Thomas R. Kline
tkline@structural.net
281.479.0391
Concrete Problems
Defects Design, materials, construction Damage g Overload, fire, impact, chemical spill Deterioration Metal corrosion, erosion, freeze/thaw, sulfate attack
Disintegration
Chemical Exposure
Attack matrix sulfurous acid Matrix modification sulfur contact alters Portland erosion exposing resistant cement paste matrix into a large coarse aggregate semi-gelatinous state
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Operating Conditions
Operating Parameters
Typically the sulfur pit concrete is exposed to operating temperatures of molten sulfur ranging between 285oF to 315 F. 315F. Temperature gradient exists within the wall mass extending from pit interior molten sulfur contact of 300F to pit exterior earth contact of 57 F. Actual exterior soil temperatures stabilized during operation reach elevated temperatures ranging between 120oF to 130oF.
Operating Conditions
Operating Parameters
Water Table Roof Slab Grade G d
Ground Pressure
Base Slab
Steam Coils
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Operating Conditions
Operating Parameters
Exterior Earth (A t l E th (Actual Ranges 120oF to 130oF) )
Operating Conditions
Operating Parameters
Small Pit Fluctuating Levels Deterioration
Operating Conditions
Operating Conditions
Operating Parameters
Type V 3 - 5,000 psi >>> 10 - 13,000 psi , p , p
Sulfur
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Operating Conditions
Operating Parameters
Sulfur impurities and by-products form Carsul Carsul settles along crevices and base regions May be mistaken for concrete
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Operating Conditions
Deterioration Mechanisms
Desiccation of the concrete mass (i.e., removal of excess moisture by high service temperatures) causing cracks Sulfurous acid attack acid generated by water leakage into the pit from cracks, failed penetration seals or jacketed pipe/coils leaks Corrosion of reinforcing steel bar above molten s lf r le els in the Vapor Zone sulfur levels Scouring effect of fluctuating molten sulfur levels in daily working pits l l i d il ki it
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Operating Conditions
Deterioration Mechanisms
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YES
Condition Survey
Repair Analysis
Repair Strategy
Evaluate
l l l l l
Contractor Methods
l l l l l
Quantify
Repair
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Repair Process
Condition Survey
Visual Inspection and Site Survey Acoustic Impact Testing Mapping of Significant Features
Field I Fi ld Investigation i i
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Repair Process
Condition Survey
Ferroscan & Standard Rebar Pachometer Survey
Field I Fi ld Investigation i i
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Repair Process
Condition Survey
Ground Penetrating Radar Line Scan
Field I Fi ld Investigation i i
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Repair Process
Condition Survey
Sample Extraction
Field I Fi ld Investigation i i
Core Extraction
Chloride Sampling
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Surface Erosion
Partial and full-depth removal and replacement Installation of a new skin (i e durability liner) new skin (i.e., Installation of a new structural liner
Corroding Reinforcing
New rebar replacement & integration with repair couplers Incorporation of corrosion inhibiting admixtures f into repair materials
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Surface Repair
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Placement Techniques
Placement Techniques
Placement Techniques
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Placement Techniques
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Sulfur Pit Repair Construction Environment Innovative Techniques To Accelerate Repair Construction Schedule
Use of site built modular site-built formwork adjusts to asbuilt Sulfur Pit site conditions with roof inplace (atypical Pits) Port locations & spacing assure port-to-port communication during repair material placement i t i l l t & adequate consolidation
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Sulfur Pit Repair Construction Environment Innovative Techniques To Accelerate Repair Construction Schedule
Use of panelized modular formwork adjusts to Sulfur Pit metrics (typical Sulfur Pits) Panelized forms are externally braced (i e (i.e., form-ties not required) works best with roof slab removed allowing internal d ll i i t l & external consolidation
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Conclusion
Devil-is-in-the-Details Even small amounts of deterioration require specific detailing so ifi d t ili things arent made worse while in-service Each Sulfur Pit is unique and requires a thoughtful enlightened approach in li ht d hi order to implement an g p enduring repair
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