CAVITATION DAMAGE IN CONCRETE AND

PROTECTION


Cavitation damage on concrete surface is most common in case of spillway in dams. This
leads to cracks on the concrete surface which further increases the risk of damage to
concrete by means of sulfate attack, freeze-thaw, alkali-silica reaction and other means.
Cavitation damage occurs on concrete surface when discontinuity or irregularities is
encountered in the path of high velocity water flow. This discontinuity or irregularity in
the flow path cause the water to lift off the flow surface, creating negative pressure
zones and resulting bubbles of water vapor. These bubbles travel downstream and
collapse. If the bubbles collapse against a concrete surface, it sends a very high pressure
impact over an infinitely small area of the surface. Such high pressure impacts can
remove particles of concrete, forming another discontinuity which then create more
extensive cavitation damage.

The initiation of cavitation damage requires irregularities along the flow surface and
a low cavitation index associated with a spillway flow. Cavitation is typically initiated by
singular isolated irregularities or roughnesses along a flow surface. Typical examples of
irregularities in hydraulic structure flow surfaces include the following:
Offsets into the flow.
Offsets away from the flow.
Holes or grooves in the flow surface.
Protruding joints.
Calcite deposits on the flow surface.

The cavitation resistance of many different repair materials has been tested by the
laboratories of Reclamation, the U.S. Army Corps of Engineers, and others. To date, no
material, including stainless steel and cast iron, has been found capable of withstanding
fully developed instances of cavitation. Successful repairs must first include mediation of
the causes of cavitation.

Fig: Extensive cavitation damage to Glen Canyon Dam
A standard rule of thumb is that cavitation damage will not occur at flow velocities less
than about 40 feet per second at ambient pressures. As flow velocities approach this
threshold, it becomes necessary to ensure that there are no offsets or discontinuities on
the surfaces in the flow path. Reclamations specifications for finishing the surfaces of
concrete structures that will experience high velocity flows are very strict. Repairs to
newly constructed concrete that fail to meet these requirements can sometimes be
accomplished by surface grinding. More likely, however, the concrete that does not meet
surface specifications must be removed and replaced with replacement concrete or
epoxy-bonded replacement concrete
Cavitation damage at, or adjacent to, control gates can usually be repaired with epoxy
bonded epoxy mortar, polymer concrete , or epoxy-bonded replacement concrete. After
performing such repairs, it might be a good idea to apply a 100-percent solids epoxy
coating to the concrete, beginning at the gate frame and extending downstream 5 to 10
feet. The glasslike surfaces of epoxy coatings may help prevent cavitation damage to the
concrete.