Repair techniques (ch.

19-20)
Conventional and electrochemical repair techniques
14-11-2016

Victor Marcos Meson

vicmes@byg.dtu.dk

Outline
1. Introduction
2. Conventional repair techniques (Chapter 19)
3. Electrochemical repair techniques (Chapter 20)
4. Summary

DTU Civil Engineering, Technical University of Denmark

14 November, 2016

1- Introduction
Repair strategy
Optimize repair works

[1]

Repair

Reduce changes/works on structure

to minimum
Repair > Replacement
Localized repair > Total repair
Conservation works > repair works
Cost-effectiveness

Level of intervention
(4)
(3)
(2)
(1)

DTU Civil Engineering, Technical University of Denmark

Monitor corrosion: No intervention

Reduce corrosion: Repair/monitor
Stop corrosion: Repair
Replace component: Rebuild

14 November, 2016

2- Conventional repair techniques

Introduction

Evaluate causes
for deterioration

Identify critical
areas

Quantify degree of
deterioration

Propose extent of
concrete removal

Evaluate exposure
conditions
Study history of the
structure

Identify signs of
deterioration (weak
spots)
Identify cracks/defects
Prepare survey plan

Core extraction and

testing
Cl-/Carbonation profiles
Potential monitoring at
reinforcement

Repair cracks/defects
Local concrete removal
Overall thickness removal
Strengthening works

More information Optimization of repair Reduced costs

DTU Civil Engineering, Technical University of Denmark

14 November, 2016

2- Conventional repair techniques

Concrete removal carbonation
Carbonation front < cover (A)
Exp. carbonation depth < cover (1)
Critical carbonation + corrosion (2)
Carbonation + corrosion + cracking (3)

Carbonation front > cover (B)

Critical carbonation + corrosion (2)
Carbonation + corrosion + cracking (3)
Critical carbonation damage
Carbonation + corrosion + cracking (3)

Safe: No expected damage

Risk: Limited damage expected
Failure: Critical damage expected
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DTU Civil Engineering, Technical University of Denmark

[2]

14 November, 2016

2- Conventional repair techniques

Concrete removal chlorides
Cl- front (0.4%wcem) < cover (A)
Expected Cl- front < cover (1)
Critical Cl- front corrosion (2)

Cl- front (0.4%wcem) > cover (B)

Critical Cl- front corrosion (2)

Safe: No expected damage

Failure: Critical damage expected
Risk: Propagation phase for chlorideinduced corrosion can be neglected, as
localized corrosion rates are higher
and structural damage severe
[2]
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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

2- Conventional repair techniques

Techniques for concrete removal
OVERALL APPROACH
Selective removal (limited to damage area)
Minimize damage to original healthy concrete
Limit damage to reinforcement
Clean and rough surface after removal (adhesion)
Cost-effectiveness
REMOVAL TECHNIQUES
Surface removal (A) Surface damage above the rebar
Milling methods: scarifier (A)
Abrading methods: sandblasting (B)
Deep removal (B) Deep damage at/past the rebar
Pneumatic breakers: jackhammer (C)
Hydro-demolition: high-pressure water jet (D)
7

DTU Civil Engineering, Technical University of Denmark

SURFACE REMOVAL
A

www.shotblastersinc.com

www.thebluebook.com

DEEP REMOVAL
C

www.designingbuildings.co.uk

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2- Conventional repair techniques

Repair material and additional strengthening
DURABILITY PERFORMANCE OF REPAIR MATERIAL
Alkaline material (i.e. cement-based)
Low Cl- diffusion coefficient
Low carbonation coefficient (if applicable)
Resistant to other attacks (Freezing)
MECHANICAL PERFORMANCE OF REPAIR MATERIAL
Bond to the substrate (surface preparation, bond agent)
Dimensional stability (drying shrinkage shear failure)
Elastic modulus lower/similar to original surface
ADDITIONAL PROTECTION
Corrosion inhibitors: e.g. increase Cl- threshold
Surface treatment: delay moisture/agents penetration
Coating reinforcement: prevent exposure (last option)
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DTU Civil Engineering, Technical University of Denmark

Repair concrete

Portland cement-based
Pozzolanic additions
High paste content
Low w/c ratio (w/c<0.40)
Rheology modifiers (thixotropy)
Polymer modified mortar (latex)
Fibres (steel, glass, carbon, PP)

Strengthening

Restore structural capacity

Increased cover thickness
Reinforcing bars / steel plates
FRP laminates

14 November, 2016

3- Electrochemical repair techniques

Introduction
[2]

Electrochemical techniques
Force switch: Anode Cathode
Galvanic-sacrificial Anode (Zinc, Aluminum)
Impressed-current anode (Titanium, Carbon)
Cathodic protection & Prevention
Prevent-/ Reduce-/ Stop-/ corrosion
Protection level dependent of potential
Prevention Protection Immunity
-500 mVSHE -700 mVSHE -900 mVSHE

[2]

Re-alkalinization & Chloride removal

Force ionic transport inside material
(Na+ K+) towards steel + Produce (OH-)
(Cl-) away from steel
E < -1250 mVSHE
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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Cathodic protection & prevention
[3]

IMMUNITY PROTECTION
Stop corrosion
Large current density (>100-200mA/m2)
CATHODIC PROTECTION
Reduce / Stop corrosion
Lower potential Lower kinetics
Moderate current density (4-20mA/m2)
CATHODIC PREVENTION
Avoid corrosion
Lower potential Imperfect passivity
Small current density needed (<2mA/m2)

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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Cathodic protection in carbonated concrete
IMMUNITY PROTECTION
Stop corrosion
Bring steel to immune state (<1000mVSHE)
Applicable to neutral environments
Lower potential below H2O stability
Large driving currents (10-200mA/m2)

[4]

CATHODIC PROTECTION
Reduce/stop corrosion
Bring steel to passive state
Increase kinetic resistance to corrosion
Increase basicity (OH-) Re-passivate
Moderate driving currents (4-8mA/m2)

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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Cathodic protection in chloride-contaminated concrete
IMMUNITY PROTECTION
Stop corrosion
Bring steel to immune state (<1000mVSHE)
Consider local conditions at corrosion pit
Lower potential below H2O stability
Large driving currents (10-200mA/m2)

[4]

CATHODIC PROTECTION
Reduce/stop corrosion
Bring steel to passive/trans-passive state
Increase kinetic resistance pitting
Increase basicity (OH-)
Lower ratio
[Cl-]/[OH-]
Remove Cl Moderate driving currents (8-20mA/m2)
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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Cathodic prevention in chloride-contaminated concrete
CATHODIC PREVENTION
Prevent corrosion Imperfect passivity
Increase pitting potential (Epit)
(E < Epit)
Lower potential (E)
Maintain basicity (OH-)
Lower ratio
[Cl-]/[OH-]
Barrier to ingress of Cl Low driving currents (1-2mA/m2)
[3-5-6]

[4]

Immunity
-800 mVSHE
-1000 mVSHE

Protection
-600 mVSHE
-800 mVSHE

Prevention
-400 mVSHE
-600 mVSHE

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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Electrochemical re-alkalinization
Working principle
Lower potential below H2O stability
Low potential (E<-1250mVSHE)
Large current density (1000-2000mA/m2)
Reduction of H2O: H2O+2e H2+2OH Electrical migration of alkali: Na+, K+
Effects & application
Increase basicity at steel surface (pH>13)
Increase alkalinity at steel surface (Na+,K+)
1A/m2 8-18 days 200-450Ah/m2
Local de-carbonation at steel surface
Alkali-Silica reaction (reactive aggregates)
Hydrogen embrittlement on HSE

[2]

[7-8]
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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

3- Electrochemical repair techniques

Electrochemical chloride extraction
Working principle
Low potential (E<-1250mVSHE)
Large current density (1000-2000A/m2)
Reduction of H2O: H2O+2e H2+2OH Electrical migration of alkali: Na+, K+
Electrical migration of Chloride: Cl Oxidation to Chlorine: 2Cl- Cl2+2e
Effects & application
Increase basicity at steel surface (pH>12)
Reduced Cl- at steel surface
1A/m2 100-300 days 1000-3000Ah/m2
Reduction of [Cl-]/[OH-] at steel surface
Alkali-Silica reaction (reactive aggregates)
Hydrogen embrittlement on HSE
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DTU Civil Engineering, Technical University of Denmark

[2]

Constant current
dissolves bound Cl-

On-Off currents
more efficient

[9]
14 November, 2016

5-Summary
Concrete repair
Prioritize local repair and minimize intervention on sound structure
Repair works need to be cost-effective Efficient repair
Conventional repair techniques
Remove contaminated/damaged concrete Replace with repair material
Degree of removal-repair depends on: current status & prediction models
Selection of adequate repair-/ reinforcement-material is critical
Electrochemical repair techniques
Non-destructive prevention-/ repair-technique
Cathodic protection: Prevention(-0.5VSHE)Protection(-0.7VSHE)Immunity(-0.9VSHE)
Electrochemical repair: Re-alkalinization(-1.3VSHE) / Chloride removal(-1.3VSHE)
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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

Thank you
QUESTIONS

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DTU Civil Engineering, Technical University of Denmark

14 November, 2016

References
[1] RILEM Technical Committee 124-SRC, P. Schiessl (ed.) (1994) Draft recommendation for repair strategies for concrete structures damaged by reinforcement
corrosion. Materials and Structures, 27, 415436.
[2] L. Bertolini, B. Elsener, P. Pedeferri, E. Redaelli, R.B. Polder, Corrosion of Steel in Concrete: Prevention, Diagnosis, Repair, Second, John Wiley & Sons, 2013.
[3] Pedeferri, P. (1996) Cathodic protection and cathodic prevention. Construction and Building Materials, 10 (5), 391402.
[4] A. Kter, M.R. Geiker, P. Mller, Management of Reinforcement Corrosion, DTU, 2006.
[5] Pedeferri, P. (1993) Cathodic prevention and protection of reinforced and prestressed concrete structures. LEdilizia, XII (10), 6981 (in Italian).
[6] Bertolini, L. (2011) A tribute to Pietro Pedeferris contribution to the knowledge on corrosion of steel in concrete and its prevention. Materials and Corrosion, 62
(2), 9697.
[7] COST 521 (2003) Corrosion of Steel in Reinforced Concrete Structures, Final Report, (eds R. Cigna, C. Andrade, U. Nrnberger, R. Polder, R. Weydert, and E.
Seitz) European Commission, Directorate General for Research, EUR 20599, 2003.
[8] Polder, R.B. and van den Hondel, H.J. (1992) Electrochemical realkalization and chloride removal of concrete, in Proc. of the Int. RILEM/CSIRO/ACRA Conf.
Rehabilitation of Concrete Structures (eds D.W.S. Ho and F. Collins), Melbourne, 31 August2 September, pp. 135147.
[9] Elsener, B. and Angst, U. (2007) Mechanism of electrochemical chloride removal. Corrosion Science, 49 (12), 45044522.

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DTU Civil Engineering, Technical University of Denmark

14 November, 2016