and a phenolic resin obtained from
an indigenous phenol with its crosslinker were mixed in different ratios and
cross linked simultaneously by a separate non interfering mechanism. The
IPN polymeric systems thus obtained where evaluated for various physico-
mechanical properties, using standard methods of testing. It was found that
elongation of IPN polymer (epoxy in combination with phenolic resin), film
increases to 17.5% as against 5% in case of neat epoxy system. This is the
most important property which could enable the coating to retain the adhesion
even at higher fatigue limits.

8.3.1.3 The Vicat softening point, the indicator of thermal stability of polymer
system is much higher in IPN polymer system. It has low moisture vapour
transmission and excellent adhesion with substrate. The coefficient of thermal
expansion of the IPN polymer film is nearly equal to that of concrete
signifying non development of thermal stresses in concrete and coating.

8.3.1.4 Coupled with excellent chemical resistance along with above
mentioned properties, IPN polymers is an excellent protective coating for
concrete structures and can be used for the protection of various structures.
This system has been used on Vasai creek bridge in Mumbai.

8.3.2. Integrated four coat system developed by CECRI, Karaikudi:

i It consists of epoxy polyamide iron oxide, epoxy polyamide MiO
undercoat, epoxy polyamide. T
i
O
2
top coat and aliphatic. It has high
alkali resistance and good adhesive.
ii The second coat consist of MiO which is porous material and is
therefore very good. The final cost i.e. aliphatic is a tough polymer
which can stand ultraviolet rays.
iii The cost treatment is about Rs. 320/m
2
.

8.3.3 Epoxy coating: They are well proven for concrete surfaces. When
formulated with liquid epoxy resin, liquid curing agents and highly penetrating
solvents, they give good performance. They are classified as under:

i Solvent base epoxy with relatively high molecular weight
ii Thin thrixotropic liquid epoxy based primer.
iii Thick epoxy coating applied by trawl or by spray.


DURABILITY OF CONCRETE STRUCTURES


Epoxy coating is cured either by amines or by polyamides. The
thickness of coating ranges between 8 to 15 microns.

8.3.4 Coaltar epoxy: They have both properties of coaltar and epoxy.
They have good adhesion to concrete and chemical resistance. They are
applied by roller, conventional means or by airless spray. They are applied in
two coats having total thickness of 15 to 20 microns. These have been used
in 1987 to 1991 in Thane Creek Rly. bridge on the piers in the tidal & splash
zones. The coatings are intact as seen in 1998. This is the cheapest and best
coating for substructure and coating over liner plates provided in the tidal &
splash zones.

8.3.5 Selection for concrete coating Recommendation:

i In Aggressive environment (Severe, Very severe and Extreme
environment):

Sub-structures of bridges - Coaltar epoxy
(In affected parts only)

Super structures of bridges - Epoxy-Phenolic IPN coating
or
CECRI Integrated four coat system

ii In non-aggressive environment ( Mild and Moderate environment):

No coating is necessary.
Good dense cover-concrete with good cement content with low w/c
and extra depth of cover is enough,
Use blended cement to make the concrete impermeable
Use clean reinforcing bars.