Cost of Corrosion

Corrosion Protection of ! Corrosion is the single most important

cause of damage to concrete structures
Reinforcing Steel in Concrete ! NACE estimates the cost of corrosion
damage to concrete structures (in the
USA) is approximately
Matt Miltenberger, P.E. $ 125 Billion per year!!!
Vector Corrosion Technologies, Inc.

Environmental Factors – Chloride Ion

Environmental Factors - Carbonation
! Reduction of pH in cover concrete that causes loss
of passive oxide layer
! Increased rate with increased w/cm
! Low pH caused by reaction of free lime
Salting of Highways Salt Dripping off Vehicles (Ca(OH)2) in concrete with atmospheric Carbon
Dioxide (CO2)
Ca(OH)2 + CO2 CaCO3 + H2O
lime (soluble) (insoluble)
pH 12-13 pH < 9

Airborne Salt Deposition Marine Exposure

Corrosion Service Life Requirements for Rebar Corrosion

End of Functional Service Life ! 1. Anode (location where metal is lost)
Anodic Ring – pH < 11 and/or chloride ion initiate corrosion
Damage

Damage ! 2. Cathode (steel surface)

Repair Events
– Oxygen and water are consumed
Initial Damage
! 3. Electrical connection (steel)
Corrosion Initiation – Electron transfer from anode to cathode
Transport ! 4. Electrolytic connection (moist concrete)
– Ionic transfer from cathode to anode
1-100 yr? 5-10 yr 5-7 yr
Time

1
 Corrosion Macro-Cell in Concrete
Chloride Contaminated Concrete Corrosion Macro-Cell
Fe + 2Cl- FeCl2 + 2e -

2Cl- FeCl2 Area )

Anode ( Corroding
Cathode
FeCl2 + 2OH- Fe(OH)2 + 2Cl-
Fe3O4
2Fe(OH)2 + 1/2O2 Fe2O3 + 2H2O
γFe2O3

2e - Anode
2OH- Fe3O4
γFe2O3
1/ O + H2O + 2e - 2OH-
2 2

Cathode ( Non-Corroding Area )

© Vector

Anodic Ring (Halo Effect) Halo Effect

! Anodic ring phenomena are associated with
a repair area that is surrounded by “new”
corrosion sites.

! Anodic ring phenomena are one of the

primary reasons for short-lived repairs.

Chloride Transport Corrosion Initiation - Microcell

Numerous anodic sites activate
O2 Cl- H2O O2 Cl- H2O

Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl
Cl - Cl - Cl - Cl - Cl - - Cl Cl - Cl Cl - Cl - - Cl - Cl - Cl - Cl - Cl
- - - Cl -Cl - - - Cl - - -
Cl Cl
- Cl -
- - - - - - - -
- -
-
- - Cl - Cl - Cl - Cl - Cl Cl
Cl - Cl Cl - - - - Cl
-
- Cl - - Cl -
Cl
-
Cl -
Cl -
-
- - - - -

2
 Corrosion Damage - Macrocell Structure after Repair
Primary anodic site cathodically protects smaller sites Secondary anodic sites activate
O2 Cl- H2O O2 Cl- H2O

Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl
- Cl - Cl - Cl - Cl - Cl - Cl - Cl Cl - - Cl -
Cl -Cl - - Cl
- -
Cl Cl Cl - - - -
Cl Cl -Cl - -
-
-
Cl
-
Cl - Cl - Cl - Cl -
Cl -
-
Cl
- Cl - Cl - Cl Cl
Cl -
Cl Cl -
- - -
-
Cl -
Cl - Cl
-
- Cl -
Cl Cl -
Cl - Cl
-
-
- - - Cl Cl - - - - - -
- -
- - - -

Anodic Ring Damage Corrosion Cell at Repair Edge

Secondary anodic sites grow Chloride Contaminated Concrete Chloride-Free Patch

O2 Cl- H2O 2OH- 1/ O +

2 2 H2O + 2e - 2OH-
Cl
-
Cl Cl
Cl -Cl -
Cl
Cl - Cl Cl
-
Cl
-
Cl
-
Cl
-
Cl
-
Cl
- Cl
Cl Cl
- - Cl
Cl
- Anode 2e - Cathode
- - Cl - Cl - Cl Cl
Cl - - Cl Cl Cl - - Cl
-
Fe Fe2+ + 2e -
- - - Cl -
-
- -
Fe2+ + 2Cl- FeCl2

FeCl2 + 2OH- Fe(OH)2 + 2Cl-

2Fe(OH)2 + 1/2O2 Fe2O3 + 2H2O

© Vector

Steel Corrosion “Battery”

Anode (Corroding steel)

-
Corrosion
Current Concrete
0.2 to 0.4 V
(µA) Resistance
+ (ohm)

Cathode (Passive steel)

Anodic Ring Corrosion
© Vector Pier Cap Repair, Pennsylvania © Vector

3
 Spalled Ceiling Patches Corroded Joint
Concrete Building, Hawaii Pittsburgh, Pennsylvania

New Concrete Extension

Old Parent Concrete

Old Retaining Wall

Concrete Patch

Failed Concrete Next to Joint

Due to Corrosion
© Vector © Vector

Corrosion Management Strategies

Corrosion Mitigation Options Levels of Corrosion Protection

! Address Cause for Corrosion Activity Corrosion Preventing new corrosion

Prevention activity from initiating
! Remove Contaminated Concrete
– Partial or full-depth repairs Corrosion Significantly reducing
Control on-going corrosion activity
! Dry the concrete
! Localized protection along interface Cathodic Highest level of protection intended
! Cathodic protection of entire element Protection to stop on-going corrosion activity
! Electrochemical treatments
Stopping active corrosion by
Corrosion
changing the environment around
Passivation the steel
© Vector © Vector

Corrosion Prevention in Concrete Repairs

Galvanic Corrosion Protection Diagram Using Discrete Galvanic Anodes
Zinc Anode ! Corrosion prevention
– Use to prevent corrosion sites from
initiating next to concrete repairs
0.4 to 0.8 V GCP current (ICRI Guideline 03730)
– At joints between new and existing
(µA) chloride-contaminated concrete
Concrete ! Alkali activated
Anodic steel Resistance
– Contains no constituents corrosive
to rebar
- Patented installation technique
Corrosion (ohm) !
0.2 to 0.4 V – Quick and easy

+ current (µA) ! Wide range of applications

– Suitable for conventionally
Cathodic steel reinforced, prestressed and post-
tensioned concrete structures

© Vector © Vector

4
 What is the purpose of the mortar
shell around the anode?
! Mortar is specially formulated to keep the
zinc active over time.
– pH ≈ 14
! Mortar accepts corrosion by-products from
the zinc core.

© Vector

Repair with Discrete Galvanic Anode

Chloride Contaminated Concrete Chloride-Free Patch

Zn + 2OH- Zn(OH)2 + 2e-

2e - 2e- 2e-
1/ O + H2O + 2e -
2 2
2OH-

2OH-

Galvanic Corrosion Prevention

Parking Garage, North York, Ontario
© Vector © Vector

Galvanic Corrosion Prevention

Port Mann Bridge: Deck Widening

© Vector © Vector

5
 Post Tension Anchor Repairs
Anode Installation
Watergate Complex, Washington, D.C. with Rebar Coating
© Vector © Vector

Corrosion Control in Sound Concrete Discrete Galvanic Anode Installed in

with Discrete Galvanic Anodes Sound Concrete
Corrosion Activity is
Reduced In Rebar

Anode Galvanically Protects

Surrounding Rebar

© Vector © Vector

Steel connection next to pre-drilled

2” diameter hole

Anode/Steel
Connector
Anode

Steel
Connection

2” Diameter
Hole
© Vector © Vector

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 Localized Protection with Discrete Embedded Galvanic Anodes in
Galvanic Anodes in Critical Areas Prestressed Box Girder Repair

Galvanic Anodes in
Drilled Holes

Prestressing
Strands

© Vector © Vector

Galvanic Anodes in Prestressed Box

Girder

! Galvanic Corrosion Control

! NYSDOT: Prestressed Concrete New York State Department of Transportation
Beam Repair © Vector © Vector

Galvanic Cathodic Protection with

Cathodic Protection Systems Distributed Anodes
! Work by applying sufficient current to
reinforcing steel to overcome the corrosion
process
! Galvanic Systems: Sacrificial metal
corrodes to provide protective current
Impressed Current Systems: D.C. power
supply provides current (rectifier or battery)

© Vector

7
 Galvanic Cathodic
! Galvanic Cathodic Protection Deck Overlay Protection in Pile Jackets
! Ontario Ministry of Transportation © Vector © Vector
© Vecto

Galvanic Cathodic Protection with Impressed Current Cathodic Protection

Activated Arc-Sprayed Zinc Discrete Anode System
- Permanent
DC Power
+
Discrete Anodes Supply

Rebar

Slot Cut for

Wiring Anodes
© Vector

Installation of Discrete Anode ICCP System Installation of Discrete Anode System

Winnipeg, Manitoba Winnipeg, Manitoba
© Vector © Vector

8
Impressed Current Cathodic Protection
Using Distributed Anode System
- Permanent
DC Power
+
Supply

Concrete Overlay

Concrete
Rebar

Embedded Anode

Electrochemical Treatments
! Proven long term performance
Corrosion Passivation ! Measurable criteria:
– ECE: Chloride content before and after
! Modify the chemistry of the concrete 700 to 1500 A*hr/m2 (SHRP)
to create a passive environment – Realk: pH before and after (phenolphthalein)
around the reinforcing steel.
100 to 250 A*hr/m2

Electrochemical Chloride Electrochemical Chloride Extraction (ECE)

Extraction SHRP Research From Salt Contaminated Concrete
Temporary Conductive
! Extensive ECE Testing Undertaken (SHRP) Anode Media

! Confirmed ECE’s Ability to: DC Power

– Halt Corrosion Source

– Restore Passive Oxide Film on Rebar

Cl- Cl-
! No Adverse Chemical or Mechanical Effects Cl-
Cl-
Cl- Concrete
! ECE Deemed one of the Most Valuable Cl- Cl- -
Cl Cl-
Technologies Evaluated
Cl- Cl-
! Long Term Data Shows Rebar Still Passive
Cl-

Reinforcement
© Vector

9
 Electrochemical Chloride Extraction (ECE) Electrochemical Chloride Extraction (ECE)
From Salt Contaminated Concrete From Salt Contaminated Concrete
Temporary Conductive Temporary Conductive
Current paths Current paths
Anode Media Anode Media

DC Power DC Power Cl-

Cl- Cl-
Source Source
- Cl- Cl-
Cl
Cl- Cl-
Cl- Cl- Cl-
Cl- Cl-
- Cl- Chloride - Chloride
Cl Cl
Cl- migrates Cl- Cl- migrates
- - -
Cl Cl Cl toward toward
surface surface
Cl - Cl- OH-
OH-

Increased pH at Reinforcement Increased pH at Reinforcement

© Vector © Vector

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-
Cl--

Chloride
migrates
toward
surface
OH-

Increased pH at Reinforcement Step 1 : Concrete Repair

© Vector © Vector

Step 2 : Install Battens © Vector Step 3 : Install Temporary Anode

10
 Several Piers Wrapped and Undergoing ECE Treatment
Step 4: Spray Cellulose Fiber © Vector Omaha, Nebraska © Vector

St. Adolphe Bridge over Red River

Piers after ECE Treatment St. Adolphe, Manitoba
Manitoba Highways and Transportation
Cleaned and Sealed © Vector © Vector

Realkalization Realkalization
! Draws highly alkaline electrolyte to the reinforcing steel Anode Electrolyte

to restore lost alkalinity to carbonated concrete

+ve

! Alkalinity around reinforcing steel is maintained over -ve

time, will not re-carbonate

Concrete

! Lower cost, less disruptive than mechanical removal

and replacement of carbonated concrete

Section 3 Reinforcement
© Vector

11
Realkalization Realkalization
Anode Electrolyte Anode Electrolyte

+ve +ve

-ve -ve

Na2CO3 & NaHCO3

Concrete Concrete
OH-

Reinforcement Reinforcement
© Vector © Vector

Realkalisation Project
Xerox Document University
Phenolphthalein Testing Leesburg, Virginia

! Testing on Cores ! The affects of

Before After realkalization: increased
pH around steel

Section 2
© Vector © Vector

Summary
Level of
Protection
Description Typical Solution

Corrosion Preventing new corrosion

Discrete Galvanic Anodes
Prevention activity from initiating
Corrosion Significantly reducing
Discrete Galvanic Anodes
Control active corrosion
Distributed Galvanic Anodes or
Stopping active corrosion
Cathodic Impressed Current
by applying on-going
Protection Cathodic Protection
electrical current
(ICCP)
Stopping active corrosion by
Reagan National Airport Facade Corrosion changing the concrete Electrochemical Treatments
Washington, DC Passivation environment around the (ECE or Realkalization)
steel

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