Basic Corrosion and Cathodic Protection for Steel-Reinforced Concrete Structures

Jeff Schramuk
NACE CP Specialist #7695 www.cpsolutionsinc.net

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
2

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
3

As a Nation, How do We Manage our Highway Bridges?

Present Condition: The U.S. earns a grade of C for maintenance of the nations nearly 600,000 highway bridges, and The Future Dilemma: The U.S. faces a shortfall of $9.4 billion per year over the next 20 years to eliminate all bridge deficiencies.
*Source: 2005 Report Card for America's Infrastructure. ASCE: Reston, VA. 4

Concrete Footing Deterioration

Column Deterioration

Beam Deterioration

Ceiling Deterioration

Parapet Wall Deterioration

Hanging Concrete Delamination

10

Leaking Expansion Joint & Patch Repairs

11

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
12

Corrosion Can be Defined as:

Practical Definition Scientific Definition

The Tendency of a Metal to Revert to its Native State Electrochemical Degradation of Metal as a Result of a Reaction with its Environment
13

Four Basic Components of A Corrosion Cell

Anode A metal electrode in contact with the electrolyte which corrodes Cathode - A metal electrode in contact with the electrolyte which is protected against corrosion Electrolyte A solution or conducting medium such as soil, water or concrete which contains oxygen and dissolved chemicals Metal Path An external circuit that connects the anode and the cathode
14

Electron Flow vs. Conventional Current

Flow of conventional current is from positive (+) to negative (-) Conventional current flow from (+) to (-) will be from the cathode to the anode in the metal path Conventional current flow from (+) to (-) will be from the anode to the cathode in the electrolyte.

15

Definitions - Anodes & Cathodes

Cathodic Area (Protected)

DC Current

Anodic Area (Metal Loss)

16

Components of a Familiar Corrosion Cell

CARBON ROD (Cathode) ZINC CASE (Anode) NH4 and Cl- Paste (Electrolyte) I I I I WIRE (Metallic Path) I e17

Practical Galvanic Series* Material

Pure Magnesium Magnesium Alloy Zinc Aluminum Alloy Mild Steel (New) Mild Steel (Old) Cast / Ductile Iron Stainless Steel Copper, Brass, Bronze Gold Carbon, Graphite, Coke
Less Active More

Potential*
-1.75 -1.60 -1.10 -1.00 -0.70 -0.50 -0.50 -0.50 to + 0.10 -0.20 +0.20 +0.40

* Potentials in Volts Versus a Saturated Cu-CuSO4 Electrode

18

Eliminating the Corrosion Cell

Cathode

Anode

19

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
20

General Corrosion
Corrosive environment is uniform around the structure
Anode area is uniformly distributed over the structure Corrosion rate is usually constant over the structure

Environments where uniform attack can occur

Atmospheric, Aqueous, Concrete

21

True Uniform Corrosive Attack

22

Galvanic Corrosion

When two different metals are connected and placed into a corrosive environment. Corrosion current is proportional to the difference in electrochemical energy between the two metals Area Effect
Avoid small anode connected to a large cathode

Distance Effect
Area closest to anode will have the greatest corrosion
23

Practical Galvanic Series* Material

Pure Magnesium Magnesium Alloy Zinc Aluminum Alloy Mild Steel (New) Mild Steel (Old) Cast / Ductile Iron Stainless Steel Copper, Brass, Bronze Gold Carbon, Graphite, Coke
Less Active More

Potential*
-1.75 -1.60 -1.10 -1.00 -0.70 -0.50 -0.50 -0.50 to + 0.10 -0.20 +0.20 +0.40

* Potentials in Volts Versus a Saturated Cu-CuSO4 Electrode

24

Galvanic Corrosion Bimetallic Connection

25

Old-New Pipe Corrosion Cell

Old Pipe (Cathode)

New Pipe (Anode)

26

Dissimilar Surface Conditions

Pipe (Cathode)

Threads Bright Metal (Anode)

Scratches (Anode)

27

Corrosion of Steel Rebar in Concrete

Concrete is an alkaline environment that passivates the steel and protects it from corrosion Deicing salts will accelerate the corrosion rate by reducing the alkalinity of the concrete Rebar corrosion (rust) has a volume 2.2 times as great as the original steel that can lead to a spall The spall delaminates the concrete and allows additional corrosion to occur on the steel rebar
28

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
29

Pitting of Coated Carbon Steel in Soil

30

Pitting at a Coating Defect

31

Coating Defects on Epoxy Coated Rebar

32

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
33

How Cathodic Protection Works

Corrosion occurs where current discharges from metal to electrolyte The objective of cathodic protection is to force the entire surface to be cathodic to the environment.

34

Galvanic Anode Cathodic Protection

Current is obtained from a metal of a higher energy level.

35

Practical Galvanic Series* Material

Pure Magnesium Magnesium Alloy Zinc Aluminum Alloy Mild Steel (New) Mild Steel (Old) Cast / Ductile Iron Stainless Steel Copper, Brass, Bronze Gold Carbon, Graphite, Coke
Less Active More

Potential*
-1.75 -1.60 -1.10 -1.00 -0.70 -0.50 -0.50 -0.50 to + 0.10 -0.20 +0.20 +0.40

* Potentials in Volts Versus a Saturated Cu-CuSO4 Electrode

36

Galvanic Corrosion No C.P. Benefit

1. Anode
Copper -200mV

3. Electrolyte 4. Metal Path

Magnesium -1.7V

2. Cathode

Steel -600mV

37

Galvanic Corrosion - Mitigated w/CP

1. Anode
Cathode

3. Electrolyte 4. Metal Path

Cathode

Anode

2. Cathode

38

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
39

Galvanic Anode CP Systems - Advantages

No external AC power is required Simple to install on new structures Seldom causes stray DC interference Minimal maintenance requirements.

40

Galvanic Anode CP Systems - Limitations

Limited driving potential Limited current output

E = (Ea Ec) I = E / Rt

Large number of anodes will be required on large mats of bare reinforcing steel

41

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
42

CP for Rebar Must be Electrically Continuous

43

Scarified & Patched Deck Awaits Anode Mesh

44

Rolling Out the Anode Mesh on the Bridge Deck

45

Drilling Holes for Anode Hold-Down Clips

46

Cutting Back Anode Mesh at Expansion Joint

47

Anode Conductor (Current Distributor) Bar

Question! Why the Double Conductor Bar?

48

Rectifier Automatic Controllers

49

Anode & Structure Connections

50

Reference Electrode and Ground Connections

51

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
52

Test Equipment Quality Assurance

Perform pre-test operational checks in accordance with the manufacturer instructions Verify battery strength (if required) Initiate corrective action for equipment out of specification Have the equipment calibrated annually
53

CP Test Equipment - Multi-Meters

54

Multi-Meter Characteristics

Basic Functions
Reads AC & DC Volts Reads Ohms (optional diode checker) Reads AC and DC Amps (be careful here!)

Performance Criteria
Field rugged, water/drop resistant High input impedance (min. 20 M-)
55

Meter Connections

56

Potential Measurements

Connect voltmeter to rebar and reference Ensure reference cell plug has good contact with damp pavement (use wet sponge, if necessary) Place reference cell away from anodes Read potential on DCV scale Record reading using standard forms If polarity is positive, verify proper connections
57

Reference Electrode Basic Components

58

Reference Electrode Ensuring Accuracy

59

Reference Cell Placement

60

Current Flow & IR Drop Error

61

IR Drop in P/S Measurements

62

Reference Electrode - Maintenance

Periodically verify cell against a known standard Keep porous plug covered when not used Clean and refill the reference cell annually
Clean copper rod with emery cloth Replace w/fresh Cu/CuSO4 solution ( full at all times) Some Cu/CuSO4 crystals should always remain in suspension Wash hands after using Cu/CuSO4 solution is hazardous
63

Topics to be Covered

Why Should We Be Concerned about Corrosion? Definitions and Terminology Some Forms of Corrosion Coatings and Cathodic Protection Cathodic Protection using Magnesium Anodes Advantages & Limitations of Galvanic Anode CP Systems Impressed Current Cathodic Protection Field Test Equipment Cathodic Protection Criteria.
64

CP Criteria for Steel in Concrete

Example of the 100 mV polarization decay criterion:

ON Potential = -650 mV I-O Potential = -500 mV The Static (Off) Potential must be -400 mV or less after no more than 4 hours
65

CP Performance - Can Be Verified

66

Questions?
Jeff Schramuk
NACE CP Specialist #7695 www.cpsolutionsinc.net

67