Optimizing Performance of Zinc Coated Reinforcing Steel in Concrete Structures
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1 Optimizing Performance of Zinc Coated Reinforcing Steel in Concrete Structures Shannon Pole, EIT March 22, 2017
2 Outline The Corrosion Problem Batch Galvanized Mitigation Solutions Zinc in Concrete Continuous Galvanized Research and Current Projects Next Steps
3 Trade association that represents the interests of the zinc industry
4 The USA Bridge Problem bridges across the USA 48% state owned 2/3 built 26+ years ago 50-80% maintenance funds for bridge decks 25-30% of corrosion could be eliminated If proper materials are used and maintained
5 Road Salt in North America
6 Galvanized Reinforcing Steel Built in 1995 Built in 1990
7 Corrosion of Black Bar In concrete, steel corrosion can cause major deterioration Corrosive elements, diffuse through the concrete matrix to reach rebar
8 Zinc Protection Zn ++ 2(OH) - Zinc Steel 2e - Zn Zn e - 2e - + H 2 O +1/2 O 2 2(OH) - Zinc Paint
9 Zinc Protection Passivation Reaction Product (CHZ) Barrier Coating Cathodic Protection High Chloride Threshold (2-4x black steel) Corrosion Product Migration Concrete Matrix Densification No stress generated at rebar surface Low ph Tolerance (Carbonation protection)
10 Batch Galvanized Coating ASTM A767 Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement
11 Batch Galvanized Process
12 Batch Galvanized Bridges Boca Chica Bridge, Florida Tappen Zee Bridge, New York Curtis Road Bridge, Michigan Athens Road Bridge, Pennsylvania
13 Continuous Galvanized Process
14 Continuous Galvanized Coating Pure Zinc Layer Thin Fe 2 Al 5-x Zn x Layer ASTM A Standard Specification for Continuous Hot-Dip Galvanized Steel Bars for Concrete Reinforcement
15 Formability
16 Duplex Bar Formability
17 Continuous Galvanized Rebar Durable, Flexible Coating Fabricate after coating Pure Zinc Improved corrosion resistance Low cost Less material, shipping, weight, etc.
18 Installing Galvanized Rebar Same as Black rebar: Overlap links Handling procedures Field Bending Possible Optional: Touch-up field cut ends
19 Route 66 Bridge
20 Parsons Precast Steps
21 Medicine Wheel, McMaster University
22 AZZ Facility Sandblast Pit
23 AZZ Facility Sandblast Pit
24 City of Canton, OH Footbridge
25 City of Canton, OH Footbridge
26 City of Canton, OH Footbridge
27 City of Canton, OH Footbridge
28 Shenzhen Metro Line No. 11, Shenzhen, China Currently under construction Opening later this year Fastest Metro line in Shenzhen with speeds of 120 km/h Galvanized rebar is being produced by Xiamen Newsteel
29 G7 Beijing Ürümqi Expressway Connects the cities of Beijing, China, and Ürümqi, Xinjiang. When complete, it will be 2,540 km (1,580 mi) in length. Galvanized rebar is being produced by Xiamen New Steel
30 Continuous Galvanized Rebar Low Cost Tough Corrosion Resistant Formable For more Information and Samples contact: Shannon Pole
31 Comparison versus Black Bar Black Epoxy Galvanized MMFX Stainless CGR* Bluebar* FHWA, 2012 *estimated
32 Zinc in Concrete Passivated by formation of a layer of adherent crystals Calcium Hydroxyzincate (CHZ) Reaction begins upon contact with wet cement solution Ceases once concrete hardens Surface film stabilizes the zinc Second level of barrier protection
33 Migration of Zinc 100x Migration of zinc-rich corrosion products away from the bar/matrix interface and well into the cement matrix. 1000x Partial dissolution of the galvanized coating and zinc corrosion product migrating into the cement matrix.
34 Load-Slip Characteristics Load (kn) Black Epoxy Galvanized Reduced slip for galvanized bars Black Steel Galvanized Steel Epoxy Coated Steel Slip ( m)
35 Improved Corrosion Resistance Pure Zinc corrodes at a slower rate than Iron- Zinc Intermettalic Less zinc consumed to form CHZ passivation layer Less zinc required to provide corrosion resistance Coating Type Average Depth of Loss to Passivation (um) Annealed (Intermettalic) 1.18 Pure Zinc 0.45
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