Fig.

7-5: Three-dimensional results of sector scan sonar

7.5 MONOLAYER, SOLVENT-FREE COATING SYSTEMS

Classic coating systems consist of four main components, namely: binder, pigments, additives and sol-
vents. These types of systems are always multi-layer systems: primer, intermediate and top coats. The
number of layers (total film thickness) depends on the required degree of protection. Humid environments,
as in marine conditions, will require at least a total minimum protection 400 to 500 µm.

Several layers are necessary, because solvents evaporate out of each layer, thus creating porosities in the
film which leads to premature failure. Several layers minimise the risk of oxygen and moisture penetrating
the steel surface and causing corrosion. Multilayer systems are often not practical or economical.

Monolayer, solvent-free systems have only recently been developed (within the past 25 years) in an effort
to minimise the disadvantages of the classic multilayer systems. Advantages of a monolayer, solvent-free
system include:

• one layer, resulting in no contaminations or adhesion defects between layers

• less application time
• surface is available for service faster
• no porosities in the film resulting in a stronger barrier

75 PIANC Report 119

Progress in chemical knowledge of resins and hardeners make it possible to achieve outstanding proper-
ties with one layer coating systems, resulting in state-of-the-art corrosion protection for steel and concrete.
Mono-layer systems are epoxy or polyurethane; coal tar epoxy was once used but is now prohibited.

Fig. 7-6: Refurbishment lock gate: new one layer coating on lock gate

Monolayer, solvent-free epoxy systems offer a tremendous advantage when down time needs to be kept
to a minimum. For example, maintenance of corrosion protection of operational lock gates and auxiliaries
or corrosion protection of hydro power facilities (pipes lines). For existing structures, a product called
Humidor® requires no waiting time for drying as it hardens and cures under water.

7.6 REHABILITATION OF GATE SILL USING A DIAMOND WIRE SAW

The lower mitre gate sill in the main lock chamber of Locks and Dam 52 on the Ohio River was severely
damaged during extreme low water conditions. Towboats had been ‘bottoming out’ on the sill, typically as
they departed the main lock chamber (400 m x 40 m) going down river.

This lock passes very high tonnage annually, making it one of the most vital projects on the inland water-
way system of the United States. Delays to commercial users cause enormous daily economic impacts;
thus, rebuilding the sill had to be accomplished in the most efficient and expeditious manner possible.

A special cofferdam was used to dewater the area around the sill and a diamond wire saw provided the
capability to ‘slice’ the old sill with one continuous horizontal cut. The diamond wire saw proved to be
extremely versatile in allowing the entire sill to be cleanly cut in approximately five days. The old sill was
broken down into pieces small enough to be lifted out through the cofferdam structure. A new concrete sill
was formed and poured, resulting in a total closure time of 14 days.

PIANC Report 119 76

 Fig. 7-7: Cross section of damaged mitre gate sill due to concrete loss

Fig. 7-8: Section of lower mitre gate sill removed by a diamond wire saw

77 PIANC Report 119

 Fig. 7-9: Hoisting a cut section of the failed mitre gate sill

7.7 USE OF ‘GRAVITY DAM’ IN PLACE OF DEGRADED POIREE DAM

Several navigation projects situated on the Green and Ohio Rivers required poiree dam closures to dewa-
ter components for performing necessary ‘in-the-dry’ repairs.

A poiree dam maintenance closure is a series of trusses and panels which rely on embedments within a sill
for assembly of the poiree dam. The underwater embedments were determined unsafe due to corrosion,
so the poiree closure system could not be used.

A ‘Gravity Dam’ was designed to accomplish closures of varying widths at these projects (averaging 90 m
wide by 4 m high). Block weights were a maximum of 53 tonnes. This closure method has been used at a
number of sites and proven to be a safe and efficient solution.

Fig. 7-10: Pumped out ‘Beartrap’ pool control structure showing upstream gravity dam closure

PIANC Report 119 78

 Fig. 7-11: Gravity Dam blocks; note 3-block lifting rods

Fig. 7-12: Gravity Dam installation on upstream closures for locks and dam 52 ‘Beartrap’ pool control structure

7.8 USE OF TEMPORARY MITRE GATE ANCHORAGE SYSTEM

Inspection revealed excessive movement of the embedded anchorage of a 22 m x 22 m lower mitre gate
at a 400 m x 35 m lock project on the Ohio River. Repairs required removal of concrete from around the
top gate anchorage, Fig. 7-13 on the next page.

79 PIANC Report 119

 Fig. 7-13: Removal of concrete around the top gate anchorage

Both anchor arms and the gudgeon pin had to be removed while not impeding commercial traffic (65 mil-
lion tonnes annually), so it was essential to conduct repairs without closing the lock.

A temporary gudgeon pin assembly was constructed on top of the existing assembly (illustrated in the fol-
lowing two photographs).

Fig. 7-14: Temporary anchor arms

Fig. 7-15: Temporary gudgeon pin

PIANC Report 119 80

The temporary upper anchorage provided continued operation of the mitre gate while major repairs were
made to the existing upper anchorage assembly (illustrated in the photo below).

Fig. 7-16: Rehab of the existing upper anchorage assembly

7.9 ELECTRO-OSMOTIC PULSING FOR PREVENTION OF WATER INTRUSION IN

CONCRETE AND MASONRY STRUCTURES

Chronic water intrusion through the floors and walls of a reinforced concrete or masonry structure intended
to remain dry can cause serious structural degradation, safety problems and damage to equipment. Water
corrodes steel reinforcement bars, cracks concrete walls and erodes mortar. Intruding water raises the
interior relative humidity, accelerating the corrosion rate of mechanical equipment in the area and creat-
ing unacceptable air quality due to the rapid growth of bacteria and mould. It also increases maintenance
requirements (frequent repairing or cleaning to combat mould growth) and can make areas unusable.

Electro-Osmotic Pulsing (EOP) technology mitigates water-related problems from the interior of affected
areas without the cost of excavation or other intrusive and expensive measures. An EOP system consists
of three essential parts: (1) anodes (positive electrodes) inserted into the concrete wall or floor, (2) cath-
odes (negative electrodes) staked into the soil outside the structure and (3) an electronic control unit that
delivers electric pulses to the anodes. The pulses of electricity draw water away from the anode, toward
the cathode, reversing the direction of water seepage.

7.9.1 The Technology

Traditional methods for correcting water seep-

age involve the application of sealants or cost-
ly excavation to place tiles around the facility
exterior. In 1994, a team of researchers from
the U.S. Army Engineer Research and Devel-
opment Centre (ERDC), DryTronic, Inc. and
APS Materials began development of an inno-
vative technology for the prevention of water
intrusion in below-grade concrete structures.

Fig. 7-17: Principles of electro-osmotic pulse technology

applied in concrete basements

81 PIANC Report 119

EOP technology is based on the concept of electro-osmosis; the movement of an electrically charged ion
in a liquid under the influence of an external electric field. EOP not only eliminates water-seepage prob-
lems from the interior of the structure without excavation, but it further mitigates corrosion damage to me-
chanical equipment and reduces the interior relative humidity of the basements. The reduction in relative
humidity or moisture content of the concrete interior surface also eliminates one of the primary sources of
disease carrying moulds and bacteria, which require a high moisture content to grow.

The system uses two sets of electrodes; one set is embedded into the interior concrete walls and the other
set is embedded in the surrounding backfill/soil. A pulsing DC voltage is applied between the electrodes to
produce an electric field across the walls/floors, which move water from the dry side (interior) toward the
wet side (exterior), preventing moisture from reaching the interior surface of the concrete. A representative
pulsating electro-osmotic sequence consists of a pulse of positive voltage (time ‘t-pos’) (as seen from the
dry side of the concrete wall), a pulse of negative voltage (time ‘t-neg’) and a period of rest when no voltage
is applied. Laboratory and field tests were conducted at ERDC Laboratories in conjunction with demon-
strations and evaluations at selected army installations to assess the feasibility and cost-effectiveness of
EOP technology in comparison with conventional dampness mitigation techniques.

Fig. 7-18: Chamber before EOP installation

7.9.2 Benefits

The following benefits are expected from the EOP System:

• The prevention of structural damage by reducing rebar corrosion and concrete cracking
• The prevention of corrosion damage to interior mechanical and electrical equipment by reducing relative
humidity
• Prolong the life of standard concrete repair technologies
• The improvement of interior air quality for the safety for occupants and workers
• Ease of EOP installation which causes less disruption to operations

Fig. 7-19: Six month after installation of EOP

PIANC Report 119 82

7.10 REPLACEMENT OF THE BOTTOM RAILS OF ROLLING GATES
(ANTWERP – BELGIUM)

The Kallo Lock in Antwerp (Belgium) is the only connection between the Scheldt and the port on the left
bank of the Scheldt. The lock was built in 1971, first used in 1981 and continuously in use until 2006. In
2004, 4,281 lock movements were counted. The chamber of the lock is 380 m long by 50 m wide and has
two upper and two lower rolling gates on bottom rails.

Fig. 7-20: Damaged bottom rails at Kallo Lock

Diving inspections showed significant wear of the bottom rails after this long period of use. Replacement of
the bottom rails and the wheels on the doors was the only long-term solution to guarantee the reliability of
the lock. To minimise impact on the navigation, putting the lock chamber totally dry during the replacement
works was not possible and a specific work method had to be worked out.

Fig. 7-21: Lowering the caisson

A caisson was designed and built to execute these works. This caisson consisted of two intermediate sec-
tions, two end sections and a connection section to connect the caisson to the dry door chamber at the
side of the lock chamber. This modulation allowed this caisson to be used in several other locks with rolling
doors in the ports of Antwerp and Zeebruges.

83 PIANC Report 119

 Fig. 7-22: Installed and dewatered caission

The rails in this caisson can be replaced and the necessary work can be done in a dry climate allowing a
high quality result. This high quality guarantees a long lifetime of the rails and connections between rails
and foundation, which improves the global reliability of the lock.

The caisson is approximately 2.5 m high, which allows ships with an immersion of ca. 9 m to pass above it.
Deeper ships can pass with high tide. For safety reasons, navigation was stopped temporarily during the
working shifts. Navigation was only possible at noon and during the night, but impact on the time schedule
was little due to efficient communication and planning of both the works and the locking operations. Easy
access to the caisson was possible by connected door chambers.

7.11 USE OF INCLINOMETER FOR CONTINUOUS MONITORING OF QUAY

WALLS

During the execution of the Kluizendock quay walls in the Port of Ghent, it was decided to instrument the
quay wall structure to be able to monitor deformations. The measurements would define the deformation
mechanism and cross-check and provide feedback with respect to the calculation methods used for de-
signing the structure. The measurements would also allow verifying the serviceability limit state both in the
stage of construction of the quay walls and after completion of the works.

The purpose was to introduce a quality control tool for soil mechanics engineering and Decision Support
System (DSS) for intervention works, based on the experience acquired at the Kluizendock quay wall
project.

The monitoring includes measurements of the vertical and/or the horizontal displacements. The measure-
ments are carried out by means of instrumentation used to measure slope angles, commonly known as
the inclinometer and a topographic survey. The basic principle of the inclinometer consists in measuring
the displacement of a materialised vertical in the ground. For the materialisations of the vertical, tubes are
incorporated in the quay wall, the so-called inclinometer tubes.

PIANC Report 119 84

Fig. 7-23: Construction progress at Kallo Lock, Belgium

85 PIANC Report 119