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ENVIRONMENTAL CONDITIONS
Sabkha brine vs. Seawater
Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals
Ions (g/l) Sabkha brine Sea water
Cl- 157.2 36.9
SO4-- 5.45 5.12
pH [n/a] 6.9 8.3
Conductivity [µmhos/cm] 208,000 46,200](https://image.slidesharecdn.com/11-150813113058-lva1-app6891/85/Epoxy-Coating-For-Steel-Rebar-14-320.jpg)
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Epoxy Coating For Steel Rebar
The document discusses the benefits of epoxy coating for steel rebar in concrete structures, particularly in GCC countries, highlighting its ability to significantly reduce corrosion and maintenance costs. It covers various corrosion protection methods, the initial and life cycle costs of using fusion-bonded epoxy coating, and emphasizes the importance of proper handling and application of coated rebar. The conclusion asserts that epoxy coatings provide the lowest life cycle cost and enhance the service life of concrete structures to 75-100 years.
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Epoxy Coating For Steel Rebar
- 1. www.jotun.comwww.jotun.com EPOXY COATING FORSTEEL REBAR Improving concrete structure durability and reducing long term maintenance costs
- 2. www.jotun.com WHAT YOU WILL LEARN Whatcauses corrosion of steel rebars embedded in concrete and how to effectively prevent corrosion comparing different corrosion protection methods. Why corrosion protection of steel reinforcement is especially important for concrete structures in GCC countries. What is the initial cost increase to a concrete structure and total life cycle cost of a concrete structure with fusion bonded epoxy coating for corrosion protection comparing to other corrosion protection methods. Table of contents Jotun Corrosion Service life and cost comparison Coating plant quality Job site practice Questions Projects Conclusions
- 3. www.jotun.com A global paintsolutions company, established in Norway in 1926.
- 4. www.jotun.com 90 countries USD 1.9bn in sales 39 factories 850advisors NACE / Frosio qualified 9000 employees
- 5. www.jotun.com 13 4 36 8 Middle East India and Africa regions includes 57 countries with 17 factories and sales offices in 10 other countries
- 6. www.jotun.com Regional Laboratories 200 people working inR&D R&D investment US34 million per year Central Lab Sandefjord, Norway Regional Labs Dubai, UAE K.L, Malaysia Pusan, South Korea
- 7. www.jotun.com For a morecolourful world, we are taking steps to be a little greener
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- 12. www.jotun.com ENVIRONMENTAL CONDITIONS Mediterranean AtlanticArabian Gulf Mean 21,380 17,480 33,660 19,800 Salt content (TDS mg/l) Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals
- 13. www.jotun.com ENVIRONMENTAL CONDITIONS Chloride andsulfate in air humidity Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals Salt (ppm/m3) UAE Long Beach Chloride 63.2 0.13 Sulfate 33.8 0.32
- 14. www.jotun.com ENVIRONMENTAL CONDITIONS Sabkha brinevs. Seawater Source: Dr. Ahmad S. Al‐Gahtani ‐ Department of Civil Engineering King Fahd University of Petroleum & Minerals Ions (g/l) Sabkha brine Sea water Cl- 157.2 36.9 SO4-- 5.45 5.12 pH [n/a] 6.9 8.3 Conductivity [µmhos/cm] 208,000 46,200
- 15. www.jotun.com • High pH = passive oxide layer • Carbonation leads to lower pH •Corrosion starts • Corrosion propagation leads to cracking • Cracking further accelerates corrosion
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- 21. www.jotun.com Without epoxy coatingWith epoxy coating
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- 23. www.jotun.com FACTS & FIGURES •Corrosion cost in UAE is estimated to be US$ 12.5 billion (Dr. Nagi/AUD) • More than 65.000 bridges use epoxy coated rebars in the US • Coated rebar has saved the federal highways over US$ 50 billion in the US (Paul Virimany, Corcon 2007)
- 24. www.jotun.com Kyösti Tuutti´s Service Life Model –Loss of cross‐section
- 25. www.jotun.com Kyösti Tuutti´s Service Life Model –Loss of cross‐section
- 26. www.jotun.com • 2011, researchreport titled “Evaluation of Multiple Corrosion Protection Systems for Reinforced Concrete Bridge Decks” • Test performed on damaged bars • 75 years service life LIFE CYCLE COST ANALYSIS – STUDY BY MATHEW O’REILLY
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- 31. www.jotun.com QUALITY CHANGES SINCE1980 • Increased coating thickness • Required roughness • Clean substrate (backside contamination) • No cracking allowed during bending • Improved storage and handling The 2014 product is greatly improved
- 32. www.jotun.com JOTUN APPROVED APPLICATOR •Plant approvals acc. To ASTM 775 & CRSI • Incorporated all changes to ensure highest quality exceeding standards • All major Rebar applicators in UAE & neighboring countries are approved Approved applicator = peace of mind
- 33. www.jotun.com SPECIFICATIONS • ASTM A775/A775M- Coating Application and Powder Qualification • ASTM A934 - FBE Coating of Welded Mesh and pre-fabricated Rebar • ASTM D3963 - Standard Specification for Fabrication and Field Requirements, Repair Material Qualification • Jotun Approved Applicator How to specify epoxy coated Rebar
- 34. www.jotun.com FIELD HANDLING • Damagedbars have lower performance than undamaged bars • BUT damaged bars still perform better than uncoated bars Appropriate handling
- 35. www.jotun.com FIELD HANDLING • Spreaderbars • Nylon or padded slings • Do not use chains or cables • Cover with suitable material and minimize condensation Unloading, storage & job-site handling
- 36. www.jotun.com FIELD HANDLING • Donot store directly on the ground Storage
- 37. www.jotun.com FIELD HANDLING • Onlybend with the permission of the engineer • Use appropiate bending diameters • Bend at ambient temperature Jobsite bending
- 38. www.jotun.com FIELD HANDLING • Liftand set bars in place (don’t drag) • Minimize traffic on bar placed bars • Inspect bars and repair damaged coating with 2- part patch material from approved coating supplier Bar placement
- 39. www.jotun.com FIELD HANDLING • Usecoated supports • Tie using coated or plastic tie wire Bar placement
- 40. www.jotun.com FIELD HANDLING • Usepower shears or chop saw • No flame cutting • Repair cut ends with two-part epoxy patching material Job-site cutting
- 41. www.jotun.com FIELD HANDLING • Useplastic headed vibrators Vibration
- 42. www.jotun.com QUESTIONS 1986 Florida keysbridges Was this distress going to be typical for the remaining 300 bridges?
- 43. www.jotun.com QUESTIONS 1986 Florida bridges Poorquality concrete and coatings leading to poor life • Poor Concrete • Poor Cover • Chloride contamination • Aggressive environment • Poorly manufactured and stored reinforcement
- 44. www.jotun.com QUESTIONS 2011 Florida bridgesperformance prediction Most bridges in Florida with epoxy-coated bars are predicted to last 100 years with minimal corrosion damage
- 45. www.jotun.com QUESTIONS Bond strength Is thebond strength to concrete less with epoxy-coated Rebar? 3 contributors to bond: • Chemical adhesion • Friction • Bearing (Primary Factor)
- 46. www.jotun.com QUESTIONS Bond strength Is thebond strength to concrete less with epoxy-coated Rebar?
- 47. www.jotun.com QUESTIONS Bond strength Is thebond strength to concrete less with epoxy-coated Rebar? Eventually lower bond strength can be easily overcome with: • Longer development length • Increased Rib area of Rebar
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- 49. www.jotun.com CONCLUSIONS • FBE‐coatings significantly reduce corrosion rates compared to uncoated reinforcement and some other technologies of corrosion prevention • FBE ‐coatings provide lowest life cycle cost among alternative technologies, with minimal increase to initial project costs • FBE – coatings increase the service life of a structure to 75‐100 years in combination with other good practices
- 50. www.jotun.com CONTACT JOTUN ADDRESS: P.O 51033 SidraOffice Tower 11th floor Al Soufouh, Dubai UAE PHONE: +971-56 225 8008 EMAIL: rene.mayer@jotun.com
- 51. www.jotun.com THANK YOU FOR ATTENDING Awealth of presentations and reports are available at www.middleeastconcrete/presentations PLEASE DON’T FORGET TO COLLECT YOUR ATTENDANCE CERTIFICATE