Bridge Office

301 St. Paul Street, 2

nd
Floor
St. Catharines, ON L2R 7R4
(905) 704-2406

Memorandum


Date: May 12, 2004

From: Bala Tharmabala
Manager, Bridge Office

To: Distribution List (Attached)

Re: Bridge Office Design Bulletin
Concrete Removal Criteria for Bridge Deck Rehabilitation


Background

Prior to 1989, rehabilitation of bridge decks involved removal and replacement of delaminated
concrete only. Since 1989, the Ministry adopted the policy of removing and replacing
delaminated concrete and concrete in areas where the corrosion potential is more negative than
-0.35V. It was believed that removing all concrete with high corrosion potentials, generally
corresponding to areas of high chloride contamination, provided an effective means of reducing
the likelihood of continued corrosion and maximizing the life expectancy of the rehabilitation
treatment.

The Ministrys recent field experience has demonstrated that this approach is costly because
the cost of removing chloride contaminated in otherwise sound concrete is high, and there are
difficulties in accurately predicting removal quantities based on half cell potentials and
controlling its removal in the field. Limited in-house research investigations have also shown
that while removal by delamination alone does reduce the service life of a rehabilitation
treatment, this reduction may not be as significant as expected.

This new concrete removal policy will confine removal to delaminated concrete and sound
concrete in high potential areas that are heavily chloride contaminated and at greatest risk for
continued corrosion activity. Where the chloride content exceeds 0.05 % by mass of concrete
(twice the previously accepted threshold for corrosion to occur), it is recognized that there is a
need to remove this concrete to reduce the possibility of future corrosion activity.

The proposed protocol is expected to result in removal of less concrete and reduce the
occurrence of costly overruns, while still achieving a reasonably long service life for the
rehabilitation.


Concrete Removal Criteria for Bridge Deck Rehabilitation, May 2004 1




New Concrete Removal Policy

Concrete removal for decks with average chloride content at the top reinforcement level less
than 0.05% by mass of concrete shall include delaminated concrete only.

Concrete removal for decks with average chloride content at the top reinforcement level greater
than 0.05% by mass of concrete shall include delaminated concrete and concrete in areas
where half-cell potentials are more negative than 0.35 volts.

The chloride limit of 0.05% by mass of concrete after adjustment for background chloride is
equal to twice the chloride threshold used in the past and is considered to be a safe and
practical upper limit to exclude deleterious chloride contaminated concrete.

Condition Survey

The number of cores to be tested for chloride profile shall be as follows:

Locations No. of Cores
Min. Max.

Corrosion Potential < -0.35 V 1 per 30 sq. m 8
(Min. 2)

Corrosion Potential 0 to -0.35 V 1 per 250 sq. m 8
(Min. 2)

For decks with less than 10% of the total deck area more negative than 0.35 V, the average
chloride content shall be calculated using all the cores tested.

For decks with more than 10% of the total deck area more negative than 0.35 V, the average
chloride content shall be calculated using only the cores taken in the high corrosion potential
areas.

This policy does not apply to post-tensioned decks and decks that are to be cathodically
protected.

Tender Quantity Estimates

If concrete removal is by delamination only, the tender quantity for partial depth Type A removal
shall include the area with corrosion potential < -0.45 V, and an allowance for annual growth of
the removal quantities as is currently required in the Structure Rehabilitation Manual. This is to
minimise the risk of overrun of the removal item due to growth of delamination in the high
corrosion potential areas. In such cases, half-cell survey during construction would not be
required. The rehabilitation treatment selection shall be based on the tender removal quantity
accordingly.



Concrete Removal Criteria for Bridge Deck Rehabilitation, May 2004 2



Implementation

1) This criteria shall be effective immediately for all new condition survey assignments and
rehabilitation contracts.

2) For stockpiled designs and designs currently underway, the regional structural sections
should assess whether the existing condition surveys provide sufficient information on
the chloride content and decide accordingly.

2) Consultants working on ministry projects should be notified of these requirements by the
office responsible for the contract assignment.

3) These requirements will be included in the next revision to the Structural Rehabilitation
Manual.



Original signed by:

Bala Tharmabala,
Manager, Bridge Office

cc: R. Mantha, Chief Engineer



Distribution List:

Managers of Engineering Heads, Regional Structural Sections

K. Bentley, Southwestern Region P. Furst, Northeastern Region
P. Makula, Northwestern Region A. Ho, Central Region
Mgr of Engineering, Northeastern Region Q. Islam, Eastern Region
L. Politano, Central Region R. Krisciunas, Northwestern Region
K. Williams, Eastern Region W. Young, Southwestern Region


Heads, Bridge Office

D. Bagnariol, Evaluation
R. Haynes, Standards
I. Husain, Design
D. Lai, Rehabilitation
C. Lam, Bridge Research
T. Merlo, Design Systems
R. Mihaljevic, Quality Assurance
Concrete Removal Criteria for Bridge Deck Rehabilitation, May 2004 3