The Use of Zinc Anodes to Extend the Life of Concrete Patch Repair Jack Bennett J.E. Bennett Consultants, Inc.

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Presentation transcript:

The Use of Zinc Anodes to Extend the Life of Concrete Patch Repair Jack Bennett J.E. Bennett Consultants, Inc.

CONCRETE The Ideal Environment For Steel Steel Passivated in Concrete By Film of - Fe 2 O 3 (Gamma Ferric Oxide)

Corrosion Rate of Steel vs. pH pH ~ 10 mils/yr. pH < 0.1 mils/yr. pH 14 >.2-.5 mils/yr. NO PROBLEM ? ? ?

SALT ! Destroys passivity of steel in concrete. Corrosion 1.1 lb Cl - /yd 3 (0.04%). Expansion due to rust causes cracks. Only 2 mils of corrosion needed to cause crack. Once contaminated, corrosion is never ending.

New Construction 1. High quality concrete. 2. Increased cover. 3. Surface sealers. 4. Waterproof membranes. 5. Coated reinforcing steel. 6. Specialty concretes. 7. Corrosion inhibiting admixture. 8. Improved construction products.

Existing Structures in Trouble REPAIR A Never-Ending Process

Conventional Patch Repair

Existing Structures in Trouble 1. Chloride Removal Effective, but Complex and Expensive. 2. Cathodic Protection Impressed Current Cathodic Protection (ICCP) Now Used on About 15 Million Square Feet Worldwide.

ICCP Does Work ! But issues of complexity, reliability, monitoring and maintenance still cause concern. FHWA encouraged development and application of Galvanic Cathodic Protection (GCP) beginning in 1993.

Zinc Anodes Used to Extend the Life of Concrete Patch Repairs 1.Simple to Install. 2.No Power Supply Needed. 3.No Wiring or Conduit. 4.No Long-Term Monitoring or Maintenance.

Conventional Patch Repair

Embedded Zinc Anode for Patch Repair

Anode Trial on PA SR 220, Lock Haven, PA Bridge Deck, Structure S Expansion Joint Repair. 4 Anodes, Type “S.” 4 Anodes, Type “C.” Installed by Penn DOT July 6, 2009.

PA DOT SR 220 Bridge

Measuring Current

Protective Current on PA SR 220 Anode Type S Anode9/15/0910/6/095/20/109/24/ mA0.73 mA0.98 mA0.76 mA mA0.65 mA0.99 mA0.85 mA mA0.68 mA0.89 mA0.80 mA mA0.71 mA1.06 mA0.85 mA Avg.0.80 mA0.69 mA0.98 mA0.81 mA

Protective Current on PA SR 220 DateAverage, 4 Type S Anodes Average, 4 Type C Anodes Sept. 15, mA0.69 mA Oct. 6, mA0.27 mA May 20, mA0.40 mA July 13, mA0.34 mA Sept. 24, mA0.36 mA Average0.84 mA0.41 mA

Measuring Steel Potential

4-hr Potential Shift on PA SR 220

Polarization on PA SR 220 Anode Type S Test Pt.Polarization 10/6/09 Polarization 5/20/10 Polarization 9/24/10 1. (2”)104 mV150 mV136 mV 2. (8”)70 mV136 mV119 mV 3. (2”)95 mV164 mV140 mV 4. (8”)60 mV117 mV106 mV Avg.82 mV142 mV125 mV

Polarization on PA SR /6/095/20/109/24/10Average Type S Anodes, 2” from Patch 100 mV157 mV138 mV132 mV Type S Anodes, 8” from Patch 65 mV127 mV113 mV102 mV Type C Anodes, 2” from Patch 12 mV1 mV17 mV10 mV Type C Anodes, 8” from Patch 18 mV-1 mV20 mV12 mV

CONCLUSIONS 1.Corrosion can be mitigated by galvanic cathodic protection (CP). 2.Zinc anodes can be effectively used to provide CP in reinforced concrete. 3.Results from tests on a PA bridge show some zinc anodes provide excellent protective current and steel polarization.

The author thanks Penn DOT for installation and monitoring of the SR 220 anode trial.