Rehabilitation of Marine Structures Course

REHABILITATION
OF
MARINE STRUCTURES
COURSE FACULTY
Prof. R.J.SHAH
PRESENTED BY
JIBEESH . R
SD 0507
Faculty of Technology , CEPT University ,
Ahmedabad
REHABILITATION OF MARINE STRUCTURES JIBEESH.R (SD 0507)
I N T R O D U C T I O N
I N T R O D U C T I O N
Codes of practice in India & all over the world assist the designer in scheme
planning and detailed design phases of a project, which lead to the development
of the Tender and Contract documents and to construction. While it is normal to
follow these codes, it is also often prudent to carry out additional investigations,
say of the soils, as well as modeling.
Despite all the advice and guidance and the increasingly sophisticated
methods of analyses available in recent years, failure of structures still occur.
While these failures can be the result of the structure being exposed to
extreme events, greater than the structure was designed to withstand, failure is
mainly because of deficiencies in their design or their construction.
Such failures are, however, rarely due to a single error, but can be the
combination of, say, an inappropriate aspect of the design, lack of quality control
during construction or of construction methods or of taking the present levels of
knowledge beyond its limits.
Up till now , reinforced concrete was thought to be as almost indestructible
material .
Over the years of use , its undoubtedly concluded that concrete is the best
ever invention amongst Civil Engineering material .
Its widespread use and the survey on its yearly consumption support the
above statement .
The reasons may be attributed to its strength and durability characteristics .
Owing to the inherent resistance it has against many naturally occurring
chemicals concrete seems to be the only choice as a basic construction
material for structures located in coastal areas .
C a u s e s f o r f a I l u r e
C a u s e s f o r f a I l u r e
The deterioration of maritime structures can be grouped as follows
Physical Damage
Impact
Overloading
Structural movement
Abrasion
Fire Damage
Frost Action
Durability of materials
Chemical Attack
Electro-Chemical Attacks
Impact , overloading and structural movement are common to all structures ,
but impact and over loading occur frequently to maritime structures .
All of these causes have long term consequential results , in that hostile
environment , and is allowed to penetrate the damaged structure through cracks
and physical damage .
Shipping impact is common and damage due to this should be looked into
very seriously .
Abrasions caused by water borne sediment is not a problem to traditional
maritime structures adjacent to the land , but rubbing by vessels , debris and
hawsers can cause considerable damage .
P h y s I c a l D a m a g e
F I R E D A M A G E
Fire damage is unusual in maritime structures . This type of damage is
presumably a possibility to offshore oil structures .
D u r a b I l I t y o f m a t e r I a l s
Lack of durability of the construction materials can be and has been a very
real factor in contributing to deterioration .
The faults may lie in
The methods of construction
In the materials
Poor manufacture and placing of concrete and positioning of reinforcing steel
is rapidly made evident when subjected to marine environment .
Poor quality cement will lead to failure and steel reinforcement containing
impurities has been found to be prone to attack by sea water.
Certain aggregates cause trouble due to their chemical and physical
properties and to the presence of organic impurities .
F R O S T
Frost action is not generally a problem for maritime structures in India but it has
a significant effect in colder climates such as found in Scandinavian countries
where it is thought to be the main cause of failure .
C h e m I c a l a t t a c k
Chemical attack is due to the action of external liquids or gases and the
associated alteration and the interaction of the constituents of concrete .
By far , the greatest source of chemical attack of maritime structures is from
sea water itself
Water has the effect of removing cementing constituents of concrete . This
action is known as Leaching and results in the loss of lime and alumina causing
the eventual replacement of concrete with a soft mushy mass .
In addition , the chemical action of sea water which is mainly due to
magnesium sulphate causes swelling of concrete .
In sheltered areas like estuaries and within harbours and docks , free carbon
di-oxide can exist , perhaps as a result of the decomposition of organic matter .
The resulting carbonic acid can severely damage concrete .
In sea water with pH value of 7 or less , this type of attack can occur .
E l e c t r o c h e m I c a l a t t a c k
Electro-chemical attack causes corrosion . Water is the primary cause of
corrosion which can occur :
With oxygen .
With galvanic action in the absence of oxygen .
With anaerobic corrosion caused by sulphate reducing bacteria .
Reasons for electro-chemical attack
In ideal circumstances , the concrete cover to the reinforcement is not initially
porous .
Chemical and physical forms of attack alter this in course of time to make the
structure to be pervious .
When this happens , an acid electrolyte is formed , which neutralizes the
protective alkaline environment of steel and leads to corrosion .
Basics of electro-chemical reaction

It is well known that , two dissimilar metals , in the presence of electrolyte ,
generate a current , the strength of which depends on the relative positions of
these metals in the electrochemical series
One becomes the cathode , and the other , the anode , the anode being
sacrificed to the cathode .
Electro-chemical reaction with concrete
In reinforced concrete , weak cells are formed between constituents of the
steel , iron and cementite (mainly iron carbide) . Also present is the original dark
coloured mill scale .
This is not uniform in composition . The outer layer is rich in oxygen and
approximates to ferric oxide (Fe
2
O
3
) . Beneath this is a layer of magnetic oxide
(Fe
3
O
4
) and beneath that is a layer of ferrous oxide (FeO). Again beneath this ,
there may be layers of hydroxides .
A substantial current is produced in the cell formed with mill scale and the
steel causing rapid corrosion and the formation of ferrous hydroxide , which
causes swelling as the later has a volume of between 4 and 7 times the
volume of steel it replaces . This produces tensile failure of the concrete in the
form of spalling and cracking .
In the upper parts of the structure , water is in constant motion upwards due
to capillary attraction . This water forms the electrolyte and the corrosion
process is continued above high water level.
At depth leaching is diminished if not non - existent . Any corrosion which
takes place is of oxygen absorption type and not of hydrogen evolution type ,
which occurs at the surface .
R e p a I r m e t h o d o l o g I e s
R e p a I r m e t h o d o l o g I e s
Adopting the correct , best and economical solution from a pool of repair
methods for a particular problem is a tough decision .
But this can be done by adopting the correct strategy and approach to the
problem through
Preliminary investigation
Detailed investigation
Engineering Evaluation
B a s I c s
Preliminary investigation deals with visual inspection and documenting the
nature of distress the structure has .
Detailed investigation deals with depth of distress and comes out with the
root cause of distress and the repair technique to be adopted .
Engineering evaluation deals with residual service life of the distressed
structure through appropriate Non-Destructive and partial destructive tests . It
also evaluates the life of the structure after repair .
Having established the causes for distress/failure , appropriate repair
methods can be suggested , by keeping in mind the original reason for such
failure .
Much of physical damage can be avoided by effective management of ports
which includes proper water traffic management and dredging .
Fire damage , though an occasional instance , can be handled by
maintaining effective fire fighting systems , keeping in mind the damage it can
create if happened .
Durability of materials is of great concern and can be taken care of properly
by sampling every materials used in the construction and conducting laboratory
tests periodically .
For the purposes of repair of concrete structures , repair can be grouped into
two major categories as.
The major difference in repair process is associated with the initial stages of
repair , where some aspects of the total exposure and de-rusting of steel
reinforcement may not be relevant to non-corrosion deteriorated concrete
repair.
Though removal of concrete and surface preparation is same for all methods
, for obvious reasons remaining repair stages are different which reflect the
difference of the various methods of application and materials associated with
these methods .
Corrosion deteriorated concrete
Non-Corrosion deteriorated concrete

Major factors influencing the selection of a repair method are
Prevailing in-service conditions.
Relative costs
Specified performance characteristics
Level of in-service performance required
Other factors which contribute to the selection of a particular method are
Horizontal , vertical and over-head repair conditions
Restricted access
Ease and practicality of erection of formwork
Under water-requirements
Tidal and splash zone repair
The available repair methods in India and across the globe are as follows
Cementitious repair
Alternative reinforcement
Barrier methods
Electro-Chemical Methods
Corrosion inhibitors
C e m e n t I t I o u s r e p a I r
Prior to commencement of any patch repair of concrete , an assessment of
the affected concrete structure should to undertaken to determine the influence
of spalled , deteriorated , damaged or honey-combed concrete on load bearing
capacity , serviceability and durability .
A step by step patch repair procedure should address the following
Surface Preparation
Method of application
Curing
Surface finish
R e p a I r s e q u e n c e
The following provides a systematic and organized step by step guide of a
typical repair for trowel applied mortars .
Investigation & Assessment
Establish the cause and extend of the concrete deterioration problem using
both physical and chemical diagnostics .
Determine areas and depth of concrete to be removed .
surface preparation completion
Remove the unsound and contaminated concrete to expose a sound and
uncontaminated concrete substrate by at least 20 mm behind and around the
rusted steel reinforcement .
Continue removal of concrete along the length of visibly corroding steel
reinforcement and make sure it extends until at least 50 mm of sound rust
free metal is showing at both ends of the rusted section .
Provide a perpendicular saw cut to a depth of at least 15 mm around the
perimeter of the area to be repaired in order to prevent feather-edging .
Remove all products of corrosion from exposed steel reinforcement . Sand
blasting method is preferred as it will also remove other contaminants
Complete the cleaning process by giving a final wash down or by blowing
down with compressed air of both the concrete substrate and steel
reinforcement to ensure the removal of all residual contamination.
Thoroughly pre-wet the prepared concrete substrate with clean fresh water.
application of reinforcement protection & substrate bonding coat
Steel reinforcement is coated with a suitable primer to provide immediate
protection against renewed corrosion .
Apply a concrete substrate bonding coat to enhance the bond at the repair
interface.
application of repair mortar
Erection of formwork or profiles if required
Apply repair material. Ensure that substrate bonding coat is in correct
condition to ensure good adhesion.
Apply normal curing procedures. That is applying a curing compound
complying with the codal provisions and in accordance with the material
manufacturers specification.
For concrete patch repairs greater than 500 mm x 500 mm in size the curing
compound should also be supplemented with heavy duty polyethylene
sheeting fastened and sealed at the edges .
Supervision & quality control
Utilize satisfactory construction practices , procedures and standards.
Re - inspect at suitable intervals to confirm the success of the repair.
a l t e r n a t I v e r e I n f o r c e m e n t
This includes materials that electrically isolate the steel from the concrete
and create a barrier for chloride ions, materials that protect steel galvanically,
and materials that have significantly higher corrosion thresholds than
conventional reinforcing steel.
A good alternative reinforcement must be resistant to damage during
shipping, storage at the construction site, installation, and concrete placement.
The reinforcement must also be able to maintain its structural function for
the service life of the structure, even in severe service environments.
Finally, the alternative reinforcement must be economical when compared to
conventional reinforcement .
available methods of alternate reinforcement
Epoxy- coatings
Metallic Coatings and Solid Metallic Reinforcing Bars .
Galvanized Reinforcement
Stainless Steel Reinforcement
Stainless Steel Clad Reinforcing Bars
Nickel-Clad Reinforcing Bars
Titanium Reinforcing Bars
Copper-Clad Reinforcement
Fiber Reinforced Plastic Reinforcement .
epoxy coatings
Currently, the primary corrosion protection system is epoxy-coated
reinforcing steel .
The method of coating reinforcing steel with epoxy was adapted from the
method used by utility companies for coating pipes in the petroleum industry.
The bar is cleaned by blasting with grit to a near-white finish to remove
millscale, rust and contaminates.
The bar is then heated to the temperature required for the application of the
epoxy powder, typically 230C, and passed through an electrostatic spray that
applies charged, dry epoxy powder to the steel. The epoxy melts, flows and
cures on the bars, which then are quenched, usually with a water spray bath .
advantages of epoxy coatings
Epoxy coatings function in two ways,
First by acting as a barrier, keeping oxygen and chloride ions from reaching
the surface of the steel .
Second by increasing the electrical resistance between adjacent steel
locations. Epoxy coatings reduce the magnitude of macrocell currents, which
are responsible for extensive deterioration .
metallic coatings and solid metallic reinforcing bars
Metallic coatings for reinforcing steel can be divided into two categories,
sacrificial or noble .
Sacrificial coatings are made up of metals that have a more negative
corrosion potential than steel, such as zinc. If the sacrificial coating is broken, a
galvanic cell is set up and the coating corrodes while protecting the steel.
Noble coatings such as copper and nickel do not corrode in concrete, but if
the coating is broken, any exposed steel becomes anodic and will corrode .
Solid metallic bars made of corrosion-resistant materials such as stainless
steel have also been used in reinforced concrete structures. These materials
must be able to serve as reinforcement as well as resist aggressive
environments.
galvanized reinforcement
Evidence began to surface in the early 1960s that hot-dipped zinc-coated
steel reinforcement may provide superior performance to that of uncoated
steel .
This consists of cleaning the steel bars by pickling, and then immersing
them in molten zinc.
The galvanized bars are dipped in a chromate bath after coating to
passivate the zinc surface and to prevent it from reacting with the hydroxide in
fresh cement paste .
working of galvanized reinforcement
Like steel, zinc has corrosion products that occupy more volume than the
original metal, and, as a result can cause concrete to crack.
An advantage of galvanized reinforcement is that, when zinc corrodes
sacrificially, a hydrated oxide [Zn(OH)
2
] is formed on the surface that acts as
an electrical insulator.
This insulator forms a barrier layer at active corrosion sites that will prevent
further corrosion from occurring
stainless steel reinforcement
The term stainless steel refers to a group of corrosion resistant steels that
contain a minimum of 12% chromium.
The chromium creates an invisible surface film that helps to make the
stainless steel corrosion resistant by resisting oxidation.
advantages of stainless steel reinforcement
Stainless steel has inherently good corrosion resistance and does not
require the aid of other corrosion protection methods, such as cathodic
protection or corrosion inhibitors.
Stainless steel has good strength and ductility, and many of the commonly
used grades also exhibit good weldability.
preferred locations of stainless steel reinforcement
Stainless steel is often used in areas where sufficient cover cannot be
obtained or at construction joints and critical gaps between columns and
decks. Because of the cost of stainless steel, many engineers do not expect
that it will become a standard for all reinforcement .

A few pictures where Stainless Steel reinforcement is used in repair as well as new construction .
Reconstruction of a sea wall in Sydney harbor
A large building complex under construction in Gulf directly facing the sea
New Precast concrete seam wall elements to replace an existing seawall
Sheik Zayed Bridge, Abu Dhabi. Lower part of supports with SSR
stainless steel clad reinforcement
Stainless steel clad bars are being studied as a lower cost , corrosion
resistant reinforcement option.
Concerns with the use of stainless steel clad reinforcement include difficulty
in bonding the cladding to the bars .
nickel clad reinforcement
Nickel clad bars are produced by applying a heavy layer of nickel to a billet
and hot rolled. It result in a continuous coating of wrought nickel on the surface
of the bar with a diffusion zone of alloyed nickel and iron underneath.
The alloyed zone provides additional protection should there be a break in
the wrought nickel barrier.
titanium reinforcing bars
A study found the corrosion rate of titanium bars to be 14,000 times less
than that of black steel in a pH 7 salt solution, and 135 times less than that of
black steel in a high pH salt solution.
The study estimated that titanium bars would extend the time-to-cracking of
concrete by about 130 times, which would not be as cost effective as using
stainless steel considering that the cost of titanium bars is about six times that
of stainless steel
copper clad reinforcing bars
Copper Clad reinforcing bars are found to be a better way to arrest corrosion
Studies made in this sector are tabulated.
REINFORCEMENT TYPE
AGE
2 7 13
BLACK BARS
Badly cracked and bars
corroded
--------- ---------
BLACK BARS
--------- Severe Cracking Severe Cracking
BLACK BARS WITH
CALCIUM NITRATE
No Cracks but minor
rust spots
Fine to wide cracks
with minor spalls
---------
EPOXY COATED BARS No Cracks
Cracked and Bars
Corroded
---------
COPPER CLAD BARS IN
BOTH MATS
--------- --------- No Cracking
COPPER CLAD BARS IN
ONE MATONLY
--------- --------- No Cracking
Recently, a number of studies have looked at the possibility of using fiber
reinforced plastic as a non-corroding reinforcement option for concrete.
There are three elements that make up a fiber-reinforced plastic bar.
The first is fibrous material, which reinforces the laminate and gives it
strength. Fibers cannot act alone because, although they are strong in
tension, they cannot support compression, torsion or bending loads.
To overcome this problem, the fibers are embedded in a resinous
synthetic polymer, which is the second element. Resins are much lower in
strength and stiffness than fibers, but act as adhesives and can transfer
loads to the fibers through shear.
The third element is a finish, or coupling agent
fiber reinforced plastic reinforcement
barriers
There are many different corrosion protection methods for reinforcing steel
in concrete that can be classified as barriers. .
Some of these methods work by preventing chloride ions from penetrating
the concrete and de - passivating the reinforcement.
Others work by reducing the movement of air and moisture into the concrete
and therefore slowing the corrosion process.
Barrier methods are often used in conjunction with other corrosion protection
methods, such as epoxy-coated steel or other alternative reinforcement.
different barrier methods
Low Permeability Concrete
Cover
Low Water/Cement Ratio
Mineral Admixtures
Silica Fume
Blast-Furnace Slag
Fly Ash
Overlays
Latex-Modified Concrete Overlays
Low-Slump Dense Concrete Overlays
Waterproof Membranes
Concrete Sealers
Linseed Oil
Epoxy
Silane and Siloxane
Methacrylate
Deep Polymer Impregnation
results of low permeability concrete @ a glance
Cure Type
Percent Silica
Fume
Water/Cementitious
Material Ratio
Time to Corrosion (years)
50 mm 75 mm
Heat 0 0.46 2 4
Tank 0 0.46 1 2
Burlap 0 0.46 1 3
Burlap 5 0.46 5 12
Burlap 7.5 0.46 6 13
Heat 0 0.37 5 11
Tank 0 0.37 4 9
Burlap 0 0.37 6 14
Burlap 5 0.37 11 25
Burlap 7.5 0.37 11 25
Heat 0 0.32 9 20
Tank 0 0.32 11 26
Burlap 0 0.32 9 20
Burlap 5 0.32 12 28
Burlap 7.5 0.32 17 38
overlays
The purpose of concrete overlays is to create a low permeability protective
layer over the conventional concrete.
An overlay serves as a barrier to chloride ions, therefore increasing the time
required for the concentration of chloride ions at the level of the reinforcement
to reach the threshold for corrosion.
Low permeability overlays also decrease water penetration into a structure,
allowing it to dry out, which reduces chloride ion mobility.
latex modified concrete overlays
Latex-modified concrete overlays consist of a conventional portland cement
concrete supplemented by a polymeric latex emulsion, usually styrene -
butadine latex.
The water in the emulsion hydrates the cement, while the polymer provides
additional binding properties.
This produces a low w/cm ratio concrete with good durability and bonding
characteristics and a low permeability to chloride ions.
Although they are not waterproof, the permeability of latex-modified concrete
overlays has been found to be only about 12% that of conventional concrete.
advantages & disadvantages of l m c
Latex-modified concrete overlays consistently outperformed conventional
and low slump dense concrete overlays in 16-year tests .
Although they did not completely stop corrosion, latex-modified overlays
extended the service lives .
Latex-modified overlays can be expected to last up to 25 years, after which
they usually need to be replaced due to rutting and general wear .
Latex-modified overlays have had problems with plastic shrinkage cracks
that deepen with age and with scaling in continuously saturated areas .
low slump dense concrete overlays
The concept of dense concrete overlays is basically that the natural capillary
void system of a concrete can be reduced by increasing the cement content of
a mix to over 470 kg/m
3
and decreasing the w/c ratio to about 0.30 to 0.32.
This leads to a decrease in permeability and an increase in strength. Dense
concrete overlays work by preventing chloride ions and moisture from
penetrating into the structure
The main problems with low slump dense concrete overlays is that they are
difficult to place, expensive, and have trouble with surface cracking.
water proof membranes
Waterproof membranes are installed on bridge decks for two reasons.
The first is to protect the concrete from deterioration induced by
freeze-thaw cycles .
The second is to protect the reinforcement from corrosion.
classification of membranes
These membranes can be divided into three general categories
built-up membranes
preformed sheet membranes
liquid membranes.
advantages & disadvantages of membranes

Characteristics Preformed Liquid
Thickness &
Quality
Uniform Difficult to achieve
Laps Require No
Poor
workmanship
More vulnerable Less Vulnerable
Curved Sections Difficult to lay Easily done
concrete sealers
The purpose of a sealer is to reduce corrosion of reinforcement in concrete
by preventing capillary action at the surface, therefore preventing water and
chloride ions from penetrating the concrete.
Sealers can either be pore blockers, forming a microscopically thin (up to 2
mm) impermeable layer on the concrete surface, or they can penetrate into the
concrete slightly (1.5 to 3 mm) and act as hydrophobic agents
Coating
Chloride gain above background value (kg/m3)
14 cycles 21 cycles 30 cycles
Control 9.1 8.99 9.34
Epoxy 0.29 0.37 0.3
Methyl
methacrylate
0.03 0.09 0.12
Polyurethane 0.04 0.15 0.14
Comparison of various concrete sealers
deep polymer impregnation
Polymer impregnation protects reinforcement from corrosion in concrete by
limiting the ingress of water, oxygen and chloride ions into the concrete by
sealing the surface pore system of the concrete.
Deep polymer impregnation is achieved by filling the concrete pores to a
depth below the top layer of reinforcement with polymer.
This is done by first applying heat to dry out the element to the desired depth
of impregnation.
Next, a monomer is applied, that infiltrates the concrete and is polymerized
in place by reheating the concrete
disadvantages
The biggest problem with polymer impregnation is achieving sufficient depth
of polymer penetration.
It is important to have low moisture in the deck, and grooves may need to be
sawed into the deck to help attain deep impregnation.
Drying the element for the monomer application can be difficult and heating
and cooling the concrete can lead to excessive thermal stresses .
electro-chemical methods
There are two electro-chemical methods viz.
Cathodic Protection
Electrochemical Chloride Extraction
Both of these methods have the ability to stop corrosion in chloride
contaminated concrete and are most often used as rehabilitation methods .
cathodic protection
The science of cathodic protection began in 1824 when Sir Humphrey Davy
used iron anodes to protect the copper sheeting on the bottom of the British
Navys sailing ships.
However, cathodic protection was not applied to reinforced concrete
structures until it was used to protect a reinforced concrete bridge deck in
1973
At first, cathodic protection was used mainly to prevent further corrosion
after repair of damaged structures, but recently, cathodic protection has been
incorporated in new construction in an effort to prevent corrosion from starting
components of a cathodic protection system
A cathodic protection system consists
the reinforcement to be protected
an anode
a power source
concrete surrounding the steel
a monitoring system
cabling to carry the system power
monitoring signals
Each cathodic protection system contains two types of anodes.
The primary anode, or anode conductor, acts as a contact point
and a power supply line for the secondary anode.
The secondary anode, usually referred to as the anode, is the
material that distributes the current over the surface of the structure.
Generally, for existing structures, the deteriorated surface of the concrete is
repaired, and the anode is placed on top of the new surface
The positive terminal of the power source is connected to the anode, and the
negative terminal is connected to the reinforcement, which becomes the
cathode.
A small amount of direct current (DC) is then applied, causing current to flow
through the electrolyte from the anode to the reinforcement, making the
reinforcement become cathodic in relation to the anode.
The electrolyte is generally the pore water in the concrete, which contains
alkalis that allow the transfer of current from the anode to the reinforcement.
Oxygen and moisture must be present in the concrete for the cathodic
protection system to work.
The anode should be designed to resist deterioration while acting to protect
the reinforcement .
Principle of cathodic protection
A typical cathodic protection setup
working of a cathodic protection system
Cathodic protection works by using current to shift the potential of the
reinforcing steel in the negative direction.
If the potential is shifted far enough so that all of the steel reinforcement
becomes cathodic, corrosion will be stopped
The standard protection criteria is generally to polarize the steel to an
instantaneous-off potential more negative than 850 mV
In concrete with a pH between of 12.5 and 13.5, the potential of the
reinforcement would need to be more negative than -820 mV to put it into the
region where corrosion of iron is thermodynamically impossible.
However, if used, these potentials are so low that hydrogen evolution can
occur on the steel surface, which can cause a number of problems, such as
large current draws, anode degradation, bond loss, and hydrogen
embrittlement
The current for cathodic protection can be supplied by two methods:
DC can be supplied by an external power source
current can be supplied by an anode that is made from a
material that is more active than reinforcing steel (sacrificial
anode).
Chemical reactions occur adjacent to the anode in impressed current
cathodic protection systems, usually involving is either the release of oxygen
[Eq. (4-1)] or the evolution of chlorine
Oxygen evolution is the most common reaction in well-designed systems

4 H
2
O 4 H
+
+ 4 OH
-
4 H
+
+ 2 H
2
O + O
2
+ 4 e
-

2 NaCl 2 Na
+
+ 2 Cl
-
2 Na
+
+ Cl
2
+ 2 e
-

impressed current anode systems
There are a number of different types of anodes that are used in impressed
current cathodic protection systems.
Coke-breeze overlay anode systems
Slotted anode systems
Conductive polymer anode systems
Grid anodes
Conductive coatings as anodes
Sacrificial anode systems
The different types of anodes that are used are
Zinc hydro-gel anode systems
Sprayed alloy anode systems
Zinc Mesh Pile Jacket Anodes
Comparison of different cathodic protection systems
Impressed-Current Sacrificial Anode
External power required Requires no external power
Driving voltage can be varied Fixed driving voltage
Current can be varied Limited current
Can be designed for almost any
current requirement
Usually used where current
requirements are small
Can be used in any level of
resistivity
Usually used in low-resistivity
electrolytes
precautions
Selection of the proper anode is important no matter which method of
cathodic protection is used.
The selected anode must be able to resist deterioration under the expected
environmental conditions and loads.
The structure must be capable of carrying the additional dead load that the
anode will place on it.
The anode must be durable enough to withstand installation demands and to
reach its design life, and the anode must also have a large enough surface
area to minimize deterioration in the surrounding concrete.
ELECTROCHEMICAL CHLORIDE EXTRACTION
Electrochemical chloride extraction (also called desalination) has been
developed as an alternative repair method in which chloride ions are pulled out
of contaminated concrete, allowing the concrete to stay in place
Electrochemical chloride removal is the process of removing chloride ions
from contaminated concrete by electrochemical means
working
The reinforcement is connected to the negative pole of a DC power source,
while a temporary external anode, placed within an electrolyte covering the
concrete surface, is connected to the positive pole.
Current is run through the reinforcement to the anode, creating an electrical
field in which chloride ions are pulled away from the reinforcement and
towards the electrolyte where they are absorbed for removal .
limitations
It can only be used in cases where there is little damage
(spalls and delamination) to the concrete surface, and where the corrosion of
the reinforcement does not yet effect the safety of the structure .
Spalls and cracks need to be repaired conventionally or sealed prior to the
application of electrochemical chloride extraction to prevent the electrolyte
from coming into contact with the reinforcement and causing a short circuit .
corrosion inhibitors
Corrosion inhibitors are chemicals that can slow down or prevent corrosion
of reinforcing steel in concrete.
Corrosion inhibitors were first investigated in the 1960s.
Some early inhibitors included sodium nitrite and the sodium and potassium
salts of chromate and benzoate.
A common inhibitor used today, calcium nitrite, was developed to be used in
concrete as a noncorrosive set accelerator
Types of corrosion inhibitors
Corrosion inhibitors are typically divided into three categories:
anodic inhibitors
cathodic inhibitors
organic inhibitors
Anodic inhibitors, made up of chromates, nitrites, molybdates, alkali
phosphates, silicates, and carbonates, act by minimizing the anodic part of the
corrosion reaction.
These inhibitors form an insoluble protective film on anodic surfaces to
passivate the steel.
Cathodic inhibitors, consisting of zinc, salts of antimony, magnesium,
manganese, and nickel, form an insoluble film on the cathodic surfaces of the
steel.
They are usually less effective than anodic inhibitors, but are also safer.
Organic inhibitors, including amines, esters, and sulfonates, block both the
anodic and cathodic reaction on the entire surface of the metal
Organic inhibitors can also act as pore blockers, reducing the permeability of
the concrete.
C a s e s t u d y
C a s e s t u d y
shell haven
Shell Haven is a port on the north bank of the Thames Estuary at the
eastern end of Thurrock, Essex, England, and a part of the Port of London.
The port facilities consist of 14 jetties of varying forms of construction , the
majority of which is reinforced concrete .
One of the jetties incorporates pre-stressed concrete deck support beams .
the problem
Two of the jetties had suffered from electro-chemical attack .
These jetties were constructed between 1922-1927 . They both required
treatment between mean low water level and the top of splash zone , but one
was unusual , in that considerable deterioration had occurred to horizontal
braces situated approximately 1m above mean low water spring tide level .
This deterioration was similar to normal electro-chemical attack except that
large cavities had formed in the main reinforcement .
These were the sites of impurities in the steel leading to rapid electro-
chemical attack .
Damages were also there due to impact of ship , which were in the form of
cracks .
One of the impact damages occurred to a pre-stressed concrete deck
support beam . The tensioning filament were not damaged .
solution
The corroded reinforcement were replaced or duplicated .
Further to this , the deterioration was treated with cathite method in which ,
the electrolyte action is halted which is producing corrosion .
In this method phosphate solution is used to treat the reinforcement .
Cracks due to impact damage were sealed and filled using epoxy resin grout
This work has been carried out down to low water spring tide level with dry
access limited to approximately an hour at times of spring tides .
For the repair of pre-stressed concrete deck support beam , epoxy concrete
was used with no attempts made to prevent the bond between the filaments
and the new concrete
STRENGTH RECOMMENDATIONS BY VARIOUS CODES
IS 456-2000 recommends 20 N/mm for PCC and 30 N/mm for RCC .
IRC 21 specifies a grade of M25 for such severe environmental conditions
Dept. of Environment . U.K recommends 255 kg/cm(25 N/mm) for concrete
in marine structures .
British code BS CP 110 specifies 40 N/mm as the minimum permissible
strength .
Australian specifications recommend a minimum strength of 265 Kg/Cm for
such environment .
reference
Dyton F.J [ 1978 ] , Case Histories of repairs of Maritime Structures ,
Maintenance of Maritime Structures , Institution of Civil Engineers , London
Pg 89-103
Vic Roads Technical Note , Cementitious Repair of Concrete Structures
Gro Markeset , Steen Rostam , Oskar Klinghoffer [ 2006 ] , Guide for the use
of Stainless Steel Reinforcement in Concrete Structures ,
T h a n k y o u..
T h a n k y o u..

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