Savcor Group Limited

For contact information please visit:

www.savcor.com
AUSTRALIA FINLAND CHINA
INDIA JAPAN NEW ZEALAND
Realkalisation is a method of restoring the
natural alkalinity in concrete to halt steel
reinforcement corrosion. This is achieved by
increasing the concrete pH level to a value
greater than 10.5 which is sufficient to
restore and maintain a passive oxide film
on the steel.
New concrete has a natural inherent alkalinity and
therefore provides passivation protection to steel. The
ingress of carbon dioxide however, creates carbonated
concrete of lower alkalinity and loss of passivation
allowing accelerated steel reinforcement corrosion
which threatens structural integrity.
Realkalisation is a non-destructive, silent, time saving
and low-cost method of concrete rehabilitation
compared to conventional repair methods. The
treatment is quality controlled and the result verified
during the process as the underlying cause of the
corrosion (carbonation) is reversed.
What is realkalisation?
Realkalisation involves an electrochemical technique of
passing a sustained low voltage current between
temporary anodes on the surface of the concrete and
the steel reinforcement over a period of three days to
one week. A surface paste of sprayed cellulous fibre
saturated with a solution of sodium carbonate is used
as the electrolyte covering the concrete surface. As the
surface anodes are embedded in this alkali rich paste,
alkali is drawn into the concrete though to the
reinforcing bars, effectively realkalising the concrete.
The natural protective oxide film then reforms and
protects the steel reinforcement against further
corrosion.
General Information Sheet:
Electrochemical Protection Systems (EPS)
Realkalisation of Reinforced Concrete Structures
Savcors services include:
Complete realkalisation pre-design
surveys;
Design and specification of repair
work and realkalisation systems; and
Installation of realkalisation systems.
Images from top to bottom:
Application of cellulous fibre.
Concrete after completion of the realkalisation process
process.
Advanced Rehabilitation Technology
How is an electrochemical realkalisation
system applied?
Firstly a detailed pre-design survey should
be carried out on the concrete elements.
The survey includes visual inspection,
carbonation depth measurement, chloride
analysis at depth, surface examination,
covermeter survey, delamination survey,
reinforcement continuity and alkali
aggregate reaction testing.
The methodology of repair work is similar to
that of cathodic protection repair where
there is no need to remove the concrete
behind the reinforcement.
During the process of repair work, and based
on the system design, rebar connections are
installed in the concrete. Black cables are
connected to the rebar and extended to a
transformer rectifier unit. At this stage, the
continuity of the rebars should be checked
and established if required.
Anode connections are made based on the
system design and red cables are connected
to the anode mesh and extended to the
transformer rectifier unit.
A reservoir is used to house the anode
system (the anode mesh and alkaline
electrolyte) to keep it in good electrolytic
contact with the concrete surface. Various
types of reservoir can be used such as
sprayed cellulous fibre, felt cloth or tank
systems, however the most common method
is sprayed cellulous fibre.
Before installing this system, wooden
battens are fixed to the concrete surface to
act as spacers between the concrete and
anode mesh. The anode mesh is fixed to
the battens, which also support the mesh fibre and
electrolyte.
The cellulous fibre which is sprayed onto the mesh
has good adhesion and is suitable for use on most
concrete surfaces: horizontal, vertical or overhead.
Regular wetting of the fibre with an alkaline
electrolyte is required during the treatment.
Cables from the rebars (cathode) and mesh (anode)
are connected respectively to the negative and
positive poles of the transformer rectifier unit which
is switched on and adjusted to give the design current
density.
The system is monitored during the treatment period
by means of current and voltage readings and testing
the pH level of the concrete. The power supply is
switched off when the concrete is deemed
realkalised. The cables are then disconnected, the
anode/electrolyte system is removed and the concrete
surface is cleaned with water.

Realkalisation restores alkalinity to carbonated
concrete
Realkalisation reinstates passivity of steel
reinforcement within concrete
Realkalisation is a permanent one-off treatment
Once the realkalisation process is complete, the
concrete can remain in its natural state or
further coated for aesthetic reasons
Savcor Group Limited
For contact information please visit:
www.savcor.com
AUSTRALIA FINLAND CHINA
INDIA JAPAN NEW ZEALAND
Advanced Rehabilitation Technology