Paper 19347 - Presentation

INSPECTION, DIAGNOSIS, MATERIALS AND PROCESSING METHODS TO REPAIR THE COMMERCIAL DECK IN PUERTO QUETZAL GUATEMALA

Edgar Maya, Lorenzo M. Martínez de la Escalera, Jorge Cantó Jorge A. Ascencio, Lorenzo Martínez Marco Vinício Morales, Leonardo De Silva-Munoz

Background



As a result of a visible degradation of the concrete crown of the commercial dock sheet piling of Puerto Quetzal in Guatemala, port authorities realized that a damage evaluation study along with repair and protection works were needed for the deteriorated concrete structure.



The methodology used for corrosion damage evaluation and the technologies applied for repairing the concrete crown and protecting it form corrosion are presented.

Aerial view of Puerto Quetzal

Comercial dock in Puerto Quetzal

Background (cont.) 

Puerto Quetzal is located on the pacific coast of Guatemala. It was finished in 1984 and is considered the most important port in Guatemala due to its import and export volumes.



The comercial dock main structure is constituted by a steel sheet piling with a reinforced concrete crown.



In 2007, repair works for the frontal face of the concrete crown were left unfinished, causing a quicklier deterioration of the steel reinforcing bars.



Corrosion of the Steel Reinforcing Bars of the Sheet Piling Concrete Crown.

Muelle Quetzal, Guatemala



Corrosion of the Steel Reinforcing Bars of the Sheet Piling Concrete Crown.

Muelle Quetzal, Guatemala

Methodology and Results of the Corrosion Evaluation in Puerto Quetzal 

PROCEDURE 

Physical impact tests.



Concrete sampling and evaluation of chloride content and carbonation.



Corrosion potential measurements.



Delamination evaluation through acoustic tests.



The Dock Was Divided into 21 Sections for better Data Interpretation



Physical Impact Tests





Physical Impact Tests on Concrete for Strength Determination

Results showed that concrete strength was adequate since 97% of the measurements were above 300 kg/cm2, while 3% were under acceptable values.

Impact tests results De 150.0 a 299.0

kg/cm2

3%

De 300.0 a 400.0

kg/cm2

14 %

Mas de 400.0

kg/cm2

83 %

Compresion tests performed according to ASTM C-805 standard



Concrete Samples Extraction





Concrete Samples Extraction

Laboratory results showed a high corrosion risk for the steel reinforcing bars. All the samples analized had a choride content higher than the recommeded limit. Concrete carbonation was also detected, although measured values sugested that carbonation had not an important influence on the corrosion of the studied concrete structure.

Sampling depth

Samples above chloride content limit (0.025 %)

From 0” to 0.5”

100 %

From 2.5” to 3.5”

94%

Sampling and analysis were performed following NACE standards establishing a chloride content limit of 0.025 % weight.



Corrosion Potential Measurements

Corrosion Potential Measurements

22%

48% 30%

LOW RISK OF CORROSION 48% HALF RISK OF CORROSION 30% HIGH RISK OF CORROSION 22%

Corrosion Potential Measurements SECCION 4 -163 mV

-121 mV

-33 mV

-532 mV

-505 mV

-392 mV

-550 mV

-528 mV

-545 mV

-506 mV

-500 mV

-48 mV

-36 mV

-49 mV

-341 mV

-235 mV

-14 mV -22 mV

-332 mV

-340 mV

-52 mV

-90 mV

-51 mV -84 mV

-359 mV

-425 mV

-407 mV

-17 mV

-128 mV -74 mV

-27 mV

-57 mV

-44 mV -50 mV

-110 mV

-103 mV -60 mV

-18 mV

+13 mV

-31 mV

-30 mV

-64 mV

+28 mV -70 mV

-55 mV

-21 mV -43 mV

-494 mV

+33 mV

-84 mV -205 mV

-50 mV

-165 mV

-10

-84 mV

-22 mV

-216 mV

-1

-539 mV -209 mV -330 mV -356 mV -510 mV -445 mV -435 mV -194 mV -512 mV -489mV -33 mV -338 mV -225 mV -1 -512 mV -368 mV -425 mV -472 mV -336 mV -508 mV

SECCION 6 +27 mV

+55 mV

+59 mV +37 mV

-180 mV

-370 mV

-20 mV

-330 mV -401 mV

-360 mV

-330 mV

-380 mV

-28 mV

-490 mV

-50 mV

-182 mV -340 mV

-326 mV

-380 mV

-37 mV

-31 mV +22 mV

-380 mV

-350 mV

-42 mV -53 mV

-208 mV

-135 mV

-330 mV

-370 mV

-62 mV

-370 mV

-330 mV

-48 mV

High corrosion risk zones

-245 mV

-220 mV

-340 mV

-404 mV

+15 mV -30 mV

-356 mV

-325 mV

-105 mV

-404 mV

-360 mV

-1 -190 mV

-416 mV

-425 mV

-204 mV

-302 mV

+18 mV

-58 mV

-480 mV

-250 mV

-64 mV -326 mV

-85 mV

-28 mV

-404 mV

-208 mV

-229 mV

-33 mV -70 mV

-50 mV

-51 mV

-160 mV

-270 mV

-15 mV

-75 mV -70 mV

-52 mV

-30 mV

-163 mV

-194 mV

-60 mV

-31mV -14 mV

+32 mV

+47 mV

-20 mV

-326 mV

-23 mV

+34 mV -50 mV

-14 mV

-17 mV

-370 mV -280 mV

-351 mV

+25 mV +22 mV

-332 mV

-270 mV

-1

-360 mV -3

-450 mV





Corrosion Potential Measurements

Corrosion risk criteria for steel – concrete potentials

Less electronegative than -200Mv

Between -200 and -350 Mv

More electronegative than -350 Mv

Probability under 10%

Uncertain probability

Probability above 90%

Criteria considered in ASTM C876-91 R99 standard



Delamination Evaluation With Acoustic Measurements

Delamination evaluation with acoustic measurements

26 %

74 %

CONCRETE IN GOOD MECHANICAL CONDITION

74 %

CONCRET WITH DELAMINATIONS OR DAMAGES

26 %

Delamination Evaluation With Acoustic Measurements SECCION 5

SECCION 8

SECCION 10

Delaminated sections

Delamination Evaluation Results Severely damaged area (Urgent attention)

20 %

Area with hidden corrosion proceses (Short-term attention)

73 %

Area with minimal corrosion problems (Long-term attention)

7%

Rehabilitation strategies 

The following strategies are recommended in order to have the best results for rehablitation and corrosion protection for sheet piling concrete crowns.

Rehabilitation strategies Demolition of 220 m3 of delaminated or deteriorated concrete.

Rehabilitation Strategies Cleaning of 1,100 m2 of exposed concrete surface and steel reinforcing bars after demolition.

Rehabilitation Strategies Instalation of distributed and embeded galvanic anodes



General Conclusions

Corrosion damage evaluation was performed on the comercial dock sheet piling concrete crown in Puerto Quetzal, Guatemala using ASTM standards.  Delamination of internal layers of concrete was detected along with severe corrosion damage on exposed steel reinforcing bars.  Rehabilitation procedures included the substitution of damaged concrete layers and instalation of galvanic cathodic protection systems.  These rehabilitation works in the crowning beam of reinforced concrete in Puerto Quetzal, are currently in process. 