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MC-KKS/B - Corrosie.info · MC-KKS/B Exclusive Cooperation ... • Areas of application and...
Transcript of MC-KKS/B - Corrosie.info · MC-KKS/B Exclusive Cooperation ... • Areas of application and...
Durable Corrosion Protection of Chloride
Contaminated Concrete Structures with
MC-KKS/B
Exclusive Cooperation
• Introduction to the causes of the corrosion of the
concrete reinforcement and structure of the protection
system
• Application of
• Step-by-step explanation of the system‘s application
• Development of the system
• Areas of application and reference buildings
• Synopsis
Outline
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Steel corrosion
Solution 3: Principle K (Rili-SIB)
Ship sacrificial anodes
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Sir Humphry Davy
Concrete surface Connection
Cathodic corrosion protection with zinc
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reinforcement (cathode) concrete
Blasted concrete
surface
Blasted connection
Cathodic corrosion protection with zinc
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reinforcement (cathode) concrete
Zinc layer (anode)
Cathodic corrosion protection with zinc
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reinforcement (cathode) concrete
Cathodic corrosion protection with zinc
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Deckschicht
Time saving Cost saving
Maintenance-free No reduction of
headroom and bearing
load
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Maintenance concept (qualified planner)
Assessment of the actual state:
chloride analysis, potentials,…
+
Metal conductive through connection of the reinforcement
Confirmation of the applicability of
Application
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• Rehabilitation of cracks, hollow areas and
loose concrete areas
• Repair work on damaged steel
reinforcement
• Filling and reprofiling
Selective refinishing of damaged spots
Application
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Cemented and blasted connection
Welding of the connection
bolt
Insertion of connections
Application
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Description of the thermal spraying process
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- Flame spraying process since 1909
- Arc spraying process since 1911
- Since then mainly applied for the corrosion protection of steel
- Since the 1970s applied for reinforced concrete
Tensile bond test of zinc on concrete
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Test field in Helgoland
Test field in Duisburg
Online monitoring
Development of the system
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Environmental conditions
Helgoland
http://blog.bild-in-sicht.de/wp-content/uploads/2012/01/helgoland-sturm1.jpg
http://www.kuestenforum.de/showthread.php?t=2660
Development of the system
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Outdoor exposure Helgoland
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Outdoor exposure Helgoland
Development of the system
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Unprotected sample (after
13 years)
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Development of the system
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Structure of the samples
- CEM III/A 42,5
- 0 %, 1 % et 3 % chloride portion
- fly ash admixture
+ carbonated up to the reinforcement
=> high electric resistivity
- with and without zinc layer
(d = 250 µm)
Development of the system
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Current 0.1 mA/m² 1.0 mA/m² 2.0 mA/m² 5.0 mA/m²
Duration > 1000 years > 100 years 53 years 18 years
Assumption: 1,2 kg Zn/m²; charge: 780 Ah/kg Zn
Durability of galvanic anodes
=> Theoretical durability: more than 50 years!!!
780 Ah/kg x 1,2 kg/m² = 936 Ah/m²
Protective current: 2 mA/m²
936.000 mAh/m² / 2 mA/m² = 468.000 h
Development of the system
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Previously: manual floor application
Today: automated floor application: - Car parks in Erlangen (6500 m²), Frankfurt (two
test fields of 150 m² each), Schweinfurt (2500 m²), Blaubeuren (1500 m²), Hanover (2000 m²), Ludwigshafen (700 m²), Bielefeld (1000 m²)
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Development of the system
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- Cooperation with MC-Bauchemie
- Tests of various coating systems carried out
on real structures
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Development of the system
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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)
Car park Blaubeuren (1500 m²)
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Development of the system
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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)
„The average surface tensile strength amounts to
1.424 N/mm².“
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Development of the system
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(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)
„The average tensile bond strengths of the zinc layer before the
application of the primer amounted to 1.364 N/mm².“
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Development of the system
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„The primer leads to a significant increase of the surface bonding strength,
i.e. the surface quality of the concrete in the system of concrete/zinc/resin
was enhanced by in part more than 100 %,…“
(Source: Documentation Dr. Reul, Ingenieurbüro für Bauchemie, Illertissen)
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Red:
special primer
Development of the system
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Car park Blaubeuren (1500 m²)
Test field Date 100-mV Criterion Current Temperature
1 (car park
middle)
30.08.12 fulfilled after 45 min 56.3 mA 16.0 °C
2 (car park
end)
25.10.12 fulfilled after 50 min 36.5 mA 9.0 °C
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• Car parks
• Bridges and industrial constructions
• Offshore structures (dolphins, shipyards, dry docks, etc.)
• Foundations
Typical areas of application of the system
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Reference buildings
• Reinforced concrete dolphins in Bahrain
• Car park in Schwäbisch-Hall
• Car park of the university RWTH Aachen
• Water tower in Luxemburg
• 2 industrial buildings in Hoechst Industrial Park
• Bridge over the Emscher in Dinslaken
• SNCF bridge in Wimereux (F)
• Building facade in Biarritz (F)
• Car park in Frankfurt
• Car park in Erlangen
• Bridge of a chemicals plant in Wesseling
• Car park in Schweinfurt
• Car park in Saas-Fee (CH)
• Car park in Blaubeuren
• Harbour area in Nice (F)
• Car park in Hanover
• Car park in Tettnang
• Car park in Bielefeld
• Car park in Munich
• Car park in Sindelfingen and Böblingen
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Synopsis
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• Short duration of the rehabilitation works =>
high time saving compared to other repair
systems
• High cost saving thanks to the short duration
of the rehabilitation works and the absence
of drilling and demolition works
• Maintenance-free performance of the
system => fewer errors, no high follow-up
costs, no external electrical components
• No reduction of the headroom and the static
load capacity
• Durability of the anode at least 30 years
Bottleneck
ramp
Bottleneck
access
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Thank you very much for
your attention
Dipl.-Ing. Markus Kattannek; Grillo-Werke AG; E-Mail: [email protected]
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