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Our Approach P rovides a practical, innovative approach for the - - PowerPoint PPT Presentation

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Our Approach P rovides a practical, innovative approach for the restoration, preservation and maintenance of reinforced concrete structures, steel rust inhibitors and asphalt rejuvenator solutions.. Through the use of proprietary technology

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SLIDE 1

Our Approach

§ Provides a practical, innovative approach for the restoration, preservation and maintenance of reinforced concrete structures, steel rust inhibitors and asphalt rejuvenator solutions..

  • Through the use of proprietary technology and site specific

solutions, Surtreat can provide surface-applied migrating technology for inhibiting reinforcing steel corrosion and

  • ther concrete deteriorating conditions follows….
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SLIDE 2

Our Business

  • Mitigate corrosion, improve concrete strength, reduce

porosity and provide resistance to carbonation.

  • This will increase the ability of concrete to resist attack and

penetration by moisture, salts, acids and other aggressive chemical solutions, which ultimately begin to deteriorate the structure.

  • Surtreat is unique in the industry because of our ability to

cost-effectively protect a structure and mitigate the causes

  • f corrosion and deterioration.
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SLIDE 3

PROJECTS

  • INTERNATIONAL
  • CANADA – CPR RAIL, MINISTRY HIGHWAYS VANCOUVER, TORONTO METRO
  • ASIA – CHINA ROADWAYS, BRIDGES, SINGAPORE BUILDINGS
  • REPUBLIC OF KOREA – POWER PLANTS, BRIDGES, SUBWAY, SEAWALLS, AIR FORCE BASES
  • AFRICA – S. AFRICA ESKOM POWER, DEBEERS MININGS, LIBYA KHOMS POWER STATION
  • MIDDLE EAST – DUBAI – HIGH RISE BUILDINGS, FOUNDATIONS, PIERS
  • EUROPE – TURKEY –CHEMICAL PLANT
  • RUSSIA – Sochi Airport Runways
  • JAPAN – BRIDGES, WAREHOUSE FACILITY
  • UNITED STATES
  • Highway Roads and Bridges, Coastal Facilities and Waterfront Properties, Industrial

Facilities, Utilities, Parking Structures, Environmental Remediation, Treatment Storage and Disposal, Food Processing Facilities, Airports, Property Management Companies, Salt Domes, Historic Building Restoration, Monuments, Government, NASA, US Army Corps of Engineers, Stadiums, Condominium Balconies and Walkways

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SLIDE 4

Our Commitment

  • Analyze the structure
  • Provide site specific formulations for the

conditions

  • Controlled application
  • Verify Installation and performance
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SLIDE 5

Our History

  • Since 1989, hundreds of successful projects
  • Offices located in the United States, Russia,

Hungary, Canada, S. Korea, and S. Africa

  • Supporting Members of ACI, ICRI, NPA, IPI
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SLIDE 6

The Problem

  • Over time carbon dioxide, chlorides, acids or other chemicals enter

the concrete through the gel pores and cracks which reduces the pH.

  • With the drop in pH and elevation of chlorides, the passivating film
  • n the rebar is compromised.
  • With the presence of water and oxygen, corrosion begins.
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SLIDE 7

Corrosion Process on Surface of Steel

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SLIDE 8

Corrosion Damage

  • Crack

– run parallel to main reinforcement

  • Delamination

– separation of steel from concrete

  • Spall

– detachment of a section of concrete

  • Failure

– Collapse of a significant portion

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SLIDE 9

CUT & PATCH – The Anodic Ring

Accelerates corrosion in adjacent areas by creating a higher degree of Anode/Cathode Potential Difference (Anodic Ring Effect)

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SLIDE 10
  • Rebar rust creates a force on the concrete of

up to 8000 lbs/sq.in. resulting in concrete spalls

  • Sealers, coatings and water repellents cannot

stop the Anodic/Cathodic reaction once it has begun

CORROSION

An Electrochemical Process

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SLIDE 11

Traditional Concrete Protection Methods

Coatings and Sealants

DO:

  • Reduce Porosity
  • Reduces water, air, and

contaminants entering the concrete

DO NOT:

  • Control pH*
  • Purge/stabilize contaminants
  • Establish protective film on rebar
  • Provide resistance to acid*
  • Last indefinitely

Have no value and can accelerate corrosion if applied after contaminants are present and corrosion has begun

*Coatings on new concrete can retard carbonation *Some specialty coatings are acid resistant

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SLIDE 12

Traditional Concrete Protection Methods

Water Repellents

DO: Reduce Porosity (Surface Tension)

  • Reduce water and

contaminants entering the concrete

DO NOT:

  • Control pH
  • Purge/stabilize contaminants
  • Establish protective film on rebar
  • Provide resistance to acid
  • Last indefinitely
  • Can accelerate carbonation
  • Water will penetrate under pressure

(auto/truck traffic)

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SLIDE 13

DO:

  • Establish protective film on rebar

DO NOT:

  • Control pH
  • Purge/stabilize contaminants
  • Reduce porosity
  • Reduced water, air, and

contaminants

  • Provide resistance to acid
  • Last indefinitely

Vapor phase corrosion inhibitors are water and require periodic re-application

Concrete Protection Methods

Vapor Phase Corrosion Inhibitors

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SLIDE 14

SUMMARY

  • New concrete has a high pH which continually regenerates the protective

coating on the rebar.

  • A drop in pH will occur over time as a result of the concretes exposure to

carbon dioxide, chlorides, acids and other chemicals.

  • The pathway for these chlorides and pH reducing contaminants to enter

the concrete are cracks and gel pores.

  • Traditional methods of blocking these pathways, sealers, coatings and

water repellents may provide short term protection for new concrete but breakdown with time as they are organic.

  • Sealers, coatings and water repellents have little to no value once

corrosion has begun and they may speed up the process.

  • Migratory corrosion inhibitors are organic and water soluble resulting in a

relatively short life.

  • Patching without pacifying the steel in the surrounding concrete will lead

to accelerated corrosion (anodic ring).

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SLIDE 15

SURTREAT

  • The SURTREAT Total Performance System is able

to transform corrosion active concrete to a passive state as measured by corrosion current which can be converted to corrosion rate, an industry accepted standard.

  • TPS reverses the conditions that affect the

durability of concrete by protecting against freeze/thaw, salt scaling, alkali-aggregate reactions and sulfate attack.

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SLIDE 16

LONG TERM SOLUTION

  • Control pH
  • Establish a protective film on the rebar
  • Purge/stabilize contaminants
  • Reduce porosity (water, air, and contaminant pathways)
  • Provide resistance to acid
  • Last indefinitely
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SLIDE 17

LONG LASTING

  • SURTREAT TPS formulas are inorganic and there is no known reason

for their chemistry to break down

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SLIDE 18

SURTREAT TPS Customized Solutions

Attacks corrosion on all fronts:

  • Establishes a protective film on the rebar
  • Controls pH
  • Purges/stabilizes contaminants
  • Reduces porosity (drop)
  • Provides resistance to acid
  • Lasts indefinitely

Additional Benefits

  • Converts existing rust to hard insert shell
  • Increases compressive strength
  • Increases hardness
  • Increases flexural modules
  • Increases abrasion resistance
  • Improves adhesion
  • Breathable surface
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SLIDE 19

Pennsylvania Turnpike Bridge

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SLIDE 20

Test Results

Compressive Strength – Before Application 3,215 PSI – After Application 5,429 PSI 41% Increase Water Permeability – Before Application 2.5 cc per minute – After Application .10 cc per minute 96% red. pH – Before Application 8-9 at l/2 inch depth – After Application 10-11 at l/2 inch depth

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SLIDE 21

New Jersey Turnpike Installation

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SLIDE 22

Test Results

Compressive Strength Increase 119% 2897 PSI to 6370 PSI pH level at surface increase 57% 7 pH to 11 pH pH level at l/8” increase of 10% 10 pH to 11 pH Water Permeability decrease of 82% .55 cc/minute to .05 Water Soluble Chloride decrease of 5% 1000 ppm to 950

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SLIDE 23

San Luis Pass Bridge Galveston TX

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SLIDE 24

San Luis Pass Test Results

 Water Permeation on Wall Surface

Decrease of 145% 230 seconds to 563 seconds

 Water Permeation on Roadway Surface

Decrease of 280% 442 seconds to 1680 seconds

Half Cell Corrosion Change 101%

  • 165mV before to -82mV after treatment
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SLIDE 25

PARKING GARAGES

n

Central Parking – Columbus OH, Memphis TN, Milwaukee WI

West Penn Hospital, Pittsburgh PA

JLT Airport Parking, St. Paul MN

Austin TX new garage

Miller Parking, Chicago IL

Crestwood Mall, St. Louis MO

UMB Bank, Kansas City MO

Westfield NJ

Sterling Land Properties, Pittsburgh PA

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SLIDE 26
  • W. Penn Hospital Pittsburgh

Pennsylvania

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SLIDE 27
  • W. Penn Hospital Application
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SLIDE 28

JLT PARKING ST PAUL MINNESOTA

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SLIDE 29

JLT PARKING installation

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SLIDE 30

Austin TX installation

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SLIDE 31

Miller Parking Garage Chicago Illinois

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SLIDE 32

SURTREAT protection on a new Parking structure in Austin, TX

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SLIDE 33

UMB BANK Kansas City Missouri

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SLIDE 34
  • St. Paul MN Airport Garage
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SLIDE 35

Boston MA Logan International Airport

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SLIDE 36

Surtreat Application at Boeing

 Protection against

Foreign Object Debris (FOD)

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SLIDE 37

NASA TEST RESULTS

 Corrosion Inhibition

 Half Cell Positive Change of 43%

  • 350mV to -200mV

 Corrosion Current Change of 133%

  • 90 micro amps to +30

 Polarization Resistance change of 55%

4281 ohm-cm2 vs. 6612

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SLIDE 38

NASA CAPE KENNEDY PAD 39A

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SLIDE 39

Reduction in Corrosion Rate

  • NASA Kennedy Space Center

50%

  • Korean Construction Materials Institute

64%

  • Pennsylvania Turnpike Bridge

31%

  • Shipps Landing Balconies, Florida

70%

  • Jacksonville Florida Parking Garage

120%

  • Rand University, South Africa

50%

TEST RESULTS

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SLIDE 40

% Reduction

  • Pennsylvania Turnpike Bridge

98%

  • Seymour Johnson Air Force Base

95%

  • New Jersey Turnpike Bridge

91%

  • Alcosan Sewage Plant

75%

  • Rand University South Africa

85%

  • Korean Construction Materials Inst.

87%

POROSITY REDUCTION

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SLIDE 41

Increase

Kunai Bridge, South Korea 50% Pennsylvania Turnpike Bridge 58% Pennsylvania DOT Bridge 29% New Jersey Turnpike Bridge 120% New York Thruway Bridge 15% Canadian Pacific Railroad Bridge 67%

STRUCTURAL STRENGTH INCREASE

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SLIDE 42

Test Results Silver – Silver Chloride Half Cell

Half-Cell Potential - mV Test Location Before Application After Application % Change NASA Kennedy Space Center TPS-II – 2 inches 350 200 (12 months) 43% TPS-II – 2 inches 390 170 (12 month) 56% Korean Construction Materials Institute TPS-II – 3.5 inches 545 200 (90 days) 63% TPS-V – 3.5 inches 557 200 (90 days) 64% PA Turnpike Bridge TPS-II – 1.2 inches 243 168 (30 days) 31% Windjammer Condos, FL - Balcony TPS-II – 1.2 inches 350 50 (5 years) 86% Shipps Landing, FL – Balconies TPS-II – 1.2 inches 250 75 (30 days) 70% Suddath Parking Garage – Jacksonville, FL TPS-II – 1.2 inches 316 + 64 (180 days) 120% Rand University – South Africa TPS II 340 160 (75 days) 50%

Surtreat Product Performance Corrosion Inhibition (protective film on reinforcement steel indicator)

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SLIDE 43

Surtreat Product Performance

Porosity Reduction

Test Results Germann GWI – Flux Rate Water Column Absorption

% Decrease Water Column Source Before Treatment After Treatment % Change 14 day – 10% 14 day – 0% 100% Pittsburgh Test Lab 28 day – 13% 28 day – 3% 77%

Flux Rate Mm/sec x 10-3 Project/Location BAR Pressure Before Application After Application % Change PA – Turnpike Bridge 1.5 1.08 0.02

  • 98%

Korean Construction Materials 1.0 8.9 2.8

  • 69%

Korean Construction Materials in Lab 1.0 3.9 0.5

  • 87%

Seymous Johnson AFB 1.0 4.33 0.22

  • 95%

New Jersey Turnpike Bridge 3.0 0.24 0.022

  • 91%

Alcosan Sewage Plant 2.5 0.48 0.12

  • 75%

Rand University – South Africa 0.5 3.5 0.5

  • 85%
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SLIDE 44

Rapid Chloride Permeability

Coulombs Source Before Treatment After Treatment % Change American Engineering Testing 350 300 14% American Engineering Testing 320 290 9% American Engineering Testing 1600 1200 25%

Chloride Content Wt % Source Before Treatment After Treatment % Change Pittsburgh Testing Lab 0.5-1.0 inches 0.16 0.11 31% Korean Construction Materials Lab 0.5-1.0 inches 0.003 0.002 33% Rand University – South Africa 0.5-1.0 0.124 0.059 52

Chloride Ion Permeability

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SLIDE 45

Surtreat Product Performance

Increase Concrete Strength

Test Results Capo Pull-out Force

Before Treatment After Treatment % Change Test Location Product kN PSI kN PSI kN PSI Kunai Bridge, Korea TPS-II 33 5000 48 7500 45% 50% PA Turnpike Bridge TPS-II 22 3200 33 5050 50% 58% Penn DOT Bridge TPS-II 24 3500 30 4500 25% 29% NY Thruway Bridge, Seymour Johnson AFB TPS-II 37 6000 42 6900 14% 15% Canadian Pacific RR Bridge TPS-II 15 2100 24 3500 60% 67% U.S. DOE Fernald Ohio Storage Pad TPS-II 42 6800 44 7150 5% 5%

Test Location Before Treatment PSI After Treatment PSI % Change PSI Laboratory 1000 2000 100% NY Thruway Bridge 3400 4300 26% USS Coke Works 3000 4000 33% Korean Construction Materials Lab Deteriorated Concrete 2700 3700 37%

Core Compression Tests

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SLIDE 46

Surtreat Product Performance

Corrosion Current Micro Amps Test Location Before Treatment After Treatment % Change NASA Kennedy Space Center TPS-II (2 inches)

  • 90

+30 (12 months) 133% TPS-V (2 inches)

  • 50

+20 (12 months) 140% Polarization Resistance

  • hm – cm2

Test Location Untreated Treated % Change NASA Kennedy Space Center TPS-II 4281 5365 25% TPS-V 4281 6612 55% Corrosion Rate Measurements Micro Meters per year (μm/yr) Test Location Untreated Treated % Change Shea Stadium Ramp – NYC TPS-V 43 (av) 14 (av) 67 TPS-V 99 (Hot Spot av) 15 (Hot Spot av) 85 Parking Garage 420 E 51st – NYC TPS XII + TPS II 37 (av) 22 (av) 41 TPS XII + TPS II 104 (Hot Spot av) 14 (Hot Spot av) 86

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SLIDE 47

Surtreat Product Performance

Flexural Strength Test Location Before Treatment PSI After Treatment PSI % Change Korean Construction Materials Lab New Concrete 418 475 14% Korean Construction Materials Lab Deteriorated Concrete 270 449 66% Tension Shear Strength Test Location Before Treatment PSI After Treatment PSI % Change MDT Laboratory (Epoxy bond – concrete failure) 300 500 67% Rand University – South Africa 354 468 32

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SLIDE 48

NYS Thruway Authority

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SLIDE 49

Logan Airport New Terminal

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SLIDE 50

Logan Surtreat Application

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SLIDE 51

Logan Completed Surtreat

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SLIDE 52

SURFACE APPLIED COATINGS TO PREVENT CORROSION OF REBAR IN CRITICAL FACILITIES

Ashok Kumar

  • L. D. Stephenson

U.S. Army Corps of Engineers, Engineer Research and Development Center Construction Engineering Research Laboratory, P. O. Box 9005 Champaign, IL 61826-9005 14 February 2008

US Army Corps

  • f Engineers

Engineer Research & Development Center

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SLIDE 53

54

CORROSION PROBLEM

Severely corroded rebar in bridge support beam (left) and underneath deck (right)

  • Alkaline (pH 13) concrete cover (about 2 inches) inhibits corrosion but

decreases with time

  • Carbonation: CO2 and other acidic compounds lead to pH <11

air and water (moisture), Cl- accelerate corrosion

  • Corrosion product expands concrete and cause it to degrade, spall
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SLIDE 54

55

Objective

  • To demonstrate and implement technologies

for inhibiting corrosion of reinforcing steel (rebar) in concrete structures in a severely corrosive environment climate

  • Two patrol bridges located at Fuel Tank Farm

and two structural beams located at warehouse at Naha Port, Okinawa

  • Two Rebar Corrosion Mitigation Technologies
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SLIDE 55

FAR-16: Corrosion Prevention of Rebar in Concrete in Critical Facilities Located in Coastal Environments at Okinawa

  • Problem: Severe corrosion of rebar in concrete
  • Technology Solution: Migrating corrosion inhibitor and sacrificial corrosion

protection compounds that can be applied to wall surfaces and provide protection

  • Applications: ring girder on wall of warehouse used by all services at

Okinawa Port; Patrol bridge at fuel tank farm at Okinawa, Japan

  • Benefits: Prevents corrosion of rebar; extends service life of rebar and

concrete surfaces

Okinawa Port Warehouse Ring Girder Patrol Bridge Rebar

1 ft.

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SLIDE 56

57

CONCLUSIONS

  • The data quantitatively shows that the inhibitor

application has significantly reduced the corrosion of the reinforcing steel.

– It can be projected that the service life is extended by more than 10 years based on the short-term data collected.

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SLIDE 57

 STRENGTH

% Increase Kunai Bridge, South Korea 50% Pennsylvania Turnpike Bridge 58% Pennsylvania DOT Bridge 29% New Jersey Turnpike Bridge 120% New York Thruway Bridge 15% Canadian Pacific Railroad Bridge 67%

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SLIDE 58

ROADWAYS & BRIDGES

Pennsylvania Turnpike

Pennsylvania Dept. of Transportation

New York State Thruway Authority

Port Authority of Allegheny County PA

Missouri Dept. of Transportation

Oklahoma Dept. of Transportation

Canadian Pacific Railway, Canada

West Virginia Dept. of Transportation

New Jersey Dept. of Transportation

New Jersey Turnpike Commission

JUNGNEUNG KOREA

US Fed. Highway Administration

Iowa – Plymouth County

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SLIDE 59

Surtreat Application New Jersey High Authority

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SLIDE 60

Test Results

Compressive Strength Increase 119% 2897 PSI to 6370 PSI pH level at surface increase 57% 7 pH to 11 pH pH level at l/8” increase of 10% 10 pH to 11 pH Water Permeability decrease of 82% .55 cc/minute to .05 Water Soluble Chloride decrease of 5% 1000 ppm to 950

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SLIDE 61

Field Test Kit – Schedule D

SCHEDULE - D

Field data collection kit

Cordless hammer drill and bits One-inch diamond core drill Hammer Tape measure Marking chalk Rainbow Indicator Hydrochloric acid and dropper Sample bags Quick set repair cement Digital camera Notebook Gloves-work and rubber Rags and towels Liquid measuring container in milliliters One pint each TPS I II III IV XII Paintbrushes Water Ryland tube (porosity measurement) Silicon sealant Impact hammer Miscelleanous hand tools

Field test equipment

GalvaPulse Rebar finder GWT Water Permeability Capo Pullout Chloride measurement system Water pump