05 Corr Repair

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
10
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?
11

H2O Dense overlay No chlorides High pH Chloride & Lower pH Cl
Penetrating Sealer
H2O No chlorides High pH
Cl Chloride & Lower pH
12
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
13
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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15
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Removing all the Chloride Contaminated Concrete
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18
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
20
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
25
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-
26
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-
27
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-
28
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
29
Electrochemical Chloride Extraction
www.norcure.com
www.norcure.com
www.norcure.com
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www.norcure.com
Cellulose fibres soaked in anolyte (e.g. sodium borate) sprayed on concrete surface www.norcure.com
www.norcure.com
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www.norcure.com
www.norcure.com
www.norcure.com
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www.norcure.com
www.norcure.com
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www.norcure.com
www.norcure.com
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www.norcure.com
www.norcure.com
www.norcure.com
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www.norcure.com
CP Repair Strategy
ECE Repair Strategy
Yes
Apply ECE Protect from further Cl ingress
38
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
www.norcure.com
www.norcure.com
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www.norcure.com
www.norcure.com
www.norcure.com
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Before
After
Protecting the Repaired Structure
41
?
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
42
Broomfield, 1997
Broomfield, 1997
REPAIR?
Yes
DESIGN/ SELECT REPAIR
EXECUTE REPAIR
Adapted from Emmons, 1994
43

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Repair & Maintenance of Concrete Structures

5. Repair of CorrosionCorrosion-Damaged Structures

Repair the Symptom

Address the Cause

Alter the Process

Do Nothing Else Future Prevention

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

Patch Repairs Check List

Chloride & Lower pH

Creation of a New Galvanic Cell

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

Anode: 2Fe 2Fe2+ + 4e-

Anodic Ring Ring Effect

Improving the Performance of Patch Repairs Treating the Surface

But does it reduce corrosion?

Improving the Performance of Patch Repairs Treating the Surface

But does it reduce corrosion?

Improving the Performance of Patch Repairs Treating the Surface

H2O No chlorides High pH

Cl Chloride & Lower pH

But does it reduce corrosion?

Improving the Performance of Patch Repairs Treating the Steel Rebar

EpoxyEpoxy-coating the exposed steel

But does it extend the time to the next repair?

Improving the Performance of Patch Repairs Treating the Steel Rebar

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

Norcure Embedded Galvanic Anode

Sacrificial metal (zinc) core

Cementitious matrix Tie wires

Improving the Performance of Patch Repairs Installed Galvanic Anode

Removing all the Chloride Contaminated Concrete

Complete Slab Replacement

O2 + H2O + 4e- 4OH-

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

Requirements for Impressed Current CP

Control & Monitoring

Apply Cathodic Protection

Apply Cathodic Protection

The CP system is then connected.

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

Criteria: Absolute potential Instant-off potential Polarization decay

Electrochemical Chloride Extraction

ECE Repair Strategy

Apply ECE Protect from further Cl ingress

Repair of Carbonation-Induced Corrosion

Protecting the Repaired Structure

DESIGN/ SELECT REPAIR

Adapted from Emmons, 1994

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