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CHAPTER - 8
8.2 Selection and coating for steel: The metallurgists and electrochemical
engineers have developed several methods for protection of steel from
corrosion in concrete. The most commonly known systems of protection of
steel from corrosion in concrete are :
Manufacturer Product
These bars have dual micro structures i.e. the surface layer is tempered
martensite while the inner shell is ductile ferrite-pearlite. To increase
corrosion resistance of these bars certain elements like nickel, chromium,
copper and phosphorus are also added. These bars form a protective layers
DURABILITY OF CONCRETE STRUCTURES
on the surface when they come in contact with atmospheric oxygen and
moisture. This layer is formed over a period of time. In concrete oxygen is
not available. Hence, the protective coating may not form when such bars
are used as reinforcement in concrete. Obviously, there appears to be no
advantage in using such bars in place of mild steel. Even, when exposed to
atmosphere in marine environment the chlorides present in the air break the
protective layer thereby reducing corrosion resistance. Therefore, in marine
atmosphere these bars do not give good resistance to corrosion as in normal
atmosphere. Secondly, their chemical composition is such that it may lead to
pitting corrosion which is highly undesirable. In mild steel bars conforming to
IS:1786, although is less corrosion resistance, but corrosion occurs all over
the surface without pitting.
Merits
Demerits:
8.2.3.1 This is a new method developed by CECRI. This system has been
developed to overcome demerits of inhibited cement slurry coating system.
DURABILITY OF CONCRETE STRUCTURES
8.2.3.2 This system consists application of one coat of rapid setting primer
followed by a coat of cement polymer sealing product. The primer and
sealing products have thermoplastic acrylic resin as basic raw material.
Sealing product is formulated with resin mixed with cement as a pigments.
Rapid setting primer and sealing coats both are patented item. This system
has been developed mainly as a factory / shop process. The approach
behind development of this system is that the base metal of rebars, contains π
electrons which get readily released in corrosive environment leading to
oxidation of iron and thereby formation of Fe 2O3 (rust) as principal deterrent.
In order to prevent this oxidation a surface coating capable of
interacting/nullifying the released electrons is provided. Further prestressing
and reinforcing steel, in concrete during service life, are exposed to an
alkaline environment and this necessitates introductions of a top coat which
should be compatible to primer and alkaline environment. To meet these two
contingencies, suitable polymers are carefully tailored through the formation
of a single phase in the polyblend which provides the necessary mechanical
and physical properties.
Merits :
Demerits :
• This system is newly developed system and the long term results
are not known.
8.2.3.5 Performance : This system is now being used on three fly over
bridges in Mumbai at Goregaon, Andheri and Mankhurd. As the system is a
newly developed system, hence field performance is not known. However
laboratory performance of the system, as reported by CECRI, is very good.
The system has passed bondability test, chemical resistance test, salt spray
test, impressed voltage test and abrasion resistance test as per test
procedure described in ASTM A77/775M-94. From structural point of view,
the coated bars have shown greater bond strength as compared to uncoated
bars.. This coating is superior to old CECRI coating and can be used
effectively in marine structures in future.
8.2.4.3 Inspection and testing : Fusion Bonded Epoxy Coated Rebars are
tested at the coating plant to the codal requirements as specified in IS:13620-
1993. On line and off line holiday checks, thickness checks are carried out.
The adhesion of the coated bars are also tested frequently by bending of the
bar. Beside this, various other tests are performed in laboratory like chemical
resistance, short spray, resistance in continuance boiling water, abrasion
resistance and impact resistance etc. These are conducted on every batch
of production.
Merits :
Demerits :
8.2.4.6 Performance:
iv The cleaned rebars are the fluxed to protect from surface
degradation. This is achieved by dipping the rebars in zinc
ammonium chloride solution and thoroughly dried.
v Then the rebars are immersed in a bath of molten zinc (98.5%pure)
at specified temperature of about 45 0C.
vi The time of immersion which is variable with the size and chemical
composition of rebars should be such that the thickness of coating
achieved should be at least 610 gm/m 2 (84 micron)
vii Then the rebars are air dried completely to be ready for use.
Merits:
Demerits:
• If galvanized bars are mixed with ungalvanized bars for use in the
same structure, accelerated depletion of the galvanizing occurs.
• Electrochemical treatment to galvanized bar is fraught with danger
as it can result in severe pitting due to formation of galvanic cells.
• It is not suitable for protection against chloride attack.
8.2.5.4 Performance :
Merits :
Demerits:
8.2.7 Truncated inhibited cement slurry coating for dry climate as used
for Konkan Railway bridges and structures: In dry climate, it is not
necessary to use the full CECRI system. The following procedure was
adopted in Konkan Railway for structures away from coastal area.
8.3 Coatings for concrete : The protective surface coating, as the name
implies, protects the concrete surface from aggressive chemical attack.
Surface coating of the concrete reduces the ingress of oxygen, water gases
and chemicals present in the industrial and other aggressive environment. So
surface coating for concrete is an effective method of protecting life of
reinforcement steel. The coating on concrete should be breathing type.
DURABILITY OF CONCRETE STRUCTURES
8.3.1.3 The Vicat softening point, the indicator of thermal stability of polymer
system is much higher in IPN polymer system. It has low moisture vapour
transmission and excellent adhesion with substrate. The coefficient of thermal
expansion of the IPN polymer film is nearly equal to that of concrete
signifying non development of thermal stresses in concrete and coating.
8.3.3 Epoxy coating: They are well proven for concrete surfaces. When
formulated with liquid epoxy resin, liquid curing agents and highly penetrating
solvents, they give good performance. They are classified as under:
8.3.4 Coaltar epoxy: They have both properties of coaltar and epoxy.
They have good adhesion to concrete and chemical resistance. They are
applied by roller, conventional means or by airless spray. They are applied in
two coats having total thickness of 15 to 20 microns. These have been used
in 1987 to 1991 in Thane Creek Rly. bridge on the piers in the tidal & splash
zones. The coatings are intact as seen in 1998. This is the cheapest and best
coating for substructure and coating over liner plates provided in the tidal &
splash zones.
• No coating is necessary.
• Good dense cover-concrete with good cement content with low w/c
and extra depth of cover is enough,
• Use blended cement to make the concrete impermeable
• Use clean reinforcing bars.