brian mcfarland - lnec
TRANSCRIPT
Carbonation, Chlorides & Electrochemical Repair
Brian McFarlandB.Eng (Hons) C.Eng M.ICE M.IEI M.ICorr MCS
McFarland Associates Limited
2nd Transnational WorkshopduratiNET
The Queen’s University of BelfastThe Queen s University of Belfast22nd June 2009
Overview
Carbonation, Chlorides& Electrochemical Repair& Electrochemical Repair
Carbonation
Chloride Attack
Inspection & Testing
Traditional RepairTraditional Repair
Electrochemical Repair
Case HistoriesCase Histories
The Problem
Millions of pounds are spent every year dealing with the symptoms of corrosion
Expense Disruption Danger
The Cause of the Problem
Poor design Chloride attackCarbonation Freeze thawCarbonation Freeze thawASR Low coverSulphate attack Poor site practiceImpact damage ErosionCh i l tt kChemical attack
Carbonation
Loss o f passivated
layer
C b
y
Carbon Dioxide
Rust
Carbon Dioxide
Chloride attack
P a s s iv e la y e r d e s t ro y e d , fo rm a t io n o f a n a n o d e a n d s u b s e q u e n t e le c t ro c h e m ic a l p ite le c t ro c h e m ic a l p it c o r ro s io n
C h lo r id e io n s p e n e t ra tep e n e t ra te c o n c re te
C h lo r id e c o n ta m in a te d c o n c re te
Chloride induced corrosion pits
Inspection & Testing
Chloride threshold values
Chloride content Risk of
(% cement) corrosion
< 0 4 Negligible< 0.4 Negligible
0.4 – 1.0 Possible
1.0 – 2.0 Probable
> 2.0 Certain
Ref: Browne (1982)( )
Half cell potential threshold values
CSE Corrosion Condition
> -200 mV Low – 10% risk of i
0 100 200 300 500400 600 200 mV corrosion
200 to 350 mV Intermediate corrosion
0 100 200 300 400 500 600
-200 to –350 mV risk
High <90% risk of
1
2< -350 mV High - <90% risk of
corrosion2
3
< -500 mV Severe corrosionA B C D E
Traditional repair methods
BUT traditional patch repair alone does not . . . . .
Stop ongoing corrosion
Prevent further spalling
Break the repair cycle
Chasing the corrosion
BRE Digest 444
The problem … “the newly established cathodic area within the repair will drive the new anode site in the contaminated region”
How does this mechanism work? …………….
Chloride contaminated concrete prior to patch repair
Steel
Chloride Chloride Chloride0.8% 4.0% 0.8%
Concrete
Chloride contaminated concrete prior to patch repair
Chloride Chloride Chloride0.8% 4.0% 0.8%
cathode anode cathode
Patch repair
i i i t d ff tincipient anode effect
Chloride Repair ChlorideChloride Repair Chloride0.8% 0.8%
anode cathode anodeanode cathode anode
Downsides of Traditional Repair
Break out all contaminated concrete
Expensive
Noisy
Dusty
DisruptiveDisruptive
Electrochemical Repair
Electrochemical Repair“Fighting Fire with Fire”
Cathodic Protection
Realkalisation
Chloride Extraction
Sacrificial Anodes
Next Generation Hybrid Systems
Cathodic Protection
Realkalisation
+ve
Anode Elec tro lyte
ve
- ve
ConcreteK 2 C O 3 .K H C O 3
ConcreteO H - N a +
N a +
Reinfo rcem ent
K +
Chloride Extraction
Current
+ve
Anode Elec tro lyteCurrentpaths
Cl-
Cl-
+ve
- veCl-
Cl- Cl-Cl-
Cl-
O H -
Cl-
Cl-
Cl
Cl-
Conc reteCl-Cl-
Re info rcem ent
Hydroxide Precipitation
Proc. 7th Int. Conf. Concrete in Hot and Aggressive Environments, Vol. 2, p.477, 2003
Sacrificial Systems
XP for patch repairs
CC for blanket protectionfor blanket protection
LJ for jetty piles
All the Galvashield systems work on the same principle …
Oil Rig Example
Photo Courtesy of Wilson Walton
Hybrid Systems
• Chloride extraction type process
• Cathodic prevention type process (low maintenance)( )
• Single electrode system
Hybrid Application
• Install discrete alloy electrodes
• Apply specialised electrochemical treatment for 1 week
• Connect activated sacrificial anode to steel
Hybrid Application
Duoguard AnodesIn Drilled Holes
Temporary DC p yPower Supply
(present for ~ 1 week)
Monitoring options
Measure …….
CurrentCurrent
Temperature
Steel potentialSteel potential
Residual life
Manual monitoring boxg
Automated monitoring box
Current output can be easily monitored
Eaton Park Pavillions, Norwich: CC anodes installed April 2001:Current Density results
6 30
5
6
25
30Current Density (mAm2) Temperature (degC)
July 01
June 02 June 03
3
4
sity
(mA
/m2)
15
20
ure
(deg
C)
June 03
2
3
Cur
rent
Den
5
10
Tem
pera
t
0
1
-5
0
Dec 01Feb 03
0 100 200 300 400 500 600 700 800
Time (days)
Residual life can be calculated
Predicted anode life (Galvashied CC65)
0.0010
mps
0.0006
0.0008
outp
ut /
Am
0 0000
0.0002
0.0004
Cur
rent
0.00000.00 5.00 10.00 15.00 20.00 25.00 30.00
Life / Years
Comber Bridge
Comber Bridge
Comber Bridge
Comber Bridge
Carrick Leisure Centre
Carrick Leisure Centre
Lakeland Forum
Lakeland Forum
Eglinton Church
Eglinton Church
Red Arch Bridge
Red Arch Bridge
Red Arch Bridge
Ballylumford Jetty
Ballylumford Jetty
Beatties Bridge
Beatties Bridge
Conclusions
Carbonation & Chloride Attack are the main problems encountered
Traditional Repair alone rarely deals with the source of the problem
Electrochemical Repair treats “Fire with Fire” and deals with the source of the problem – reinforcement corrosion
Realkalisation & Chloride Extraction are time consuming and costly
Cathodic Protection requires a power source and monitoring and is prone to breaking down vandalism and failure of the anodesto breaking down, vandalism and failure of the anodes
Sacrificial Anodes are passive
H b id S l ti i i th b fit f CP CE d SA ith t thHybrid Solutions maximise the benefits of CP, CE and SAs without the downsides