DSS Corrosion Inhibitor Evaluations(Hycrete)

Scott A. Civjan

University of Massachusetts, Amherst

Northeastern States Materials Engineers’ AssociationOct. 19, 2004

Outline

Corrosion Testing (UMass, UConn)

Materials Testing (UConn, UMass)

Field Applications

NETC Project 03-2

References UMass (NETC 97-2)

Civjan S. A., LaFave J. M., Lima J., and Pfiefer D. “Effectiveness ofCorrosion Inhibiting Admixture Combinations in Structural Concrete”Cement and Concrete Composites, Elsevier – In Publication

Civjan, S. A., LaFave, J. M., Lovett, D., Sund, D. J., and Trybulski, J.“Performance Evaluation and Economic Analysis of Combinations ofDurability Enhancing Admixtures (Mineral and Chemical) in StructuralConcrete for the Northeast U.S.A.” Final Report (NETC 97-2).http://docs.trb.org/00960060.pdf

UConn (CT DOT Project 96-2) Allyn, M. and Frantz, G. C. “Strength and Durability of Concrete

Containing Salts of Alkenyl-Succinic Acid.” ACI Materials Journal2001; V. 98 (1); 52-58.

Allyn, M. and. Frantz, G.C. “Corrosion Tests with Concrete ContainingSalts of an Alkenyl-Succinic Acid.” ACI Materials Journal 2001, V. 98(3): 224-232.

Corrosion Testing

UConn

Corrosion Testing – UConn (Allyn and Franz 2001a)

48/100 Weeks

w/cm of 0.38 to 0.45

1 or 2 Percent Hycrete DSS Addition by Cement Weight

Linear Polarization Testing

Sponsor: Connecticut DOT Project 96-2

UConn

Lollipop (2”and 3”) and Slab Specimens

15% NaCl Ponding

4 Days Wet, 3 Days Dry

Up to 2 Years

Sponsor: Connecticut DOT

From UConn Project 96-2Phase II Report

From UConn Project 96-2Phase II Report

From UConn Project96-2 Phase II Report

UConn

“Complete lack of corrosion in specimens containingthe new chemicals”

Specimen dropped/cracked

Saw Cut Specimens

Sponsor: Connecticut DOT

UMass

Slab Specimens – 24 week ponding cycles

Visual Inspection

Half-Cell

Macrocell

Destructive Evaluation

Chloride Testing (Minimal)

Sponsor: New England Transportation Consortium

Goal: Evaluate Performance of Admixture Combinations

Mix Design

14 Mix Designs

12 w/cm=0.40, 2 w/cm=0.47

Single: CN, SF, FA, GBFS, Hycrete DSS

Double CN+(SF, FA, GBFS or Hycrete DSS)

Triple CN+SF+(FA or GBFS)

Hycrete DSS: 2 Mixes

Additions 1/2% Cement Content

Mix Design

Dosages

CN: 14.8 l/m3 (3 gal/yd3)

SF: 6% Cement Replacement

FA: 15% Cement Replacement

GBFS: 25% Cement Replacement

Hycrete DSS: Additions 1/2% Cement Content

Replacements/Additions = Weight Basis

10Ω

305

75180

25

25

50 50305

NaCl Solution

Wiring toelectricallyconnect anodeand cathode steel

Specimen raised to allowair flow to bottom surface

Sides Sealed with Epoxy

Reinforcing Bars

Plexiglas Dike

Specimen Details

Modification of ASTM G-109

Specimen Details

Replicates of 3

A and B: Non-Cracked

C: Pre-Cracked

Test Protocol

1st 12 Weeks - Cycled

4 Days Ponded/3 Days Dry

Ponded: Min. 21°C (70° F)15% NaCl Solution

Dry: Min. 38°C (100° F)

2nd 12 Weeks – Ponded

24 Week Cycles

108 Weeks Total

Some Specimens Continued to 204 Weeks

Test Protocol - Enclosures

ThermostatHeat Lamp

Temperaturecontrolledenclosure

Specimens

Macrocell Readings – Iron Loss

Metal loss in grams/amp-hour

=atomic weight/[(Faraday’s Constant) * (electron charge change)]

= ( )( )

( )electronsmolsamphrsmolgrams

2/)*(96489

/3600/8.55 =1.04 grams/amp - hr (1)

Iron Loss – Control/Single

Iron Lost (Non-Cracked Specimens): Control/Single Admixtures

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1.10

1.20

M1A

1-R

M1A

2-R

M1B

1

M1B

2

M2A

1

M2A

2

M2B

1

M2B

2

M3A

1

M3A

2

M3B

1-R

M3B

2-R

M4A

1

M4A

2

M4B

1-R

M4B

2-R

M5A

1

M5A

2

M5B

1

M5B

2

M6A

1

M6A

2

M6B

1

M6B

2

Specimen Label

108 weeks

96 weeks

84 weeks

72 weeks

60 weeks

48 weeks

36 weeks

24 weeks

12 weeks

Control SFCN GBFS DSSFA

Iron Loss – Control/Single

Iron Lost (Non-Cracked Specimens): Control/Single Admixtures

0.00

0.05

0.10

M1A

1-R

M1A

2-R

M1B1

M1B2

M2A1

M2A2

M2B1

M2B2

M3A1

M3A2

M3B

1-R

M3B

2-R

M4A1

M4A2

M4B

1-R

M4B

2-R

M5A1

M5A2

M5B1

M5B2

M6A1

M6A2

M6B1

M6B2

Specimen Label

108 weeks

96 weeks

84 weeks

72 weeks

60 weeks

48 weeks

36 weeks

24 weeks

12 weeks

Control SFCN GBFS DSSFA

Iron Loss – Double

Iron Lost (Non-Cracked Specimens): Double Combinations

0.00

0.05

0.10

M7A

1

M7A

2

M7B

1

M7B

2

M8A

1

M8A

2

M8B

1

M8B

2

M9A

1

M9A

2

M9B

1

M9B

2

M10

A1

M10

A2

M10

B1

M10

B2

Specimen Label

108 weeks

96 weeks

84 weeks

72 weeks

60 weeks

48 weeks

36 weeks

24 weeks

12 weeks

CN/SF CN/GBFSCN/FA CN/DSS

Iron Loss – Triple and High w/cm

Iron Lost (Non-Cracked Specimens): Triple Combinations/High w/cm

0.00

0.05

0.10

M11

A1

M11

A2

M11

B1

M11

B2

M12

A1

M12

A2

M12

B1

M12

B2

M13

A1

M13

A2

M13

B1

M13

B2

M14

A1

M14

A2

M14

B1

M14

B2

Specimen Label

108 weeks

96 weeks

84 weeks

72 weeks

60 weeks

48 weeks

36 weeks

24 weeks

12 weeks

**= Values Negative for M14B **

CN/SF/FA CN/SF/GBFS CN/SF/FACN/SF

MacroCell Readings

Hycrete DSS

Calcium Nitrite

3 years

3 1/2 years

MacroCell- Pre-Cracked

Voltage vs. Time for M1C1

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

1 85 169 253 337 421 505 589 673 757

Time (Days)

Vo

lta

ge

(m

V)

Voltage vs. Time for M2C1

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

1 85 169 253 337 421 505 589 673 757

Time (Days)

Vo

lta

ge

(m

V)

3 1/2 years

3 1/2 years

Iron Loss – Pre-Cracked

Iron Lost (Pre-Cracked Specimens)

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

M1C1

M1C2

M2C1

M2C2

M3C1

M3C2

M4C1

M4C2

M5C1

M5C2

M6C1

M6C2

M7C1

M7C2

M8C1

M8C2

M9C1

M9C2

M10C1

M10C2

M11C1

M11C2

M12C1

M12C2

M13C1

M13C2

M14C1

M14C2

Specimen Label

108 weeks

96 weeks

84 weeks

72 weeks

60 weeks

48 weeks

36 weeks

24 weeks

12 weeks

M6 and M10

SpecimenRankings

Mix Average Cumulative

Iron Loss (%) Through 108 Weeks

Magnifier Over M10AB Notes

M10AB 4.93E-03 1X No Cracking M6AB 5.39E-03 1X No Cracking M2AB 5.45E-03 1X No Cracking

M11AB 6.80E-03 1X Cracking in one specimen only M9AB 9.54E-03 2X No Cracking

M12AB 2.22E-02 4X Cracking in one specimen only M8AB 2.33E-02 5X No Cracking

M14AB 3.78E-02 8X Cracking in one specimen only M3RB only

6.52E-02 13X Specimen with no initial cracking

M4AB 7.82E-02 16X Cracking in one specimen only M5AB 8.13E-02 16X Cracking in one specimen only M10C 8.54E-02 17X No Additional Cracking M6C 8.88E-02 18X No Additional Cracking

M13AB 9.54E-02 19X Cracking in one specimen only M14C 2.51E-01 51X M4C 2.52E-01 51X

M11C 2.54E-01 51X M9C 2.55E-01 52X

M12C 2.96E-01 60X M1AB 3.22E-01 65X Control M8C 3.84E-01 78X

M7AB 3.96E-01 80X M3AB 4.86E-01 98X Premature Cracking in A M7C 5.31E-01 108X M5C 5.67E-01 115X

M13C 5.76E-01 117X M3C 5.80E-01 118X M2C 6.65E-01 135X M1C 8.11E-01 164X Control

Chloride Results (Water Soluble)Table 7: Water Soluble Percent Chloride by Weight of Concrete

Depth Specimen 0 to13 mm 13 to 25 mm 25 to 38 mm

M1B 0.53 0.49 0.46 M2A 0.49 0.28 0.25 M3A 0.42 0.39 0.37 M4A 0.46 0.42 0.26 M5A 0.46 0.38 0.17 M6A 0.23 0.06 0.05 M7A 0.79 0.71 0.64 M8A 0.65 0.54 0.36 M9B 0.48 0.29 0.11

M10A 0.22 0.13 0.04 M11A 0.30 0.25 0.13 M12A 0.51 0.30 0.13 M13A 0.54 0.50 0.43 M14B 0.79 0.68 0.45

*Notes: All data is from autopsied specimens, after 108 weeks of testing for all but M6A and M10A which were after 84 weeks of testing

New Results Pending

(Assistance?)

Spray Application

>36 weeks

Materials Testing

UConn

Materials Testing

_, _, 1 and 2 %

Sponsor: Connecticut DOT

Absorption

Freeze Thaw

Compressive Strength

From UConn Project96-2 Phase II Report

UConn

Absorption – Dried at 100oC

Control 8.5

_ % 5.1

_ % 3.8

1 and 2 % 3.0

Absorption - Dried at 40oC

Relative Values Similar ASTM C642-90

Control 8.5

_ % 5.1

_ % 3.8

1 and 2 % 3.0

UConn

Freeze-Thaw -18 to 4 oC >300 cycles

Reported Acceptable for HPC

ASTM C666-92

From UConn Project 96-2Phase I Report

UConn

Stable Air Entrainment

Better Without De-foaming Agent

Likely Best with Full De-Foamingand Air-entraining Admixture

ASTM C666-92

If allowed to dry before testing“resistance to freeze-thaw damagemight increase very significantly”(Phase II pg. 124)

UConn

Strength Loss

10 to 20 % Reduction

up to 37% reduction

_, _ %

1 and 2 %

Possible De-foaming Agent Issue

From UConn Project 96-2Phase I Report

UMass

Compressive Strength – NETC Test

_ % Hycrete DSS

Triple Combinations: Strength Increased 15%

GBFS, CN/GBFS: Strength Increased 15%

CN+Hycrete DSS: Strength Reduced 25%

Hycrete DSS: Strength Reduced 10%

Compressive Strengths

0

1000

2000

3000

4000

5000

6000

0 14 28 42 56 70 84 98 112 126 140 154 168 182 196Days

Control

1/4% DSS

1/2% DSS

1% DSS

Field Implementation

Field Implementation

Guard Rails – Connecticut DOTPhoto Courtesy of CT DOT

1 Year

50 Barriers

I-84

New York/New Jersey Port Authority - Sidewalks

Ohio – Noise Barriers/black steel

Florida

Rhode Island

Texas

Ohio DOT Spec Approval

New Jersey Turnpike Authority

Field Implementation

100 yd3 Deck

Hycrete

High Performance

Bridge Decks

Kansas Bridge Project Photo Courtesy of Broadview Technologies

Field Implementation

2-decks with black barsembedded @ 1”

560 yd3

Hycrete vs. NormalHigh Performance

Corrosion Readings @28 days and once/twiceyearly for 10 years

FHWA Funding

Kansas» KU and KS DOT

» Lab and Field Studies

Virginia DOT

NETC 03-2“Field Studies of Concrete Containing Salts of

an Alkenyl-Substituted Succinic Acid”

NETC 03-2

Large Scale Mix Design

Materials Testing

Project Selection

Field Implementation

Long-Term Corrosion Monitoring

University of Massachusetts, Amherst

Initiated 09/15/04

Questions?

civjan@ecs.umass.edu

References civjan@ecs.umass.edu UMass (NETC 97-2)

Civjan S. A., LaFave J. M., Lima J., and Pfiefer D. “Effectiveness ofCorrosion Inhibiting Admixture Combinations in Structural Concrete”Cement and Concrete Composites, Elsevier – In Publication

Civjan, S. A., LaFave, J. M., Lovett, D., Sund, D. J., and Trybulski, J.“Performance Evaluation and Economic Analysis of Combinations ofDurability Enhancing Admixtures (Mineral and Chemical) in StructuralConcrete for the Northeast U.S.A.” Final Report (NETC 97-2).http://docs.trb.org/00960060.pdf

UConn (CT DOT Project 96-2) Allyn, M. and Frantz, G. C. “Strength and Durability of Concrete

Containing Salts of Alkenyl-Succinic Acid.” ACI Materials Journal2001; V. 98 (1); 52-58.

Allyn, M. and. Frantz, G.C. “Corrosion Tests with Concrete ContainingSalts of an Alkenyl-Succinic Acid.” ACI Materials Journal 2001, V. 98(3): 224-232.