ACI 364.

13T-15
TechNote

Repairs for Reinforcement with Shallow

Cover
Keywords: cathodic protection; concrete cover; corrosion; corrosion inhibitor; deterioration; epoxy; membrane; protection; reinforcement.

Introduction
A reinforced concrete structure needs a surface repair due to corrosion of the reinforcement, which resulted
from an inadequate concrete cover (less than code minimum).

Question
What are the recommended remedies to extend the service life of this type of surface repair?

Answer
Many surface repairs have limited service life due to inadequate protection against corrosion-related deterio-
ration of embedded steel reinforcement. A number of protection options are available to extend the service life
of surface repairs, such as increasing cover thickness, enhancing the concrete performance using admixtures
or coatings, coating the reinforcement, installing cathodic protection measures, or a combination of these. The
degree of corrosion protection required is a function of the exposure conditions; the actual concrete condition;
and the type, layout, and service use of the structure. Therefore, final selection and design of a remedial measure
should consider these factors. The development of the reinforcement must also be considered to maintain the
structural integrity of the structure. Furthermore, in accordance with ACI 562, the repaired elements should
comply with applicable building code requirements and relevant fire regulations valid at the project location.

Discussion
Prior to designing or implementing repair, the contributing cause(s) for the noted deterioration should be
identified. To offer appropriate and cost-effective remedial actions, one needs to identify the existing condi-
tions, such as chloride levels, state and characteristics of the concrete, actual concrete cover thickness, and
the required level of protection for the structures. Geographic location and surface orientation are two key
controlling factors.

Geographic location—ACI 362.1R lists five exposure groups used to describe the different levels of exposures
for parking structures, as shown in Fig. 1. Some reinforced concrete structures in the regions with northern
climates (Zone III) are exposed to deicing salt and freezing-and-thawing cycles. Corrosion protection is critical
for these elements. By the same token, structures in regions with southern climates (Zone 1 and part of Zone
II6), with the exception of coastal exposures, typically need a lower level of corrosion protection because of the
differing exposure.

Surface orientation—One consideration for having the appropriate corrosion protection level provided by
concrete cover is the orientation of the surface (horizontal or vertical). Vertical surfaces are not usually as
prone to severe corrosion-related deterioration as horizontal surfaces; an exception is where calcium chloride
was added to concrete to facilitate winter construction. Such practice was commonly done before the 1970s.
The primary reason is that water is not likely to stay on the vertical surfaces to penetrate through the concrete
cover. As a result, protection requirements for elements with vertical surfaces may not need to be as stringent
as that for horizontal surfaces.

Cracking and low-quality concrete can contribute to corrosion-related damage. Therefore, to select the proper
level of surface protection, one should consider the physical condition and material properties of the structural
element.
1
2 REPAIRS FOR REINFORCEMENT WITH SHALLOW COVER (ACI 364.13T-15)

Fig. 1—Geographic weather exposure zones per ACI 362.1R-12. (Zone III and Zones CC are the
most demanding condition, and Zone I is the least. Zone CC is coastal exposure condition.)

Once the corrosion protection that is needed for the structural elements is defined, different remedial options
can be selected to achieve the target levels of protection. There is a variety of protection remedies that can be
implemented to minimize the impact of corrosion-related deterioration, thereby extending the service life of the
concrete surface repair (Table 1) (ACI 546R; NACE SP0187).

Corrosion protection options—Six protection options are identified and discussed as follows:

1. Use of corrosion inhibitors

A schematic drawing of using corrosion inhibitor in repair concrete is shown in (b) of Table 1. The most
commonly used corrosion inhibitor is calcium nitrite, which is added to the repair concrete mixture as an addi-
tive. The inhibitor protects the steel from chloride-induced corrosion by reacting with ferrous ions to repas-
sivate the reinforcing steel surface. This method has good performance history and has been widely used,
provided the nitrite and chloride ratio is in an appropriate range per manufacturer’s recommendations.

Another form of applying corrosion inhibitor is to use a penetrating corrosion inhibitor (also known as surface-
applied corrosion inhibitors or migrating corrosion inhibitors). These materials are applied over existing
concrete surfaces and intended to penetrate into the concrete. Effectiveness varies depending on the applica-
tion condition and location, how the product is applied, the particular proprietary product, the actual concrete
cover thickness, and the in-place concrete properties. Penetrating corrosion inhibitors remain controversial,
with some studies demonstrating effectiveness while other studies show little or no effectiveness (EFC 38).

2. Protective barrier coating or waterproofing membrane on concrete surfaces

Applying a coating or waterproofing membrane on the concrete surface, as shown in (c) of Table 1, is an
effective means to reduce moisture and chloride ion penetration into concrete, thereby minimizing corrosion
of the embedded reinforcement. There are different types of commercially available membranes, ranging from
the commonly used polyurethane to polyurea and other systems such as a composite systems that uses an
epoxy top coat with a polyurethane main coat (ACI 546.3R). These products should be selected with input
from licensed design professionals and the material manufacturers. Appropriate maintenance of these barrier
systems is required to prevent the penetration and accumulation of water in damaged areas.

3. Protective coating on the exposed surfaces of the reinforcement

Zinc-enriched coating, epoxy (ACI 364.3T), and cementitious products are commonly used coatings that can
be applied over the reinforcing bars or tendons, as shown in (d) of Table 1. The coating forms a barrier, stop-
ping the chloride ions, moisture, and oxygen from reaching the steel and isolates the steel electrically from the
surrounding concrete, thereby reducing the corrosion potential.

American Concrete Institute – Copyrighted © Material – www.concrete.org

 REPAIRS FOR REINFORCEMENT WITH SHALLOW COVER (ACI 364.13T-15)
Table 1—Different corrosion protection options
(a) Insufficient concrete cover
(b) Corrosion inhibitor
(c) Protective barrier (coating or waterproofing
membrane)
(d) Protective coating applied on the reinforce-
ment
(e) Increasing the concrete cover thickness
(f) Repositioning of the reinforcement
(discrete anode connected to the reinforcement)
(distributed anode embedded within the cover
and connected to the reinforcement)
(g) Galvanic cathodic protection with
embedded anodes
American Concrete Institute – Copyrighted © Material – www.concrete.org
3
This shows the condition where the concrete cover is less than required to provide
adequate protection from the environment, such as chlorides and carbon dioxide
(carbonation). The various methods listed in the following may be used singularly or
in combination, depending on how aggressive the corrosive environment is.
Inhibitors protect the bar from corrosion. Costs are generally relatively low as
compared to most alternative methods listed in the following. Most often, corrosion
inhibitors are used as admixtures added to the repair material(s). Migrating corrosion
inhibitors can also be applied directly onto the concrete surface to be protected.
Coatings and membranes are effective in eliminating chloride penetration. Special
coating systems are required to prevent carbonation of concrete. Consult with coating
manufacturers for specific installation recommendations and surface preparation
requirements.
Bar coatings protect the coated section of the bar directly from chlorides and mois-
ture. Surface condition of the bar shall conform to the requirements stipulated by the
coating manufacturer.
Increasing the repair layer thickness is a simple and effective way to add cover. Review
aesthetic considerations as well as headroom, egress, and drainage effects if this
method is considered.
Remove and relocate existing bars to code required depth within the repair. This
method is very expensive if relocation of bars involves doweling into existing concrete.
Embedded galvanic anodes are either of discrete or distributed types. Discrete galvanic
anodes are used in concrete rehabilitation to prevent the formation of new corrosion
sites adjacent to completed surface repairs (known as the ring anode, incipient anode,
or halo effect). The discrete anode consists of a sacrificial zinc core that is activated by
the surrounding, specially formulated, mortar to keep the zinc active. Discrete anodes
are quickly and easily fastened to the exposed reinforcing steel, usually using metal
ties. Distributed galvanic anode systems are installed to provide galvanic cathodic
protection over a large area and typically consist of specially configured zinc mesh or
rods designed to prevent passivation when embedded in the recommended concrete
or mortar. Once installed, the zinc core of both discrete and distributed galvanic
anodes corrodes preferentially to the surrounding reinforcing steel, thereby providing
galvanic corrosion prevention to the adjacent reinforcing steel.
4 REPAIRS FOR REINFORCEMENT WITH SHALLOW COVER (ACI 364.13T-15)

Another method for galvanic cathodic protection of reinforcing steel in concrete uses
zinc metallizing. After sandblasting the concrete surface, the zinc is flame- or arc-
sprayed over the surface to be protected. The zinc is connected to the steel either
through surface plates that are in contact with embedded steel, or spalled concrete is
removed and zinc is sprayed directly onto the steel (ACI 362.1R).

(h) Galvanic cathodic protection with superfi-

cial anodes connected to the reinforcement
(i) Impressed current cathodic protection
Impressed current cathodic protection systems (ICCPs) consist of inert or sacrificial
anodes positioned near (but not in electrical contact) to the reinforcing steel that
are powered by an external DC electrical source and embedded in a material that is
conductive to ions. The reinforcing steel to be protected is electrically connected as
the cathode. ICCP, if properly designed, installed, monitored, and maintained, can
prevent and mitigate corrosion of reinforcing steel. Electrical continuity between all
reinforcing steel and metallic embedment is necessary for cathodic protection to
be effective. Other metals in concrete shall receive additional attention. A corrosion
monitoring system should be provided for the reinforced concrete structure to allow
an estimate of the extent or degree of corrosion activity on the structure as well as to
determine the effectiveness of the corrosion control method used.

Advantages of using a protective barrier coating include:

a) It provides additional equivalent cover to trouble spots. Equivalent cover corresponds to the actual
concrete cover thickness that would provide the same level of protection.

b) It provides another layer of protection to the steel if cracks develop in the repair material. Popovic (1998)
reported that some protection can be provided even with partially coated bars.

c) It provides additional resistance to the ingress of oxygen, moisture, and chlorides to the surface of the rein-
forcing steel. Such additional protection is critical in situations where thin concrete cover over the reinforce-
ment cannot be avoided.

Disadvantages of using a protective barrier coating may include:

a) The application of some protective barrier coatings on reinforcing steel requires a certain amount of time
(application in layers, drying period after each layer). Besides, many materials, especially those containing
epoxy, have a finite open time beyond which they reduce bond or even become bond breakers.

b) Because it is difficult to coat the entire bar, the effectiveness of the coating may be limited or, at times, its
use can be detrimental.

4. Increased or modified concrete cover

Increasing the concrete cover ((e) of Table 1) is one of the most cost-effective methods to protect embedded
reinforcement against steel corrosion. Alternatives to increasing the repair concrete layer thickness include the
use of higher-quality concrete with a low permeability and repositioning the reinforcing bars or tendons into the
concrete element, as shown in the latter case in (f) of Table 1. Any repositioning of reinforcement should involve
an engineering evaluation. For larger areas, a concrete overlay with the added cover can be used.

Depending on the extent and detailing of exposed reinforcing bars, it may not be feasible to reposition the bars
to achieve the specified concrete cover. Increasing concrete cover could be unacceptable because of the surface
discontinuity that may result in more than one location, which could be aesthetically unacceptable as well as
creating potential tripping hazards. To avoid ponding in floor slabs, the impact to the overall drainage profile
should also be evaluated before concrete cover is increased locally.

5. Use of galvanic cathodic protection for reinforcement

There are different forms of galvanic cathodic protection. A commonly used system is sacrificial anodes that
are positioned and tied to the reinforcing bars, as shown in (g) of Table 1. A sacrificial anode may also be spray-
applied on the concrete surface, as shown in (h) of Table 1. By connecting steel to a sacrificial metal that is more
electro-negative, corrosion is directed away from the reinforcing bars to the sacrificial anode (NACE 01105).

There are a number of products available on the market, and supplier’s installation recommendations should
be followed.

American Concrete Institute – Copyrighted © Material – www.concrete.org

 REPAIRS FOR REINFORCEMENT WITH SHALLOW COVER (ACI 364.13T-15) 5

6. Use of impressed current cathodic protection (ICCP) for reinforcement

This method, illustrated in (i) of Table 1, involves actively applying electric current to counteract the current
of the corrosion cell. This method can effectively combat active steel corrosion in a reinforced concrete struc-
ture, depending on the design, installation, monitoring, and maintenance of the system. The total installation
and operating costs for such systems are relatively high because the applied electric current will need to be
maintained as long as the protection is be assured and, thus, are most generally used in structures with a very
sensitive or critical operational role. The ICCP method should not be used for prestressed concrete construc-
tion because of the potential for hydrogen embrittlement in the prestressing steel.

Summary
The level of corrosion protection should be designed to match the aggressiveness of the environment where
the structure is located and level of existing deterioration. As a general rule, at least two methods should be
considered in shallow cover repair situations. Additional protection can be added as the situation demands.
For example, protection for a parking structure repair in a northern climate would often include protective
method options 1, 2, and 3. If more protection is required, option 5 can also be considered. As expected, costs
will increase with the number of protective methods used. By the same token, the anticipated service life of
the repair also would increases with the number of protection strategies effectively implemented. If costs for
surface repair and protection escalate, alternate repair or replacement schemes, such as removal of the entire
surface and replacement with a complete overlay, can be considered.

References
ACI Committee documents and documents published by other organizations are listed first by document
number and year of publication followed by authored documents listed alphabetically.

American Concrete Institute

ACI 362.1R-12—Guide for the Design of Durable Parking Structures
ACI 364.3T-15—Treatment of Exposed Epoxy-Coated Reinforcement in Repair
ACI 546R-14—Guide to Concrete Repair
ACI 546.3R-14—Guide to Materials Selection for Concrete Repair
ACI 562-13—Code Requirements for Evaluation, Repair, and Rehabilitation of Concrete Buildings and Commentary

European Federation of Corrosion Publications

EFC 38-2006—Corrosion of Reinforcement in Concrete – Mechanisms, Monitoring, Inhibitors and Rehabilita-
tion Techniques

NACE International
NACE 01105-2005—Sacrificial Cathodic Protection of Reinforced Concrete Elements – A State-of-the Art-Report
NACE SP0187-2008—Design Considerations for Corrosion Control of Reinforcing Steel in Concrete

Authored documents
Popovic, P. L., 1998, “Durable Repairs for Corrosion Damaged Concrete,” International Concrete Repair Work-
shop, Houston, TX, Mar.

American Concrete Institute – Copyrighted © Material – www.concrete.org

6 REPAIRS FOR REINFORCEMENT WITH SHALLOW COVER (ACI 364.13T-15)

Reported by ACI Committee 364

David A. VanOcker, Chair Marjorie M. Lynch, Secretary

Randal M. Beard Kal R. Hindo Alexander M. Vaysburd

Benoit Bissonnette Charles J. Hookham James Warner
Christopher D. Brown Ashok M. Kakade David W. Whitmore
Ryan Alexander Carris Keith E. Kesner
Larry D. Church Erick N. Larson
Bruce A. Collins John S. Lund Consulting Members
Boris Dragunsky Pritpal S. Mangat Robert V. Gevecker
Paul E. Gaudette Surendra K. Manjrekar Stephen A. Johanson
Timothy R. W. Gillespie James E. McDonald Emory L. Kemp
Fred R. Goodwin Jay H. Paul Howard H. Newlon Jr.
Zareth B. Gregorian Murat B. Seyidoglu Weilan Song
Pawan R. Gupta K. Nam Shiu Dela Tharmabala
John L. Hausfeld Thomas E. Spencer Robert Tracy
Robert L. Henry Valery Tokar William F. Wescott

ACI TechNotes are intended for reference for the design and construction of concrete structures. This document is intended for the use of
individuals who are competent to evaluate the significance and limitations of its content and who will accept responsibility for the appli-
cation of the information it contains. The American Concrete Institute disclaims any and all responsibility for the accuracy of the content
and shall not be liable for any loss or damage arising therefrom. Reference to this document shall not be made in contract documents.

ACI 364.13T-15 was adopted and published October 2015.

Copyright © 2015, American Concrete Institute.

All rights reserved including the rights of reproduction and use in any form or by any means, including the making of copies by any photo
process, or by electronic or mechanical device, printed, written, or oral, or recording for sound or visual reproduction or for use in any
knowledge or retrieval system or device, unless permission in writing is obtained from the copyright proprietors.

For additional copies, please contact:

American Concrete Institute, 38800 Country Club Drive, Farmington Hills, MI 48331
Phone: +1.248.848.3700, Fax: +1.248.848.3701
www.concrete.org
American Concrete Institute – Copyrighted © Material – www.concrete.org