Eric Williams, National Sales Manager - US

Vector Corrosion Technologies

Evaluation, Repair and Protection of Concrete
Structures
Outline
• Introduction to Vector
• Non-Destructive Testing
• Corrosion Basics
• Corrosion Solutions
• Galvanic Protection
• ICCP
• Fusion Technology
• Electrochemical Treatments
• Sustainability and Preservation
 A Group of Companies Focused on Preserving and Extending the Life of
Parking Structures and Buildings
Vector Corrosion Technologies
- R&D, Manufacturing and Supply of Technologies for
Corrosion

Vector Construction
- Specialist Repair and Cathodic Protection Contracting

Vector Corrosion Services

- Concrete Durability Consulting, Concrete & Corrosion
Evaluation, Service Life Modeling, Cathodic Protection Design

NDT Corporation
- Non-destructive Testing and Evaluation of Concrete
including ground penetrating radar, sonic/ultrasonic (impact
echo/ultrasonic pulse velocity) and Geophysical Testing
 Investigation and
Condition Assessment
Methods
 Types of Inspections
• Visual Inspection
• Identify areas of visual damage
• Cracking
• Spalls
• Exposed steel
• Delamination Survey
• Hammer sounding
• Chain drag
Ground Penetrating Radar – Theory
• Electromagnetic evaluation of concrete
• Reinforcement layout
• Location of embedded metals
• Cover Depth
• Qualitative condition of reinforced concrete
• Chlorides, moisture, and concrete deterioration attenuate GPR signal
GPR – Silo Cover Depth Survey
Vertical Reinforcement Cover Depth
Silo 1 2 3 4 5 6 Total
Minimum (in) 0.25 0.25 0.25 2.25 0.25 0.25 0.25

Maximum (in) 6.75 7.00 6.75 4.75 7.75 5.00 7.75

Average (in) 3.45 2.66 2.99 3.38 2.69 2.41 3.02
Standard
1.39 1.19 1.37 0.59 1.60 1.07 1.26
Deviation (in)

Horizontal Reinforcement Cover Depth

Silo 1 2 3 4 5 6 Total

Minimum (in) 0.25 1.00 0.25 0.25 0.25 0.00 0.00

Maximum (in) 6.50 6.75 6.50 5.50 7.25 7.60 7.60

8.0
Average (in) 3.04 3.85 3.36 1.98 3.96 3.89 3.34
Cover Depth (in)

6.0

4.0 Standard
1.60 1.19 1.56 1.65 1.57 1.71 1.70
Deviation (in)
2.0

0.0
1 2 3 4
Silo 5 6 Total
Corrosion Potential Results
• Ranges: (with copper-copper sulphate)

> -0.20 V >95% probability of no corrosion

-0.20 to -0.35 V corrosion activity uncertain (50%)

<-0.35 V >95% probability of corrosion

At standard conditions (readings vary with temperature and humidity)

Section 2
Corrosion Potential – Bridge Deck
Sonic/Ultrasonic Testing
Sensors

Impact
Micro-cracked
Area Delamination

Full Thickness Coating Thickness

Pipe Resonance No Resonance Resonance

• Stress wave generated with a projectile impact

• Travel time of compressional and shear wave measured at each sensor
• Wave velocities calculated
• High velocity = high strength concrete
• Low velocity = cracked, deteriorated concrete
Sonic Testing – PT Overpass
Questions on Testing?
The Nature of Corrosion
• Corrosion is a natural process where a metal wants to
revert back to its natural state

Gold Iron
Steel, Concrete and Corrosion
The highly alkaline environment of concrete passivates
and protects embedded steel

But concrete is porous like a sponge…

Keeping water and contaminants out is key!
Corrosion Cell in Concrete

Fe Fe2+ + 2e -

Anode -350 mV
Fe3O4
+ ions γFe2O3

2e -
- Fe3O4
ions γFe2O3
1/ + H2O + 2e - 2OH-
2O2

Cathode -200 mV
Battery Example
Corrosion of Steel in Concrete
Chloride-induced Corrosion
• Caused by chlorides breaking up
passive oxide layer
• Sources of chlorides:
• Marine Environments
• De-icing Salts (NaCl, CaCl2) Corrosion Animation
• Chemical Plant Environment
• Cast-in Chlorides
• Vicious Circle: Chlorides are
never consumed
Corrosion Induced Damage
• Conventional mild reinforcing bar
• In most cases loss of steel section not primary concern
• Typically damage to concrete becomes significant and
observable prior to severe section loss
• High Strength Tendons
• Minor section loss of steel can have significant effect on
strength
• Steel can have significant section loss without significant
concrete damage
Carbonation
• Reduction of pH in cover concrete
which causes loss of passive oxide
layer
• Low pH caused by reaction of free
lime (Ca(OH)2) in concrete with
atmospheric carbon dioxide (CO2)

Ca(OH)2 + CO2 CaCO3 + H2O

lime (soluble) (insoluble)
pH 12-13 pH < 9 Carbonation Testing of Core Taken
from Precast Double T Stem
Current State of Repair
• Corrosion is one of the largest
costs to the U.S. economy, with
direct and indirect costs estimated
at over 6% of GDP
• The annual cost to owners in the
United States to repair, protect and
strengthen concrete structures is
estimated between $18-$21
billion.
• In one study, it was reported that
only a little more than 50% of the
repairs performed are performing
satisfactorily.
Patch Accelerated Corrosion

Bridge Pier Bridge Deck

 Patch Accelerated Corrosion
Chloride Contaminated Concrete Chloride-Free Patch
-ions
-350 mV 1/ O +
2 2 H2O + 2e - 2OH-

Anode 2e - Cathode
Fe Fe2+ + 2e - -200 mV
+ions

-200 mV
Cathode
Installed Galvanic Anode
-200 mV

-350 mV

-1100 mV
Localized
Protection for
Repairs using
Type 1 Anodes
Bridge Deck Edge in
Pickaway County
Ohio
Anode Installation

Testing anode connection to reinforcing steel.

Discrete Anodes Protection
Concrete Repair

Point
Anodes

Area of Influence

Base Concrete
BNSF – Grant Ave Bridge,
Springfield MO
Half-Cell Potentials – Pier 1 S

Standard Measurements

Delta Analysis
 Element
Chloride Testing Results
Location Near Surface Reinforcement
Depth
Pier 1 - South North Face 313 876
Column 1
Pier 1 - North East Face 416 644
Column 3
Pier 2 - North West Face 157 667
Column 3
Pier 2 - South East Face 107 223
Column 3
Pier 3 - North West Face 829 215
Column 1
Pier 3 - South East Face 279 149
Column 4
Pier 1 – North East Face 1073 555
Footing
Pier 2 - North West Face 2151 196
Footing
Pier 3 - North West Face 950 743
Footing
West Abutment (50’,2’) 267 207
East Abutment (4’,4’) 263 196
Galvanic Encasements
• What is a galvanic
encasement?
• Overbuild system for one step
repair and protection
• Can include supplemental
reinforcing for strengthening

• Embedded galvanic anodes

provided within encasement
area
• Annular space filled with mortar
or concrete
Joint Elimination W/ DAS Anode- Rt. 431, McLean County KY

…innovative solutions to concrete problems TM

www.vectorgroup.com
Joint Elimination W/ DAS Anode-
Rt. 431, McLean County KY

…innovative solutions to concrete problems TM

www.vectorgroup.com
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
I-75 Ohio DOT
Arlington Memorial Bridge
More Than a Bridge
 Arlington Memorial Bridge

• Construction began in 1926 and opened to traffic in May of 1932

• Over 85 year old historic structure
• Architectural elements included granite facing, sculptures of eagles and vases, poppies and
oak leaves to invoke national strength
Arlington Memorial Bridge
Rehabilitation
• Rehabilitation of AMB
• Estimated 68,000 Vehicles pass through on a daily basis
• Continued and accelerated deterioration of the concrete deck
would require a full bridge closure in 2021
• Design Build Project
• Funded in 2017
• Worth over $225M
• Goal was to add 75 year extension of service life
• Replacement of Bridge Decks
• Evaluation and Corrosion Mitigation
Corrosion Mitigation Approach
• Corrosion and concrete
materials evaluation
• Rehabilitation rather than
replace more of the structure
• Focusing efforts on elements
that won’t meet service life
requirements
• Consider alternate corrosion
mitigation strategies
 Initial Corrosion Solution:
Global Impressed Current Cathodic Protection
System (ICCP) - Permanent
• What is an ICCP system?
+ DC Power
• External D.C. power supply makes
electrons flow from anode to Supply
reinforcement (cathode) Concrete Overlay
• Benefits
• Long term solution Concrete
• Adjustable level of protection Rebar
• Able to provide a high level of control
• Disadvantages of ICCP
• Requires detailed design and careful installation ($)
Embedded Anode
• Specialized materials and equipment ($)
• Continued ongoing maintenance for life of system
($)
 Corrosion Solution Implemented:
Targeted Protection using Galvanic and Fusion
Systems
• Targeted Protection used in areas that
would not meet service life
requirements
• 2 Types of Anodes used
• Type 2 embedded galvanic anodes
installed around the perimeter of
concrete repairs
• Fusion anodes installed into “hot spots”
as identified by half cell corrosion
potential survey
• Benefits of Fusion and Galvanic
Systems
• No outside power needed
• Monitoring of system not required
• Much more economical choice in this
case than ICCP
Measuring Potential of Steel in Concrete
ASTM C876
Copper Sulphate Corrosion
Electrode Condition

Low – 10% risk of

> -200 mV
corrosion

Intermediate
-200 to –350 mV
corrosion risk

High - <90% risk of

< -350 mV
corrosion

< -500 mV Severe corrosion

Galvashield® Fusion™ T2
Two Stage Anodes
Single wire
installation
Galvashield CC
alkali-activated anode

Self-powered
ICCP System
Fusion T2 Anodes in Hot Spots
Fusion T2 Anodes in Hot Spots
Type 2A Embedded Galvanic Anodes

• Sound Concrete

• Targeted Protection

• Suitable for conventionally

reinforced, prestressed and
post-tensioned concrete
structures
• Estimated amount to be
installed – 1,500-2,000
Anodes around perimeter of concrete repair
Galvashield Fusion Summary
• High Density Charge pushes away Chlorides and re-passivates steel
• No Outside power or maintenance required!!
• Able to have greater spacing between anodes compared to
Galvashield CC
• Less Holes/Less Anodes
• Quicker Installation process saving $$$
• Ongoing galvanic protection for 30+ years
 Arlington Memorial Bridge
“Before us is the broad and beautiful river, separating two of the original thirteen States, which a late
President [Andrew Jackson]... desired to span with arches of ever-enduring granite, symbolical of the
firmly established union of the North and the South." —Secretary of State Daniel Webster, 1851

Questions?
Name That Bridge????
I-480 Substructure - Omaha, Nebraska
• Summer of 1998 and
1999, the Nebraska
Department of Roads
had undertaken a large
rehabilitation project on
Interstate Route 480

• Consisted of re-decking
approximately 0.6 miles

• Investigation of the
supporting piers

• Found Numerous
delaminatations, spalls
etc. due to chloride
intrusion
 Norcure ® ECE Treatment Process
• Addresses the cause of corrosion
• Chloride levels are significantly reduced
• Alkalinity is increased at the level of the steel
• Reinforcing steel is returned to a passive, non-corroding state
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
Electrochemical Chloride Extraction (ECE)
From Salt Contaminated Concrete
Temporary Conductive
Current paths
Anode Media

DC Power
Source
- Cl-
Cl
Cl- Cl-
- Cl-
Cl
Cl- Concrete
Cl- -
Cl Cl -

Cl- Cl-
OH-

Reinforcement
Electrochemical Chloride Extraction (ECE)
From Salt Contaminated Concrete
Temporary Conductive
Current paths
Anode Media

DC Power Cl-
-
Source Cl
Cl- Cl-
Cl- Cl-
Cl- Cl-

Cl- Cl- Concrete

Cl-

OH-

Reinforcement
Electrochemical Chloride Extraction (ECE)
From Salt Contaminated Concrete
Temporary Conductive
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
Norcure® ECE Treatment Process

First Step

• Concrete Repairs
completed

• All spalls and

Delaminations
must be repaired
prior to ECE
treatment
Norcure® ECE Treatment Process
• Wood Battens
and Wire
Mesh Installed
over area to
be treated
Norcure® ECE Treatment Process

• Red Anode Wire

Connected to Wire Mesh
• Black Cathode Wire
Connected to reinforcing
steel
Norcure® ECE Treatment Process
Cover Anode with Electrolyte
Norcure® ECE Treatment
Process

Installation Complete
Ready to Start
Treatment
• System is wrapped
• Drip system installed
• ECE System is run for 6-8 weeks

…innovative solutions to concrete problems TM

www.vectorgroup.com
 Norcure® ECE
Treatment
Process

• 30,000+ Sq ft

• Recommend to
put coating,
sealant or some
form of barrier
to stop ingress
of new
chlorides

Piers after ECE Treatment

Cleaned and Sealed
Concrete Preservation is a Sustainable Activity
The construction industry is the single largest consumer of resources
and raw materials, almost 50% of the total.

It is estimated that up to 40% of solid waste derives

from construction and demolition.

For every 10,000 yd3 of concrete preserved :

• 20,000 tons of rubble is kept from the landfill and a similar
amount of natural resources are conserved.
• Avoids the generating thousands of pounds of pollutants like
SO2 and NO2
• Conserves enough potable water to fulfill the daily needs of
2,500 people
• Prevents significant release of heat into the atmosphere,
enough BTU’s to boil 30 Olympic sized swimming pools
• Avoids carbon dioxide generation equivalent to the annual
emission of 1,250 people
WeSaveStructures.info

WeSaveStructures.Info is an educational
website that promotes the benefits of
preservation technologies that extend the
useful service life of concrete structures.
To illustrate the sustainability of concrete
preservation, this website has useful
Environmental Impact Calculator.
 Eric Williams
Nick Drews QR Code for PDH Credit
Business Development National Sales Manager -
Manager US
Mid West Vector Corrosion
Vector Corrosion Technologies
Technologies ericw@vector-
nickd@vector- corrosion.com
corrosion.com Cell: 570-412-5031