Professional Documents
Culture Documents
discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/248536786
CITATIONS
READS
53
54
3 AUTHORS, INCLUDING:
Zuhua Zhang
Xiao Yao
SEE PROFILE
SEE PROFILE
(This is a sample cover image for this issue. The actual cover is not yet available at this time.)
Faculty of Engineering and Surveying, University of Southern Queensland, Toowoomba, QLD, 4350, Australia
College of Materials Science and Engineering, Nanjing University of Technology, Nanjing, 210009, China
a r t i c l e
i n f o
Article history:
Received 19 May 2011
Received in revised form 27 April 2012
Accepted 26 May 2012
Available online xxxx
Keywords:
Marine concrete
Geopolymer
Coating
Field experiment
Integrity
a b s t r a c t
Previous studies have shown a high potential of using geopolymers as new inorganic coatings in protecting
marine concrete. This article reports the results of the experiment on eld application. Geopolymer coatings
were in-situ applied on the surfaces of concrete accropodes along the coast. It was observed that the geopolymer coatings set within 4 hours, bound strongly with concrete and were able to resist the wave shock
in the rst tide rise. There was a modicum of calcite detected by X-ray diffraction (XRD) but no sulphate
was found in the coatings within 6 months. One issue raised during in-situ application is the large shrinkage
of the geopolymer paste under ambient condition. Micro-cracks on the surfaces were observed after 7 days
although the MgO-based expansion agent and polypropylene (PP) bers were added to withstand the shrinkage. The humidity of the atmosphere and the thickness of the coating layer are the two signicant factors affecting the integrity of coatings. It was noted that the coating with a thickness of 5 mm at the tidal area,
where contact with seawater periodically, exhibited the best integrity. To solve the problem of large shrinkage, it is recommended to use suitable aggregates in coating paste and to develop appropriate shrinkage reducing agents together with careful curing procedures.
2012 Elsevier B.V. All rights reserved.
1. Introduction
The concrete structures exposed to aggressive marine environment, especially the steel reinforced structures, readily deteriorate
with time. This is because the cement hydration products and the
reinforced steel bar in concrete react quickly with aggressive
mediums. The mechanisms are mainly due to the carbonation of the
cement hydration products Ca(OH)2 in wet environment with the
presence of Cl , Mg 2+ and SO42 ions. The carbonation products
CaCO3 may block the capillary pores at the beginning; however, it
can be further dissolved when contacting with water. Consequently,
the pores allow more corrosive ions to move in and meanwhile the
decreased alkalinity of cement matrix due to the loss of Ca(OH)2 further increases the potential of chloride corrosion. Chloride ion is one
of most dangerous ions for the reinforced concrete. It acts as a catalyst
to destroy the passive layer on steel and leads to a continuous corrosion once the pH of the pore water in concrete decreases to a critical
level. Besides, the reactions between the magnesium and sulfate ions
with the cement hydration products form expansive products and
further cause micro-cracks, which become the ingression channels
could be controlled by using MgO-based expansion agent and polypropylene (PP) bers. However, since the experiments were performed at
the laboratory condition (Relative humidity= 90 5%, 20 2 C), it
was difcult to conclude that the investigated geopolymer systems
were capable of providing a sustainable anticorrosion coating for concretes exposed to natural marine environment. The primary purpose
of this technical paper is to update the research progress and to report
the results from the eld experiment.
2. Experimental programs
2.1. Field location
The eld experiment was performed on Shanghai Jinshan coast
(Hangzhou Bay, N30.705239, E121.334724). The large temperature
change between summer (up to 38 C) and winter (low to 10 C)
is the reason to select this location for examining the weatherability
of the coating. The eld experiment started from 20th August 2010
(middle of summer) and the observation lasted for 6 months till
20th February 2011 (middle of winter). During this period, the observed temperature varied from 38 C (highest in summer) to 4 C
(lowest in winter). A longer observation will be performed after this
stage when more eld information is obtained and taken into consideration of geopolymer formulation and coating procedures.
Three accropodes on the coast were chosen as the concrete substrates. The concrete accropodes are placed in the tide zone to absorb
the wave energy, therefore to reduce the impact of wave on seawall
(Fig. 1(a)). The deterioration of accropods is very fast. Fig. 1(b)
shows the damaged accropods after being in service for only
6 years. Fig. 1(c) shows the characteristics of the three selected surfaces (denoted as SI, SII and SIII respectively): SI does not contact
with seawater while SII and SIII are immersed in seawater periodically.
The difference is that SII is back to the wave shock while SIII is face to
the wave shock.
SI: dry
Fig. 1. Field experiment location (a), the deteriorated accropodes (b), and the surfaces
to be coated (c).
Table 1
Composition of geopolymer coating.
mass%
Metakaolin
Slag
Activator
PP ber
MgO
42.97
7.52
47.17
0.39
0.95
59
carried out. The sampling and testing procedures for XRD were described elsewhere (Zhang et al., 2010b).
PP fibres
Geopolymer
coating
Concrete
substrate
Fig. 3. Geopolymer coating forcedly broken off with cement substrate bound together.
The cracked chips are linked by PP bres.
b
24 h
180 d
24 h
180 d
10 mm
d
24 h
180 d
10 mm
24 h
180 d
10 mm
Fig. 2. Geopolymer coatings solidied for 24 h and aged 180 d: a whole view on accropods (a); cracks to micro-cracks appeared on coating surfaces on SI (b), SII (c) and SIII (d).
Arrows point to micro-cracks.
-Quartz
kaolinite
calcite
180 d
4. Summary
28 d
10
20
30
40
50
60
70
80
2-theta (degree)
Fig. 4. XRD patterns of the geopolymer coating on SIII at ages of 28 d and 180 d.