Deck Problems After Patching

Deck Problems after Patching 2/16/2016
Corrosion Mitigation of
Reinforced Concrete Structures
Erik Thorp
Vector Corrosion Technologies
Corrosion Ravaged Columns

Chicago, Illinois
1
Halo Effect
Corrosion Basics
2
Causes of Corrosion
• Chlorides
• Carbonation
• Dissimilar Metals
Results in the Destruction of the

Steel’s Passive Oxide Layer
Corrosion Cell in Concrete

Fe Fe2+ + 2e -
Fe2+ + 2Cl- FeCl2
Anode
FeCl2 + 2OH- Fe(OH)2 + 2Cl-
Fe3O4
2Fe(OH)2 + 1/2O2 Fe2O3 + 2H2O
γFe2O3
2e -
2OH- Fe3O4
γFe2O3
1/ O + H2O + 2e - 2OH-
2 2
Cathode
3
Why Does This Occur?
Corrosion Potential for Steel in Concrete
Metal Voltage
Steel in Chloride-Free
0 to -200 mV
Concrete
Steel in Chloride-
-350 to -500 mV
Contaminated Concrete
*Typical potentials measured with respect to copper-
copper sulfate electrode
Corrosion Cell in Concrete

Fe Fe2+ + 2e -
Fe2+ + 2Cl- FeCl2
Anode-500 mV -350 mV
Fe3O4
2Fe(OH)2 + 1/2O2 Fe2O3 + 2H2O
γFe2O3
2e -
2OH- Fe3O4
γFe2O3
1/ O + H2O + 2e - 2OH-
2 2
Cathode -200 mV
4
“Chip and Patch” Repair Method
© Vector
Patch Accelerated Corrosion

Chloride Contaminated Concrete Chloride-Free
2OH- Patch
1/ O + H2O + 2e - 2OH-
-350 mV 2 2
Anode 2e - Cathode
Fe Fe2+ + 2e -
-200 mV
Fe2+ + 2Cl- FeCl2

2Fe(OH)2 + 1/2O2 Fe2O3 + 2H2O
-200 mV
5
Halo Effect
Halo Effect
6
Galvanic Corrosion
Protection Systems
Galvanic Protection Systems

• Two different metals are connected in
same electrolyte (concrete)
• More “active” metal = anode
• More “noble” metal = cathode
• Anode corrodes to protect cathode
• Natural reaction
– no external power required
• Safe for prestressed concrete
7
Galvanic Protection
e-
Partial Galvanic Series
electronic
Metal Voltage K+
Na+
Zinc -1100 mV
Steel in -200 mV to ionic

concrete -500 mV
*Typical potentials measured with CL-
respect to copper-copper sulfate
Zinc OH- Steel
electrode
Galvanic anodes naturally operate based on the principle of dissimilar metals corrosion like commonly
used batteries. Current flows from the anode (the metal with the most negative potential) to the cathode
(steel).
8
Embedded Galvanic Anodes for

Corrosion Prevention
Activation Technology
Alkali Activated
• High pH is
corrosive to zinc but
not to steel
• Allows zinc anodes
to provide protection
to reinforced
concrete over time
9
Patch Accelerated Corrosion

Chloride Contaminated Chloride-Free Patch
Concrete
Potential Difference Between Patch and

Chloride Contaminated Concrete
Results in Accelerated Corrosion
Installed Galvanic Anode

Chloride Contaminated Concrete Chloride-Free Patch
-350 mV -200 mV
-1100 mV
Anode Galvanically Protects
Surrounding Rebar
10
Anode Installation
Installing anodes around the perimeter of the repair.
Quick and Easy Installation
11
Anode Installation
Testing anode connection to reinforcing steel.
Anode Installation
Embedding anodes with repair material.
12
Point Anodes Protection

Concrete Repair
Point
Anodes
Area of Influence
Base Concrete
I-94, Jackson, Michigan

Michigan DOT
13
Type 1A Embedded Galvanic

Anodes
Joints and
Interfaces
14
Corroded Joint
Pittsburgh, Pennsylvania
New Concrete Extension
Old Retaining Wall
Failed Concrete Next to Joint

Due to Corrosion
© Vector
Old Chloride New Chloride-Free

Contaminated Concrete Concrete Extension
Potential Difference Between New Concrete

and Old Chloride Contaminated Concrete New Tied-in Steel
Results in Accelerated Corrosion
Previous Edge of Old Concrete
Accelerated Corrosion at Joint Interface
15
Old Chloride New Chloride-Free

Contaminated Concrete Concrete Extension
Surrounding Anode Galvanically Protects

Rebar is Protected Adjacent Rebar
Galvashield XP Prevents Accelerated Corrosion
Bridge Widening
Port Mann Bridge, Vancouver, British Columbia
16
Embedded Galvanic Anodes -

Nomenclature
Type 1
–Installed in Standard Repairs
Type 2
–Installed in Sound Concrete
Source: Installation of Embedded Galvanic Anodes (ACI RAP Bulletin 8, 2010)
17
Drilled in Discrete Anodes
Corrosion Control Anode Installation

Corrosion Activity is
Reduced In Rebar
Anode Galvanically Protects

Surrounding Rebar
18
Steel connection next to pre-drilled

2” diameter hole
Anode/Steel
Connector
Anode
Steel
Connection
2” Diameter
Hole
Anode Connection to Reinforcing Steel
19
Predrilled Holes for CC Installation

Parking Garage Deck
20
Point Anodes
vs.
Distributed Anodes
Point Anodes Protection

Concrete Repair
Point
Anodes
Area of Influence
Existing Chloride
Contaminated Concrete
21
Distributed Anodes Protection

Concrete Distributed
Repair Anodes
Existing Area of
Concrete Influence
22
On Many Slab Bridges…

• Slabs are in good condition
• Deterioration at abutment around the key way
Typical Slab Bridge Abutment

Approach Slab Existing Bridge Deck Slab
Spall
23
After Conventional Patching

Repair
Abutment Repair Detail With

Galvanic Protection
Replace Joint Seal
Approach Slab Existing Bridge Deck
± 6-in SCC Facing

Galvanic Strip Anodes
#5 @ 18” OC EW ECR
#5 ECR Dowels
24
Final Product
25
Galvanic Anodes
Bridge Deck Overlays
26
27
Corrosion Ravaged Columns

Chicago, Illinois
28
Galvanic anodes
'Rod' Anodes Point Anodes
100
Current Density (mA/m )
2
10
Cathodic Protection
1
Cathodic Prevention
0.1
0.0 2.0 4.0 6.0 8.0 10.0 12.0
Time (years)
Galvanic Anodes for Corrosion Prevention

In New Construction
Galvashield N
29
Precast Closure Strip
Galvanode ASZ+
Activated Arc Spray Zinc
30
DECK PROTECTION
“Distributed” Protection
with Activated Arc
Sprayed Thermal Zinc
31
Activated Arc Sprayed Zinc on

Bridge Columns
Electrochemical Treatments
• Chloride Extraction (ECE)

• Re-alkalization
• *Lithium Impregnation (ASR Treatment)
32
Electrochemical Chloride
Extraction
• Temporary electrical treatment applied to passivate
active corrosion by reducing chloride and increasing
pH around the reinforcing steel.
Electrochemical Chloride Extraction (ECE)

From Salt Contaminated Concrete
Temporary Conductive
Anode Media
DC Power
Source
Cl- Cl-
Cl-
Cl-
Cl- Concrete
Cl- Cl- -
Cl Cl-
Cl- Cl-
Cl-
Reinforcement
33

Current paths
Anode Media
DC Power
Source
Cl-
Cl-
-
Cl Cl- Cl-
Cl-
Cl- Concrete
Cl- Cl- Cl-
Cl- Cl-
OH-
Reinforcement

Current paths
Anode Media
DC Power Cl-
Source Cl-
Cl- Cl-
Cl- Cl-
- -
Cl Cl
Cl- Cl- Concrete

Cl-
OH-
Reinforcement
34

Current paths
Anode Media
DC Power Cl- Cl- Cl-

Cl- Cl- Cl-
Source
Cl- Cl- Cl-
- Cl-
Cl
Concrete
OH-
Reinforcement
Norcure® ECE Treatment Process
35
Norcure® ECE Treatment Process
36
Cellulose Fiber Serves as Electrolyte
37
Installation Complete
Ready to Start Treatment
Several Piers Wrapped and Undergoing ECE Treatment

Omaha, Nebraska
38
Piers after ECE Treatment

Cleaned and Sealed
Rainbow Bridge- Idaho
39
Electrochemical Chloride
Extraction
FHWA Bridge Preservation Guide

• In US, 25% of 600,000 bridges
are Structurally Deficient or
Functionally Obsolete
• 30% of bridges have exceeded
their 50 year design life
– Need repair, rehabilitation or
replacement
• A need exists to develop adopt
and implement systematic
process for bridge preservation
• Since 2008, Systematic
Preventive Maintenance (SPM)
is eligible activity under the
Highway Bridge Program
FHWA-HIF-11042, August, 2011
40
Corrosion may visit…..
But don’t let it bite!
41
Questions
Do we have a few more minutes?
42

Deck Problems After Patching

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Deck Problems After Patching

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Deck Problems after Patching 2/16/2016

Corrosion Ravaged Columns

Results in the Destruction of the

Corrosion Cell in Concrete

Why Does This Occur?

Corrosion Potential for Steel in Concrete

Corrosion Cell in Concrete

“Chip and Patch” Repair Method

Patch Accelerated Corrosion

FeCl2 + 2OH- Fe(OH)2 + 2Cl-

Galvanic Protection Systems

Steel in -200 mV to ionic

Embedded Galvanic Anodes for

Patch Accelerated Corrosion

Potential Difference Between Patch and

Installed Galvanic Anode

Installing anodes around the perimeter of the repair.

Quick and Easy Installation

Testing anode connection to reinforcing steel.

Embedding anodes with repair material.

Point Anodes Protection

I-94, Jackson, Michigan

Type 1A Embedded Galvanic

New Concrete Extension

Old Retaining Wall

Failed Concrete Next to Joint

Old Chloride New Chloride-Free

Potential Difference Between New Concrete

Previous Edge of Old Concrete

Accelerated Corrosion at Joint Interface

Old Chloride New Chloride-Free

Surrounding Anode Galvanically Protects

Galvashield XP Prevents Accelerated Corrosion

Embedded Galvanic Anodes -

Source: Installation of Embedded Galvanic Anodes (ACI RAP Bulletin 8, 2010)

Drilled in Discrete Anodes

Corrosion Control Anode Installation

Anode Galvanically Protects

Steel connection next to pre-drilled

Anode Connection to Reinforcing Steel

Predrilled Holes for CC Installation

Point Anodes Protection

Distributed Anodes Protection

On Many Slab Bridges…

• Deterioration at abutment around the key way

Typical Slab Bridge Abutment

After Conventional Patching

Abutment Repair Detail With

Approach Slab Existing Bridge Deck

± 6-in SCC Facing

Corrosion Ravaged Columns

Galvanic Anodes for Corrosion Prevention

Precast Closure Strip

Activated Arc Sprayed Zinc on

• Chloride Extraction (ECE)

• *Lithium Impregnation (ASR Treatment)

Electrochemical Chloride Extraction (ECE)

Electrochemical Chloride Extraction (ECE)

Electrochemical Chloride Extraction (ECE)

Cl- Cl- Concrete

Electrochemical Chloride Extraction (ECE)

DC Power Cl- Cl- Cl-

Norcure® ECE Treatment Process

Norcure® ECE Treatment Process