Corrosion Mitigation Systems for
Concrete Structures
Vector Corrosion Technologies
Outline
• Concrete Corrosion
• Corrosion Evaluation
• Impressed Current Cathodic Protection
• Galvanic Protection
• Electrochemical Treatments
Concrete in Society
• Concrete is the most widely used man-made
product in the world
• 6 Billion tons per year (3 - 4 Billion yd3)
• Production of 1 ton of cement produces approx 1
ton of CO2
– (CO2 Production ~ 1 Billion tons / yr)
• Production of 1 ton of steel produces ~ 2 tons of
CO2
– (CO2 Production ~ 200 Million tons / yr)
Responsible Use of Concrete
• Despite the environmental impact, concrete
is one of the most environmentally friendly
materials available if it is used properly.
• Concrete is extremely durable and has the
ability to last for many years.
– Design of long lasting structures
– Repair/rehabilitate to maintain in service
Corrosion in Reinforced Concrete
• Corrosion is the single most important
problem in concrete structures
• NACE estimates the cost of corrosion (in
the USA) to be approximately
400 Billion!!!
• It’s estimated that 25-30% of this cost is
attributed to corrosion of concrete
structures
Corrosion Cell in Concrete
Fe Fe2+ + 2e -
Fe2+ + 2Cl- FeCl2
Anode
FeCl2 + 2OH- Fe(OH)2 + 2Cl-
Fe3O4
2Fe(OH)2 + 1/ O Fe2O3 + 2H2O
γFe2O3
2 2
2e -
2OH- Fe3O4
γFe2O3
1/ O + H2O + 2e - 2OH-
2 2
Cathode
Corrosion Ravaged Columns
Chicago, Illinois
Halo Effect
Patch Accelerated Corrosion
Chloride Contaminated Chloride-Free Patch
Concrete
Potential Difference Between Patch and
Chloride Contaminated Concrete
Results in Accelerated Corrosion
New Corrosion Sites
Underside of Parking Deck Bridge Deck
Corrosion Services
• Evaluation and
Testing
• Monitoring
• Technical Site
Services
• CP System Design
• System Installation
Visual Inspection
• Identify areas of visual
damage
– Rust stains on surface
– Cracks
– Spalls
– Exposed steel
• Note exposure
conditions and other
observations
Section 2
Delamination Survey
• Performed as per ASTM
D4580
• Locate areas where
concrete has lost bond
with rebar and
delaminated concrete
which has not yet spalled
• Also known as “Sounding”
– Hammer test
– Chain drag
Section 2
Chloride Sampling
and Analysis
• To determine chloride
content at various
levels within the
concrete
• Chloride content can
be performed on
concrete cores or dust
samples
Chloride Thresholds
• 0.2% by weight of cement (ACI)
• 0.031% by weight of concrete Chloride Limit for New
• 1.2 lb Cl-/yd3 of concrete (0.71 Construction (ACI 222R)
kg/m3) Acid Sol. Water Sol. Water Sol.
• These code guidelines are Test ASTM ASTM Soxhlet
rather simplistic Method C1152 C1218
• Different concrete conditions Prestressed 0.08 0.06 0.06
have different thresholds: wet Reinforced 0.10 0.08 0.08
or dry concrete, prestressed, Wet
etc. Reinforced 0.20 0.15 0.15% by
Dry weight
• In reality corrosion activity is Cement
progressive and based on the Section 1
Chloride / Hydroxyl Ratio (Cl-
/OH-)
Section 2
pH Testing
• Mainly to determine
amount of carbonation
– Can also be used to
determine some types of
chemical contamination
• 1% phenolphthalein in
alcohol or 50/50 mixture of
distilled water and alcohol
• Generally perceived to
indicate pH of > 9.5
• “Rainbow” types also
available
Section 2
Depth of Cover Survey
• To determine the average
depth of concrete covering
the rebar within the
structure
• Compare depth of rebar
with results of chloride
and carbonation testing
• Performed using Micro
Covermeter
Section 2
Rebar Continuity
• Verify electrical continuity
of the steel
– Discontinuous steel may
pose problems for cathodic
protection
• Typical Criteria
– Less than 1 mV or
– Less than 1 ohm
resistance
Corrosion Potential
• To determine the
probability of corrosion by
measuring the potential
(voltage) of the reinforcing
steel
• Uses a reference
electrode:
– copper-copper sulfate
– silver-silver chloride
• Performed as per ASTM
C876-91
Section 2
Beam Corrosion Potential
300
Feb-05
200 Apr-05
100
0
P o te n tia l, m V C S E
-100 Proabability
Low
-200
50-50
-300
-400 High
-500
Spaces 22 through 36
-600
0 50 100 150 200 250 300 350 400 450
Distance from South End, ft
Damaged Post-Tension Cables
New York State Department of Transportation
PT Corrosion Evaluation
New York State Department of Transportation
PT Corrosion Evaluation
Classification Potential Moisture
Code for Corrosion Content
( kg/kg )
1 Very Low (Very Dry) < 0.001
Dry 2 Low (Dry) 0.001 < 0.003
3 Moderate (Dry/Wet) 0.003 < 0.007
Wet 4 High (Wet) 0.007 < 0.010
5 Very High (Very Wet) > 0.010
Post Tech Cable Break Detection
Impulse Magnetization
with Scanner
2006
Bridge Deck Scan
ICRI No. 310.1R–2008 Guideline for Surface
Preparation for Repair of Concrete Deterioration
Resulting from Reinforcing Steel Corrosion
Key Issues Re Corrosion
• Remove concrete from full
circumference of all
reinforcing steel.
• Remove corrosion by-
products from steel
• Expand area of patch outside
area of active corrosion
(clean steel).
Electrochemical Corrosion
Mitigation Systems
• Impressed Current Systems
– Permanent D.C. power supply forces current flow from
anode to reinforcement (cathode)
• Galvanic Systems
– Sacrificial metal corrodes to provide protective current
• Electrochemical Treatments
– Temporary D.C. power supply and anodes
– Passivate corrosion by changing the environment
around the reinforcement
– Electrochemical Chloride Extraction or Re-alkalization
Impressed Current Cathodic Protection
- Permanent Point Anodes
+ DC Power
Supply Permanent
DC Power Slot Cut for
Supply Wiring Anodes
Concrete Overlay
Concrete
Rebar
Embedded Anode
Distributed Anodes Discrete Anodes Drilled Holes
Impressed Current CP
• Outside power source
required
• High level of control
• System monitoring
and maintenance
required
Bok Tower
Lake Wales, FL
• Historic Bell Tower
• Dedicated in 1929 – by
President Calvin Coolidge
• Masonry encased steel
frame
• Marble and coquina
exterior
Bok Tower
• Moisture intrustion
caused corrosion of
steel beams
• Corrosion damage of
exterior stone
• ICCP with discrete
anodes installed to
protect steel frame
Bok Tower
• Discrete anodes
placed in ½ in.
diameter holes
• 32 in. spacing above
and below beams
• Installed from the
interior through brick
masonry
Bok Tower
• Remote monitoring
and control of power
• Minimal disruption
• Minimal impact on
appearance
Galvanic Protection Systems
• Two different metals are connected in same
electrolyte (concrete)
• More “active” metal = anode
• More “noble” metal = cathode
• Anode corrodes to protect cathode
• Natural reaction
– no external power required
• Safe for prestressed concrete
Potentials and Current Flow
e-
Partial Galvanic Series
electronic
Metal Voltage K+
Na+
Zinc -1100 mV
Steel in -200 mV to ionic
concrete -500 mV
CL-
*Typical potentials measured with respect
to copper-copper sulfate electrode Zinc OH- Steel
Types of Galvanic Systems
• Embedded Discrete Anodes
• Embedded Distributed Anodes
• Externally Applied Anodes
– Zinc Sheets
– Zinc Metalizing
Point Anodes
Point Anodes Protection
(Typically for Halo Effect)
Concrete Repair
Point
Anodes
Area of Influence
Existing Chloride
Contaminated Concrete
Activation Technology
Alkali Activated
• High pH is corrosive
to zinc but not to steel
• Allows zinc anodes to
provide protection to
reinforced concrete
over time
Installed Galvanic Anode
Chloride Contaminated Concrete Chloride-Free Patch
Anode Galvanically Protects
Surrounding Rebar
Discrete Galvanic Anodes
Installing anodes around the perimeter of the repair.
Discrete Galvanic Anodes
Bridge Deck - Chip and Patch Repairs.
Colorado DOT – Greeley, CO
NYSDOT Maintenance
Bridge Deck Repair
Kansas DOT Patch Repair
Arch Bridge
Bridge Widening
Corrosion Prevention
© Vector
Post Tension Anchor Repairs
Watergate Complex, Washington, D.C.
© Vector
Slab Replacement
Brookline Blvd. Garage
Pittsburgh Parking Authority
Bridge Widening
Corrosion Prevention
Point Anodes for Sound Concrete
• Embedded anode for
corrosion control
• Installed into drilled
holes
• Protect sound but
contaminated areas
• Corrosion “hot spots”
Galvanic Protection with FRP Strengthening,
Coastal Condominium
NYSDOT Bridge Maintenance
Fort Covington, NY
Galvanic Anodes inNYSDOT
Prestressed
Bridge Maintenance
Fort Covington, NY
Box Girder
NYSDOT Bridge Maintenance
Fort Covington, NY
New York State Department of Transportation
NYSDOT Bridge Maintenance
Fort Covington, NY
New York State Department of Transportation
Galvashield CC
Distributed Anodes
Concrete Repair
Distributed Anodes
Base Concrete Area of Influence
Distributed Anode System
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
Past Practice for Repairs
• Slab would be temporarily supported
• Abutments would be replaced
• Requires closure or part-width construction
Options
• Do Nothing
– Not a feasible alternative for deficient
bridges on the interstate system
• Repair bridge
– With appropriate repair, most of these bridges have
remaining service life
• Replace bridge
– Not cost-effective to remove a good slab
I-75 Ohio DOT
Forms installed
Completed repair
Kirkwood Road – Protective Current
60 120
55 Galvanic Current
Temperature
50 100
T e m p e ra tu re , d e g re e F
G a lv a n ic C u rre n t, m A
45
40 80
35
30 60
25
20 40
15
10 20
0 0
May-05 Aug-05 Oct-05 Jan-06 Apr-06 Jul-06 Oct-06 Jan-07 Apr-07 Jul-07 Oct-07 Jan-08
Date
Kirkwood Road Performance
Date Temp mA/m2 Polarization Instant Off
5/6/05 37.7 654*
7/20/05 13.9 346 1000
8/16/05 87 12.9 333 987
10/26/05 54 5.4 394 1048
12/7/05 51 3.2 339 993
5/1/06 57 7.5 335 989
12/20/06 40 4.3 500 1154
5/30/07 79 7.5 446 1100
9/20/07 75 9.7 484 1138
* Native Potential Cathodic
Protection Criteria: Polarization > 100 mV or Inst. Off > 850 mV
Galvanic Strips In 8
Bridge Deck Overlays
Lake County, OH
I-75 Ohio DOT
Distributed Anode
Strips for Pile Caps
Surface Mounted Zinc Anode
• High purity zinc foil
• Conductive adhesive
• Supplied in rolls
• Applied to concrete
surface and
connected to
reinforcing steel
Surface Applied Zinc Sheet
Application
ZincSheet Column Protection
Galvanode Zinc Tape
NY DOT
I-890 E over Little Circle
Galvanode Zinc Tape
Prestressed Concrete Balcony
Protection
Clearwater Beach, FL
Activated Arc Spray Zinc
Hospital Parking Garage
Galvanode ASZ+
Activated Arc Spray Zinc
Pile Protection Systems
• Impressed Current
– Titanium Mesh with FRP
• Galvanic Protection
– Zinc Mesh with FRP
– Distributed Anode Strips
• Used in conjunction with RC overbuilds, FRP
jackets, or nylon bags.
ICCP Jackets
Section 1 Section 3
Galvanic Jackets
Section 1 Section 3
Electrochemical Treatments
Electrochemical Treatments
• Address the cause of
the problem
• Passivates active
corrosion
• Temporary treatment
process
• No system left in place
to maintain
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
ECE Treatment Process
ECE Treatment Process
ECE Treatment Process
ECE Treatment Process
ECE Treatment Process
ECE Treatment Process
Norcure Chloride Extraction System
Historic Bridge (1933)
• Idaho’s Largest single span (210’) conc. arch
bridge
• Cost $74,000 to build
• Corrosion Evaluation in 2004
– Concrete Arches & Main Piers (below drains) had most
severe corrosion
– Corrosion Potential between -.1 to -.45 V
– Chlorides between .2 to 5.3 lbs/cy
– Recommended ECE for Arches & Piers
MAIN OBJECTIVES
• Preserve & Protect historic structure for
future generations
• Improve Safety for traveling motorists
Potential Mapping Grid
P
P
o
t
e
Electrochemical Chloride
Extraction
• Began July 20, 2006
• Completed September 14, 2006
• Treated Approximately 8,000 sf
• Temporary process, so no system left in place
• Addressed the source of the problem by reducing chlorides &
increasing pH around rebar
• Minimal Aesthetic Impact
• Allowed structure to be rehabilitated rather then replaced.
• Also placed discrete XP+ anodes in patches
Work
Platform
Installed
Electrical Cathodic
Connections to Steel
Reinforcing
2007 Awards
Program
Project of the Year
Repair and Preservation of the
Historic Rainbow Bridge
Valley County, Idaho
Vector Corrosion Technologies
Wesley Chapel, Florida
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
Re-alkalization of Carbonated Concrete
Anode Electrolyte
+ve
-ve
Na2CO3 & NaHCO3
Concrete
Reinforcement
Norcure® Re-alkalization & ECE
Reagan National Airport Facade
Washington, DC
Summary
• Large Range of Options Available for Marine
Structures
• Mitigation strategies can be
– Global, targeted, or localized in nature
• Final system selection
– Existing condition, exposure conditions, service
life requirements, maintenance considerations,
budget
Thank you!
