Anda di halaman 1dari 49

Cathodic Protection: Which one to

use & Latest Developments


Gordon Chirgwin
July 2007
Acknowledgements: Howard Morris & Michael
Moore
The problem

Rebar
Spalling loss
Is it fit-for-purpose?

Cracking

Rust
Staining Is it safe?
Delamination
Topics

Causes of deterioration
When to use Cathodic Protection
Cathodic Protection Types
Causes of Concrete
Deterioration
CONCRETE

Structural Chemical Physical

Impact AAR Thermal


Construction Sulphate Moisture
Movement Hostile Elements Erosion
Overload Fire
Construction Defects

Inappropriate concrete specification


Design/detailing
Low cover
Poor construction and curing
Cracking:
Shrinkage
Thermal
AAR
Reinforcement Protection by
Passive Film

Ca, Na, K hydroxides in hydrated cement raise the pH


to ~13.5

A protective ferric oxide film forms around the


reinforcement

Fe+3(OH)- Fe2O3.3H2O+3e-

This film stops iron dissolution, and is stable at pH >10.5


Causes of Reinforcement
Deterioration

REINFORCEMENT

Electrochemical
Corrosion

Carbonation Corrosive Stray


Contaminants Currents

At Mixing From Environment


Causes of Deterioration
Carbonation

CO2 gas dissolves in pore water Carbonic Acid


Neutralises Alkalis in Concrete, pH < 8.5
Passive Film dissolves
General corrosion starts
Causes of Deterioration
Chlorides

Airborne, splash zone, tidal,


or from additives
Cl can penetrate through
the passive film
At Cl- > threshold, passive
film breaks down, corrosion
initiates
Cl- threshold value is
typically 0.06% by wt of
concrete
Pitting corrosion
Corrosion of Reinforcement
Anodes and
Cathodes

Cl- Cl-

Oxygen & Oxygen &


Moisture +ve Ions +ve Ions Moisture
Fe Fe++
Rebar e- e-
Cathode Anode Cathode

Anodic Reaction (Oxidation)


Cathodic Reaction (Reduction)
Fe Fe2+ + 2e-
O2 + 2 H2O + 4 e- 4OH-
High pH Maintained Fe2+ + H2O FeOH+ + H+
pH reduced
Causes of Deterioration
Stray Current Corrosion

e- DC POWER e-
- SUPPLY
+

Direction of Positive Current Flow

Oxidation Reduction
Reaction Reaction
3+
Fe
Dissolving 2+ Protected
End Fe Fe End Anode
Cathode 2+
Fe
Discontinuous Steel
Body

Electrolyte
Causes of Deterioration
Stray Currents

Caused by DC current flowing through the


reinforcement
Where the DC current leaves the reinforcement,
corrosion occurs
Very high rate of localised reinforcement
corrosion
Trams and trains most common source
General Deterioration Model

T5
DAMAGE LEVEL
5. loss of structural
integrity
T4
suggested limit states
4. loss of steel
section
T3

3. first crack
T2
T1

2. rate of corrosion
1. threshold exceeded
INITIATION PROPAGATION
Causes of Deterioration
The Consequences:
Expansive corrosion
Crack, Delamination,
Spalling
Loss of reinforcement
section
Damage to prestress

Strength and safety have been compromised


No longer fit for purpose
Corrosion of Steel in
Concrete

Topics
Causes of deterioration
When to use Cathodic Protection
Cathodic Protection Types
Repair Options
Possible Strategies

Leave as is and monitor


Down grade functionality
Modify environment (incl. coating
application)
Low durability repair
High durability repair
Strengthen
Reconstruction
Demolition
Repair Options
Repair Methods

Patch repairs
Corrosion inhibitors
Crack injection
Chloride extraction
Realkalisation
CP by sacrificial anodes/impressed current
Composites
Electrochemical repairs

Advantages:
Minimise concrete repairs (make good cracks
and spalls)
Typically lower life cost compared to rebuild or
conventional repair
Long term reduction and control of corrosion
Can combine with conventional repair
Electrochemical repairs

Possible Problems:
Discontinuous Steel
Electrical Shorts to Surface
Electrically Resistant Repair Materials &
Concrete
Prestressed Steel
Alkali Silica Reactivity
Bond Strength
Epoxy Coated Steel
Galvanized Steel
Anode Suitability
When to use CP

Corrosion deterioration
Structure in fair condition overall
Structure capacity good
Moist environment
High durability repair
General Deterioration Model

DAMAGE LEVEL
5. loss of structural
integrity
suggested limit states
4. loss of steel
section

Electrochemical
3. first crack
treatment zone
2. rate of corrosion
1. threshold exceeded
INITIATION PROPAGATION
Impressed Current System

Cable
Cable + -
DC
Source
Anode

Continuity bar

Reinforcement
Repair Options
Cathodic Protection Impressed Current

1. Break out, augment, patch


2. Anodes e.g. Ti mesh
and conductor bars

3. Conductive coating
4. Mesh with protective
overlay if vulnerable
Advantages and disadvantages of
impressed current systems

Suitable for all reo High cost for small


densities systems
Suitable for all Risk of overprotection
environments Complex control and
Not limited by monitoring
concrete resistivity
Can be used to
prevent corrosion
entirely
Sacrificial systems

Spray on zinc anodes


Encased Mesh anodes
Discrete embedded anodes
SACRIFICIAL ANODE SYSTEM

ANODE WIRING

CONCRETE

REBAR
Encased mesh anode

Cable

Continuity bar
connected to
reinforcement

Reinforcement

Conductive
Zinc Mesh Anode Grout
Mesh anode in form
Mesh anode in form
Bomaderry Creek
Discrete embedded anode

Cable

Reinforcement

Discrete Conductor bar


embedded anode connected to
reinforcement
Discrete Embedded Sacrificial
Anode

Conductive Wire
mortar
Discrete Embedded Sacrificial
Anode

Conductive Wire
mortar

Zinc anode
Installing into Ryde Bridge
Abutment
Advantages of sacrificial systems

Simpler installation
No need for complex control systems
No risk of overprotection
Simple monitoring
Robust
Low cost on small systems
Disadvantages of sacrificial
systems

Life of anode depends on current draw and


mass of zinc
Effectiveness of anode varies with total
charge passed (corrosion polarisation)
Effectiveness limited by concrete resistivity
Difficult to predict anode life
Not cost effective if high reo density
Not suitable in dry environments
The End

Thank you
Any Questions ?

Anda mungkin juga menyukai