REPAIR OF CORROSION AFFECTED

REINFORCED CONCRETE
STRUCTURES

PRESENTED BY:
RASHMI R
 WHAT IS
CORROSION?

The process of formation of rust over the

surface of reinforcing bar and resulting in the
lowering strength of steel is known as corrosion.
CORROSION PROCESS:

•In order to understand the mechanism behind corrosion of

reinforcing steel in concrete, one has to know about the chemical
reactions involved in it.
•It is widely accepted that, at the early age of the concert, this
high alkalinity results in the transformation of a surface layer.

•When a concrete structure is often exposed to atmosphere,

chloride ions from cement paste these will slowly penetrate
into the concrete, mostly through the pores in the hydrated
cement paste.
 Occur of Corrosion

Once corrosion sets in on the reinforcing steel bars, it proceeds

in electrochemical metal, cells formed on the surface of the
metal and or solution surrounding the each cell is consists of a
pair of electrodes.
 Corrosion: Structural effects:
In the case of concrete structures the first direct effect of the
reinforcement corrosion is its section decreases due to the
corroding process.

Corrosion also may reduce the steel elongation at

maximum load, affection the structure.

Accordingly, reduction of structural capacity of

reinforced concrete elements affected by rebar corrosion.
 Induced Cracking Of
Concrete

Three main phenomena, which are direct consequence

of corrosion
Reduction of rebar section due to corrosion.
• Reduction of bond strength.
•Loss of concrete integrity due to cover cracking and
spalling.
 Causes for failures
The following are the major causes for failures of structures
o Structural deficiency due to defects in construction, use of inferior and
substandard materials, poor workmanship, and negligence in quality
control and supervision.

oDamages caused due to fire, foods, earthquakes, etc.

oChemical deterioration and marine environments

oDamages caused due to abrasion, wear and tear impact, dampness, etc

oMovements of concrete caused due to settlements of foundation,

thermal expansion etc.
Sealing of cracks

For this, the cause of crack has to be determined. If the cause

of the crack is such that it is unlikely to recur, then it can be
filled with a rigid material. But, if the crack is caused due to
movement and is likely to continue then any attempt to seal the
crack against further movement may cause a new
crack along the side of the old one.

 Repair of cracks where no further movement is

expected

The procedure for carrying out this type of repair is as follows:

Step 1
The crack is thoroughly cleaned using compressed air.

Step 2
Superficial seal is applied over the crack at the surface by using a
fast setting polyester resin or a thermoplastic material into which
injection nipples are fixed at intervals.

Step 3
Injection is started at the lowest point and when resin reaches the
next higher point, the injection gun is moved up to the next and
the lower point is sealed. The process is continued until the whole
crack gets sealed.
 Repair of cracks where further movement is
expected
When a crack is subjected to continuing movement,
it is necessary to reduce the strain in it to reasonable amount.
This can be easily done by widening the crack at the surface and
sealing it with an elastic material, such as polysulphide rubber.

Stress Corrosion Cracking

CRACKING OCCURS IN PIPES
Repair of a severely corrosion damaged member, where cover
Concrete has spallen and reinforcement has been exposed.

Remove of all defective concrete and expose corroded

reinforcing bars to their full circumference

Remove the corrosion product from reinforcing bars until

they shine

Apply anti-corrosion protective priming coat to

protect reinforcing bars

Patch with repair mortar and resurface to required

thickness

Apply protective coating and follow up with

decorative painting
 Corrosion Inhibitors

Inhibitors are chemicals that react with a metallic surface,

or the environment this surface is exposed to, giving the
surface a certain level of protection.

Inhibitors slow corrosion processes by either

 Increasing the anodic or cathodic polarization behavior
(Tafel slopes);
 Reducing the movement or diffusion of ions to the metallic
surface;
 Increasing the electrical resistance of the metallic surface.
Corrosion Inhibitor
 Corrosion Resistance Steel
 Corrosion resistance of steel in Portland cement concrete
results from a passivating film of gamma ferric oxide. The
film is formed and maintained in an alkaline environment
produced by cement hydration; however, high
concentrations of chloride will cause corrosion if air
bubbles form on the steel surface
 Corrosion resistant steel
characteristics
 The new corrosion-resistant steel plate, which combines
several particular elements significantly reduces corrosion
to one fifth of the level seen with conventional materials.

 It shows excellent corrosion-resistance, even for general

corrosion*1 which occurs on rear side of the tank's upper
plate.

 It has the same weld ability and machining performance as

conventional steel plates used in the hull structure.

 It reduces maintenance work in dry dock, which is

conducted every two and a half year.
 Corrosion Resistant
Coatings
 Corrosion resistant coatings protect metal components against
degradation due to moisture, salt spray, oxidation or exposure to
a variety of environmental or industrial chemicals. Many of the
coatings listed below also provide a bonus of abrasion resistance,
non-stick performance and chemical protection.

There are 2 types of thermal spray coatings for corrosion

 Anodic Coatings
 Cathodic Coatings
Anodic Coatings
Anodic coatings for the protection of iron and steel
substrates are almost entirely limited to zinc and aluminum
coatings or their alloys.
Where coatings anodic to the substrate are applied, the
corrosion protection is referred to as cathodic protection or
sacrificial protection. The substrate is made to be the cathode
and the coating the sacrificial corroding anode.

 Cathodic or sacrificial protection

 A barrier to the environment
Cathodic Coatings
 Cathodic coatings are those which comprise a coating
metal which is cathodic with respect to the substrate. A
stainless steel or nickel alloy coating would be cathodic to
a steel base. Cathodic coatings can provide excellent
corrosion protection.

 If the substrate is exposed to the corrosive environment,

the substrate will become the anode and corrosion will be
dramatically accelerated resulting in spalling of the
coating.
Fig shows the structure where cover concrete has spallen and reinforcement has been
exposed.
Surface coatings

It is necessary

•After the completion of repair work, to treat both the repaired

areas and the rest of the structure with some coatings

• To reduce the permeability of concrete, to moisture, carbon

dioxide, and other aggressive agents.

• To give aesthetic look to the structure by coating the patches.

Fig shows the structures which are affected by corrosion.
 Cathodic Protection
 Cathodic protection is a highly adaptable and effective
means of preventing corrosion on a variety of underground
or underwater structures. There are basically two types of
systems: namely, galvanic and impressed current. Each has
characteristics which make it more adaptable under given
circumstances.

 Cathodic protection designs can differ considerably

depending upon the coating, the configuration of the
structure, the environment and the presence of neighboring
structures. When a system is designed, installed and
maintained properly, cathodic protection is one of the most
effective and economical methods of preventing corrosion.
 Cathodic protection can mitigate the
detrimental effects of metallic
infrastructure corrosion

Pre stressed Concrete Coated Steel Pipe Corrosion

Cylinder Pipe Corrosion
Reinforcing Steel in Concrete Corrosion Pit Cast Iron Pipe Corrosion
 Benefits of Applying Cathodic
Protection

 Reduction in the corrosion to the water infrastructure.

 Reduction in water main breaks.
 Reduction in non-metered water loss.
 Reduction in costs for emergency repairs.
 Increased water main service life.
 Increased level of reliable water service to customers.
 Increased health and security of the municipal water
supply.
 Conclusion

Although many repair materials have been introduced

in the construction industry in the recent past, careful
judgment should be exercised by the engineers, while
selecting them. The decision should be governed by
the results of the insitu testing carried out on the
corrosion affected or damaged structure.

“Maintenance is better than Repair”

 REFERENCES

 “Concrete technology” by M.S. Shetty

 “Properties of concrete” by Nevelli

Websites:
• www.ndt.net
• www.icivilengineer.com
• www.google.com