Repair Options for

Corrosion-Damaged Reinforced Concrete

Bridge Superstructure Elements

S A Kristiawan, PhD
sa_kristiawan@uns.ac.id

Jurusan Teknik Sipil

Fakultas Teknik
Universitas Sebelas Maret

Performance level; Load

Performance of Bridge in Time

Load

Bridge
deterioration
Design service life

Time

Corrosion-Damaged

Corrosion caused
by carbonation

Corrosion-Damaged

Pitting corrosion
caused by chloride
penetration

Corrosion-Damaged

Corrosion of
reinforcement
causing cracking
and rust staining

Corrosion-Damaged

Spalling due to chloride

corrosion of reinforcement

Breakdown of Passivity by Carbonation

Concrete cover
Passivating film

Steel
In alkaline environment (pH > 11.5) ferrous & ferric hydroxide adhere to the steel surface
forming passivating film; The high pH is due to the dissolved ion OH - from calcium
hydroxide into pore solution

H2O

Fe++

Cathode(OH)

O2

Anode
e-

CO2 can react with solid Ca(OH)2, CSH gel, alkali and calcium ions in the pore solution. As a
result of this reactions is a drastic decrease in the alkalinity of pore solution and steel loss
its protection. Hence, corrosion reaction take place.

Breakdown of Passivity by Chloride

Passivating film

Cl-

Cl-

Clcover

Concrete

Steel
pit

Depassivation by the effect of chloride ions:

Ferric oxide is more resistant to chloride than ferrous oxide. The ferrous react
with chloride:
Fe(OH)2 + Cl- [FeCl]x
The reaction cause steel loss its protection in the area where ferrous oxide is not
converted to ferric oxide.

Corrosion Reaction
H2O

Fe++

Cathode(OH)

O2

Anode
e-

Anode Reaction:

Ferrous hydroxide:

2Fe + 4e- 2Fe++

Fe++ + 2(OH)- Fe(OH)2

Cathode Reaction:
4e + O2 + H2O (OH)
-

Ferric hydroxide:
-

Fe(OH)2 + 2H2O + O2 4 Fe(OH)3

Damaged Process

The relative volume of iron

and its reaction product

Economic Consequences

14% Bridge rated structurally deficient and the primary cause of

deficiency was corrosion of reinforcing steel

Annual cost of corrosion is estimated at $8.29 billion

The cost does not include indirect cost incurred by travelling public
due to bridge closures

14% of 587,964 bridges

Repair Problem Statements

How to identify and determine the extent of

corrosion?
What action should be performed when
corrosion is identified?
How to choose the right repair options?

Standard Decision-Making Process is a

must!!!
This will help in avoiding unnecessary expenditure in
repair and rehabilitation of existing structure

Assessing Current Condition of

Bridge Structure
The AASHTO Manual
Type of
Inspection

When
perform

Feature of
Inspection

1. Initial
Inspection

Upon
completion

Baseline structural condition

2. Routine
Inspection

Every 2 years

Physical & functional condition,

identify changes since last
condition

3. Damage
Inspection

Trigger by
damage

Inspection of damage to identify

the need for further action

4. In-Dept
Inspection

Focuses on
certain section

Investigate deficiencies not

detected during Routine Inspection

The required data for

corrosion-damaged action

Routine Inspection
Metho
d
Visual
Survey

Data
collected
Rust staining,
cracking,
delamination and
spalling

Interpretati
on

This survey is sufficient to detect

corrosion
But not answer the following
questions:
When does the structure need repair?
To what extent the repair should be
performed?

The required data for

corrosion-damaged action

Modifying the extent of Routine

Inspection
Metho
Data
Interpretati
d

collected

Visual
Survey

Addition
al
Survey

Rust staining,
cracking,
delamination and
spalling
Chloride ion
distribution, concrete
cover, quantity
damaged

on

Ok

With these additional survey:

Progress of Corrosion can be determined time to
repair, type of repair

Proposed Inspection

Preliminary Corrosion Condition

Evaluation (PCCE): perform in
conjunction with Routine Inspection, but
not in 2 years interval. Perform when the
first sign of corrosion initiation observed

In-Depth Corrosion Condition Evaluation

(In-Depth Inspection): when bridge is
deemed to be repaired

Key to Repair Strategy

Data from PCCE may be used:
to predict when repair should be
done Perform service life
modelling
Data from In-Depth Inspection:
to perform service life modelling
to choose repair option
Calculate Susceptibility Index (SI)

Service Life Modelling

time
initiation
propagation

Limit of serviceability
Level of damage
load

Corrosion level
Limit of chloride at the
surface of reinforcement

Limit of corrosion
causing structural failure

time

Time to Initiation (Ti)

Time to Initiation (Ti)

Position of
reinforcement

C(x,t) % by weight of cement

D can be determined from plotting C(x,t)

vs x obtained from measurement on
existing concrete at time t

Critical chloride content 0.15%

Predicted chloride content
Measured chloride content

10

20

30

40

50

60

70

80

Depth (mm)

Time to Propagation (Tp)

Time to Propagation (Tp)

Susceptibility Index

Susceptibility Index (Examples)

Susceptibility Index

Optimal Major Repair Options

Minor Repair and Major Repair

Minor Repair as necessary

PCCE
(after 1st
sign)

Service
Life
Modellin
g

In-Depth (2
year before
major repair)

Service
Life
Modellin
g and SI

Major
Repair
option

Major
Repair
schedu
led

Minor and Major Repair

Hasil identifikasi selama PCCE mungkin

mengharuskan dilakukan minor repair pada lokasilokasi tertentu.

Minor repair dapat dilakukan sesuai kebutuhan

sampai major repair dijadwalkan.

Metode umum yang dipakai dalam pelaksanaan minor

repair adalah patch repair.

Saat major repair dilaksanakan pun, patch repair

merupakan companion terhadap metode major repair.

Patch Repair

patch repair: replace localized areas of

deteriorated concrete

patch rehabilitation : remove concrete i.e.

damage, sound but corroding, sound but
critically contaminated.
( the deteriorated concrete is removed to the
depth of 2.5 cm below reinforcement)

Patch Repair
Disadvantages: - do not address the cause of the
problem
- halo effect (new repair material
trigger potential
different),
corrosion takes place by shifting the
New repair
Old parent
anode-cathode
material; pH
concrete; low
>11.5
becoming
cathode
(formerly
anode)

pH
becoming
anode
(formerly
more active
cathode)

Sealers or Surface Treatments

Notes on Surface Treatments

Check kandungan ion Cl- didalam beton yang akan di

lindungi dengan surface treatment tsb!!

Surface treatment hanya efektif mengurangi

kemungkinan korosi apabila ion Cl - yang ada didalam
beton dalam jumlah yang setelah terdifusi ke
permukaan tulangan tidak cukup untuk inisiasi korosi.

Bila ion Cl- tinggi, perlu langkah: membuang beton yang

mengandung Cl- tinggi atau mengeluarkan ion Cl -

Berarti perlu patch repair juga.

Membranes
Applied to bridge deck in conjunction
with HMA overlays
Performance criteria for membrane:
Water permeability
Chloride ion permeability
Flexibility under changing temperature
Crack bridging
Bond strength
Resistance to indentation

Overlays

Used to restore deck riding surface

The overlay functions as a barrier to
chloride penetration
Before overlays, the procedure includes
removing damaged concrete, sound but
corroding and sound but critically
contaminated.

Overlays

Surface Preparation

Overlays

Surface Preparation

Corrosion Inhibitor

Inorganic (calcium nitrite)-based inhibitor: provide

protection by oxidizing the surface of reinforcement

2Fe++ +2OH- + 2NO2 2NO + Fe2O3 + H2O

There is a competition between nitrite ion and chloride
ion to use ferrous
ion produced by the steel.
Hence, the effectiveness of nitrite inhibitor depends on
the ratio of nitrite
to chloride.

Organic (amine)-based inhibitor: block the

permeation of chloride ion and
form protective
film on the surface of reinforcement

Cathodic Protection

An Impressed-Current Cathodic
Protection

1 5 Volt,
10 - 20 mA

Cathodic Protection

Galvanic Cathodic Protection

Electrochemical Chloride Extraction