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WO2018169495A1 - Sacrificial anode for steel reinforcement in concrete - Google Patents

Sacrificial anode for steel reinforcement in concrete Download PDF

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Publication number
WO2018169495A1
WO2018169495A1 PCT/TH2017/000021 TH2017000021W WO2018169495A1 WO 2018169495 A1 WO2018169495 A1 WO 2018169495A1 TH 2017000021 W TH2017000021 W TH 2017000021W WO 2018169495 A1 WO2018169495 A1 WO 2018169495A1
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WO
WIPO (PCT)
Prior art keywords
zinc
assembly
concrete
anodes
cementitious material
Prior art date
Application number
PCT/TH2017/000021
Other languages
French (fr)
Inventor
Pinai Mungsantisuk
Original Assignee
Pinai Mungsantisuk
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pinai Mungsantisuk filed Critical Pinai Mungsantisuk
Priority to PCT/TH2017/000021 priority Critical patent/WO2018169495A1/en
Publication of WO2018169495A1 publication Critical patent/WO2018169495A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/64Insulation or other protection; Elements or use of specified material therefor for making damp-proof; Protection against corrosion
    • E04B1/642Protecting metallic construction elements against corrosion
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06Constructional parts, or assemblies of cathodic-protection apparatus
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2201/00Type of materials to be protected by cathodic protection
    • C23F2201/02Concrete, e.g. reinforced
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2213/00Aspects of inhibiting corrosion of metals by anodic or cathodic protection
    • C23F2213/20Constructional parts or assemblies of the anodic or cathodic protection apparatus
    • C23F2213/22Constructional parts or assemblies of the anodic or cathodic protection apparatus characterized by the ionic conductor, e.g. humectant, hydratant or backfill

Definitions

  • This invention is related to sacrificial anode cathodic protection of reinforcing steel in concrete.
  • the alkaline environment of concrete will change the condition of reinforcing steel from corrosion state to passive state.
  • This passive state will help to prevent the reinforcing steel from corrosion.
  • concrete is porous. If concrete is surrounded by water or moisture containing chloride such as seawater, brackish water, deicing salt, salty ground water and etc. for many years, the concrete will be contaminated with chloride ions. Finally, chloride ions will attack the reinforcing steel and cause corrosion.
  • Carbonation is another serious problem for reinforced concrete. Carbonation reduces pH in concrete from between 12.6 and 13.8 to about 8 which will cause the condition of the reinforcing steel to shift from passive state back to corrosion state.
  • the first is to minimize or delay penetration of chloride ions or carbon dioxide using coating techniques or some additive to make concrete more difficult for penetration.
  • the second is to allow chloride ions or carbon dioxide into the reinforced concrete but prevent the reinforcing steel from corrosion using cathodic protection technique.
  • the first method cannot control the corrosion completely because the coating is damaged or the concrete is cracked always. Prevention of the coating or concrete from damage or crack is nearly impossible. Therefore, prevention of chloride ions or carbon dioxide to penetrate concrete is nearly impossible as well or will cost a lot of money.
  • ICCP impressed current cathodic protection
  • SACP sacrificial anode cathodic protection
  • ICCP needs external power supply, inert anodes and wiring to complete the circuit of cathodic protection system.
  • the ICCP will require additional maintenance and monitoring which will result in additional operating costs.
  • SACP uses sacrificial anodes such as zinc, aluminium, magnesium and their alloys which have lower electrochemical potentials than steels or cathodes. Therefore, current flow in the cathodic protection system comes from the potential difference between the anodes and cathodes.
  • the major advantages of SACP are easier installation, less initial cost, maintenance and monitoring, higher reliability and less risk to hydrogen embrittlement in high strength prestressed steel because of low driving voltage.
  • the ionically conductive hydrogel is attached to at least a portion of the anode.
  • the anode is in elongated foil form.
  • the anode and the hydrogel are flexible and are conformed to the eroded area.
  • LiOH lithium hydroxide
  • the electrochemical activating agent is lithium nitrate (L1NO 3 ), lithium bromide (LiBr) or mixture of L1NO 3 and LiBr to enhance the performance of embedded anodes.
  • the electrochemical activating agent is lithium nitrate (L1NO 3 ), lithium bromide (LiBr) or combination.
  • the performance of sacrificial anode is enhanced by the use of mixture of chemicals and inert water absorbent solids, bentonite, vermiculite or combination, in a cementitious grout.
  • the present invention relates to sacrificial anode cathodic protection of reinforcing steel in concrete.
  • the sacrificial anodes for reinforced concrete in many patents are zinc, aluminium and alloys thereof.
  • zinc and its alloys are preferred as sacrificial anode.
  • Aluminium and its alloys tend to cause cracking in concrete because of higher volume expansion after they provide the current to the reinforcing steel for some period of time.
  • the zinc or zinc alloys must be surrounded in the environment with high pH to prevent passivation. The pH should be at least 14.
  • LiOH, NaOH or potassium hydroxide (KOH) can be used to activate zinc or zinc alloys. However, NaOH and KOH will react with silica aggregates to form gel.
  • This reaction is called alkali silica reaction or ASR.
  • Lithium ion can provide protection against ASR in concrete so LiOH is preferred as activator.
  • NaOH or KOH can also be used as activator for zinc and zinc alloys but they need to mix with LiOH to prevent ASR.
  • the amount of LiOH, NaOH and KOH in mortar is greater than 2%, 4% and 5% by weight respectively.
  • concentration of LiOH, NaOH and KOH in mortar will become lower after the anode has been used for many years because of the reaction and dilution. This will result in the passivation of anodes.
  • higher concentration of the chemicals minimum 4% LiOH, 8% NaOH or 10% KOH
  • the control of sand size or combination is used. The best combination is minimum 4% LiOH by weight and sand size about 30 to 60 of
  • Figure 1 illustrates the average results of the current output of the zinc anodes encased in different mortar.
  • the solid line represents average current output of zinc anodes covered by the mortar with sand size number about 30 to 60 of US standard sieve and minimum 4% LiOH by weight. While the dash line represents current output of zinc anodes covered by the mortar with sand size number higher than 60 of US standard sieve and minimum 4% LiOH by weight.
  • the letter F, S and D stand for fresh water, salt water with 3% NaCl and dry condition in the dam as described in ASTM G109 - 99.
  • the zinc anodes covered by the mortar with sand size number about 30 to 60 of US standard sieve and minimum 4% LiOH by weight can provide better uniform current output.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Prevention Of Electric Corrosion (AREA)

Abstract

The sacrificial anode cathodic protection for reinforcing steel in concrete is accomplished and enhanced by mixture control of cementitious material covering zinc or zinc alloy anode. At least 4% lithium hydroxide by weight of the cementitious material is required to prevent the passivation of the zinc anodes after use for many years. The zinc anodes covered by the cementitious material with sand size number about 30 to 60 of US standard sieve provide better uniform current output. Combination of minimum lithium hydroxide and sand size control in the cementitious material will improve the anodes performance and prevent them from passivation.

Description

SACRIFICIAL ANODE FOR STEEL REINFORCEMENT IN CONCRETE
Technical Field
This invention is related to sacrificial anode cathodic protection of reinforcing steel in concrete.
Background Art
Normally, the alkaline environment of concrete will change the condition of reinforcing steel from corrosion state to passive state. This passive state will help to prevent the reinforcing steel from corrosion. However, concrete is porous. If concrete is surrounded by water or moisture containing chloride such as seawater, brackish water, deicing salt, salty ground water and etc. for many years, the concrete will be contaminated with chloride ions. Finally, chloride ions will attack the reinforcing steel and cause corrosion.
Carbonation is another serious problem for reinforced concrete. Carbonation reduces pH in concrete from between 12.6 and 13.8 to about 8 which will cause the condition of the reinforcing steel to shift from passive state back to corrosion state.
To prevent these corrosion problems, there are two favorite methods. The first is to minimize or delay penetration of chloride ions or carbon dioxide using coating techniques or some additive to make concrete more difficult for penetration. The second is to allow chloride ions or carbon dioxide into the reinforced concrete but prevent the reinforcing steel from corrosion using cathodic protection technique.
The first method cannot control the corrosion completely because the coating is damaged or the concrete is cracked always. Prevention of the coating or concrete from damage or crack is nearly impossible. Therefore, prevention of chloride ions or carbon dioxide to penetrate concrete is nearly impossible as well or will cost a lot of money.
For cathodic protection system (CP), there are two types, impressed current cathodic protection (ICCP) and sacrificial anode cathodic protection (SACP). ICCP needs external power supply, inert anodes and wiring to complete the circuit of cathodic protection system. Thus, the ICCP will require additional maintenance and monitoring which will result in additional operating costs. SACP uses sacrificial anodes such as zinc, aluminium, magnesium and their alloys which have lower electrochemical potentials than steels or cathodes. Therefore, current flow in the cathodic protection system comes from the potential difference between the anodes and cathodes. The major advantages of SACP are easier installation, less initial cost, maintenance and monitoring, higher reliability and less risk to hydrogen embrittlement in high strength prestressed steel because of low driving voltage.
In US Patent 5,292,411 by Bartholomew et al., the ionically conductive hydrogel is attached to at least a portion of the anode. The anode is in elongated foil form. The anode and the hydrogel are flexible and are conformed to the eroded area.
In US Patent 6,022,496 by Page, zinc or zinc alloy anode is surrounded by mortar containing lithium hydroxide (LiOH). LiOH is added to maintain high pH in the mortar and prevent the anode from passivation.
In US Patent 6,193,857 by Davison and Gorrill, at least 2% of LiOH or 4% of sodium hydroxide (NaOH) is added to mortar surrounding the anode to prevent passivation.
In US patent 7,488,410 by Bennett et al., the electrochemical activating agent is lithium nitrate (L1NO3), lithium bromide (LiBr) or mixture of L1NO3 and LiBr to enhance the performance of embedded anodes.
Finally, in the PCT, WO 2007/126715 by Bennett, the electrochemical activating agent is lithium nitrate (L1NO3), lithium bromide (LiBr) or combination. Moreover, the performance of sacrificial anode is enhanced by the use of mixture of chemicals and inert water absorbent solids, bentonite, vermiculite or combination, in a cementitious grout.
Disclosure of Invention
The present invention relates to sacrificial anode cathodic protection of reinforcing steel in concrete. The sacrificial anodes for reinforced concrete in many patents are zinc, aluminium and alloys thereof. In this invention, zinc and its alloys are preferred as sacrificial anode. Aluminium and its alloys tend to cause cracking in concrete because of higher volume expansion after they provide the current to the reinforcing steel for some period of time. The zinc or zinc alloys must be surrounded in the environment with high pH to prevent passivation. The pH should be at least 14. LiOH, NaOH or potassium hydroxide (KOH) can be used to activate zinc or zinc alloys. However, NaOH and KOH will react with silica aggregates to form gel. This reaction is called alkali silica reaction or ASR. Lithium ion can provide protection against ASR in concrete so LiOH is preferred as activator. NaOH or KOH can also be used as activator for zinc and zinc alloys but they need to mix with LiOH to prevent ASR.
Conventionally, the amount of LiOH, NaOH and KOH in mortar is greater than 2%, 4% and 5% by weight respectively. However, the concentration of LiOH, NaOH and KOH in mortar will become lower after the anode has been used for many years because of the reaction and dilution. This will result in the passivation of anodes. To prevent this problem and enhance the anode performance in concrete, higher concentration of the chemicals (minimum 4% LiOH, 8% NaOH or 10% KOH), the control of sand size or combination is used. The best combination is minimum 4% LiOH by weight and sand size about 30 to 60 of
US standard sieve. The zinc anodes with cover are installed in the test specimens conformed to ASTM G109 - 99. ASTM C0876 - 91 is used to determine the potentials of the reinforcing steels and 100 mV polarization decay method is used to prove the cathodic protection of the reinforcing steels in concrete. The current flows from the zinc anodes to the steel cathodes are also measured. Both mortar with sand size number about 30 to 60 and higher than 60 of US standard sieve and minimum 4% LiOH by weight help to improve the performance of zinc anodes and result in minimum 161 mV polarization decay of the reinforcing steels which prove the cathodic protection.
Description of the Drawing
Figure 1 illustrates the average results of the current output of the zinc anodes encased in different mortar. The solid line represents average current output of zinc anodes covered by the mortar with sand size number about 30 to 60 of US standard sieve and minimum 4% LiOH by weight. While the dash line represents current output of zinc anodes covered by the mortar with sand size number higher than 60 of US standard sieve and minimum 4% LiOH by weight. The letter F, S and D stand for fresh water, salt water with 3% NaCl and dry condition in the dam as described in ASTM G109 - 99. The zinc anodes covered by the mortar with sand size number about 30 to 60 of US standard sieve and minimum 4% LiOH by weight can provide better uniform current output.

Claims

Claims
1. An assembly for cathodic protection of reinforcing steel in concrete structure, comprising:
at least one metal anode having more negative electrode potential than steels;
at least one elongated metallic conductor bonded to the metal anode(s);
an ionically conductive material which contains electrochemical activating agent for covering the metal anode(s).
2. The assembly as claimed in claim 1 wherein the metal anode is zinc or zinc alloy.
3. The assembly as claimed in claim 1 wherein the elongated metallic conductor is mild steel, galvanized steel or stainless steel.
4. The assembly as claimed in claim 1 wherein the ionically conductive material is a cementitious-based material.
5. The assembly as claimed in claim 4 wherein the cementitious-based material is made from sand size number about 30 to 60 of US standard sieve.
6. The assembly as claimed in claim 1 wherein the electrochemical activating agent is alkaline hydroxide present in sufficient amount to raise the pH of the covering material above about pH 14.
7. The assembly as claimed in claim 6 wherein the alkaline hydroxide is at least 4% lithium hydroxide by weight of the cementitious-based material.
PCT/TH2017/000021 2017-03-16 2017-03-16 Sacrificial anode for steel reinforcement in concrete WO2018169495A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/TH2017/000021 WO2018169495A1 (en) 2017-03-16 2017-03-16 Sacrificial anode for steel reinforcement in concrete

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/TH2017/000021 WO2018169495A1 (en) 2017-03-16 2017-03-16 Sacrificial anode for steel reinforcement in concrete

Publications (1)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115304323A (en) * 2022-07-21 2022-11-08 中交四航工程研究院有限公司 Conductive mortar and preparation method and application thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6193857B1 (en) * 1998-10-29 2001-02-27 Foseco International Limited Connector for use in cathodic protection and method of use
JP2016098596A (en) * 2014-11-25 2016-05-30 クリディエンス株式会社 Simple repair method and simple repair structure of reinforced concrete structure without requiring cross section repair using sacrificial anode material
JP2017014566A (en) * 2015-06-30 2017-01-19 デンカ株式会社 Cross-sectional repair process for concrete structure
JP2017014567A (en) * 2015-06-30 2017-01-19 西日本高速道路株式会社 Monitoring method for sacrificial anode construction method in concrete structure

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6193857B1 (en) * 1998-10-29 2001-02-27 Foseco International Limited Connector for use in cathodic protection and method of use
JP2016098596A (en) * 2014-11-25 2016-05-30 クリディエンス株式会社 Simple repair method and simple repair structure of reinforced concrete structure without requiring cross section repair using sacrificial anode material
JP2017014566A (en) * 2015-06-30 2017-01-19 デンカ株式会社 Cross-sectional repair process for concrete structure
JP2017014567A (en) * 2015-06-30 2017-01-19 西日本高速道路株式会社 Monitoring method for sacrificial anode construction method in concrete structure

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN115304323A (en) * 2022-07-21 2022-11-08 中交四航工程研究院有限公司 Conductive mortar and preparation method and application thereof

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