US2003093962A1PendingUtilityA1

Method of resisting corrosion in metal reinforcing elements contained in concrete and related compounds and structures

Priority: Nov 13, 2001Filed: Nov 7, 2002Published: May 22, 2003

Est. expiryNov 13, 2021(expired)· nominal 20-yr term from priority

C04B 28/02E04C 5/015C04B 41/009C04B 22/0093C04B 41/65C04B 41/508C23F 11/00C23F 11/187C04B 22/085C04B 2103/61C04B 2103/0086C04B 2103/606C23F 11/181C04B 2111/26C04B 2103/0067

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References

Claims

Abstract

A method of resisting corrosion in concrete containing metal elements is provided. It includes introducing into fresh concrete, containing metal elements, at least one compound capable of sequestering chloride ions. The method may also involve employing a compound which is capable of establishing a corrosion resistant oxide layer on the metal reinforcing elements. The invention also includes certain compounds which may be employed in the method as well as concrete structures containing the compounds. In another embodiment of the invention, concrete structures may be rehabilitated by providing an overlay containing a compound of the type which will contribute to corrosion resistance either through chloride ion sequestering or creating barriers around metal structural elements with the overlay being provided in situ or as a preformed member and with possible use of a slurry in combination with an overlay segment.

Claims

exact text as granted — not AI-modified

1 . A method of resisting corrosion of metals in a concrete structure comprising, 
 creating an overlay containing at least one compound capable of sequestering chloride ions,    securing said overlay adjacent to said concrete structure, and    sequestering chloride ions in said overlay.    
     
     
         2 . The method of  claim 1  including 
 securing said overlay to said concrete structure to permit chloride ion exchange therebetween.  
 
     
     
         3 . The method of  claim 2  including 
 creating said overlay on said concrete structure.  
 
     
     
         4 . The method of  claim 2  including 
 preforming said overlay, and  
 securing said preformed overlay to said concrete structure.  
 
     
     
         5 . The method of  claim 4  including 
 securing said preformed overlay to said concrete structure by adhesive.  
 
     
     
         6 . The method of  claim 1  including 
 effecting said securing to establish surface-to-surface contact between said overlay and said concrete structure.  
 
     
     
         7 . The method of  claim 1  including 
 applying said overlay to said concrete structure as a slurry.  
 
     
     
         8 . The method of  claim 7  including 
 applying a second layer of said overlay over said slurry.  
 
     
     
         9 . The method of  claim 8  including 
 providing said second layer with lower porosity than said slurry layer.  
 
     
     
         10 . The method of  claim 1  including 
 employing a material selected from the group consisting of concrete, asphalt, Portland cement, clay, calcium aluminate cement, and mortar in said overlay.  
 
     
     
         11 . The method of  claim 1  including 
 introducing high ionic strength liquid into said overlay.  
 
     
     
         12 . The method of  claim 1  including 
 employing said method on a concrete structure disposed at least partially under water.  
 
     
     
         13 . The method of  claim 1  including 
 performing said process without requiring ongoing input of electrical energy.  
 
     
     
         14 . The method of  claim 1  including 
 establishing said overlay with a thickness of about 0.5 to 10 inches.  
 
     
     
         15 . The method of  claim 1  including 
 employing as said compound a compound capable of establishing a corrosion resistant oxide layer on embedded metal elements.  
 
     
     
         16 . The method of  claim 1  including 
 effecting said chloride sequestration in a low-solubility compound.  
 
     
     
         17 . The method of  claim 1  including 
 employing a nitrite-containing compound as said compound.  
 
     
     
         18 . The method of  claim 1  including 
 employing said method on metal elements made of steel.  
 
     
     
         19 . The method of  claim 2  including 
 employing as said compound, a compound capable of liberating nitrite ions.  
 
     
     
         20 . The method of  claim 1  including 
 employing as said compound a compound selected from the group consisting of 
 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O; 3CaO.Al 2 O 3 .Ca(NO 3 ) 2 .nH 2 O; 3CaO.Fe 2 O 3 .Ca(NO 2 ) 2 .nH 2 O; and 3CaO.Fe 2 O 3 .Ca(NO 3 ) 2 .nH 2 O  
 wherein n=0 to 24.  
 
 
     
     
         21 . The method of  claim 2  including 
 employing as said compound a compound selected from the group consisting of 3Me(II)O.R 2 O 3 .Me(II)(anion) 2 .nH 2 O and 3Me(II)O.R 2 O 3 .Me(II)(anion).nH 2 O, 
 wherein Me(II) is one or more cations, R 2  is Al 2 , Fe 2  or Cr 2 , anion is NO 2 , NO 3 , CO 3 , BO 4 , or OH and n is 0 to 24.  
 
 
     
     
         22 . The method of  claim 14  including 
 establishing said overlay with a thickness of about 1 to 4 inches.  
 
     
     
         23 . The method of  claim 2  including 
 employing as said compound, a compound selected from the group consisting of CaO.Al 2 O 3 .Ca(NO) 2 .nH 2 O and 3CaO.Al 2 O 3 .Ca(NO 3 ) 2 .nH 2 O 
 wherein n=0 to 24.  
 
 
     
     
         24 . The method of  claim 1  including 
 said metal elements being embedded reinforcing elements.  
 
     
     
         25 . The method of  claim 1  including 
 effecting said compound introduction into ingredients of said concrete prior to creating said overlay.  
 
     
     
         26 . The method of  claim 1  including 
 effecting said overlay creation by mixing said compound in dry form with cement in dry form and subsequently adding water to said compound and cement mixture.  
 
     
     
         27 . The method of  claim 26  including 
 adding other ingredients to said mixture prior to adding said water.  
 
     
     
         28 . The method of  claim 2  including 
 employing said compound in the following reaction to create the chloride-sequestering compound and to establish said corrosion resistant oxide layer  
 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O+2Cl −   3CaO.Al 2 O 3 .CaCl 2  . nH 2 O+2NO 2   −   
 wherein n=0 to 24.  
 
     
     
         29 . A concrete assembly comprising 
 a concrete structure,    a plurality of metal elements within said concrete structure,    an overlay containing a compound capable of sequestering chloride ions disposed within said concrete structure, and    said concrete structure and said overlay being disposed in close adjacency to permit ion exchange between pores of said concrete structure and said overlay.    
     
     
         30 . The concrete structure of  claim 29  including 
 said concrete structure being a portion of a bridge.  
 
     
     
         31 . The concrete structure of  claim 29  including 
 said concrete structure being a portion of a pier.  
 
     
     
         32 . The concrete structure of  claim 29  including 
 said concrete structure being a portion of a highway.  
 
     
     
         33 . The concrete structure of  claim 29  including 
 said concrete structure being a portion of a parking garage or parking lot.  
 
     
     
         34 . The concrete structure of  claim 29  including 
 said compound being capable of establishing a corrosion resistant oxide layer on said metal reinforcing elements.  
 
     
     
         35 . The concrete structure of  claim 29  including 
 said chloride ion sequestering compound being a low-solubility compound.  
 
     
     
         36 . The concrete structure of  claim 29  including 
 said chloride ion sequestering compound being a compound containing nitrite.  
 
     
     
         37 . The concrete structure of  claim 29  including 
 said compound being selected from the group consisting of 
 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O; 3CaO.Al 2 O 3 .Ca(NO 3 ) 2 .nH 2 O; 3CaO.Fe 2 O 3 .Ca(NO 2 ) 2 .nH 2 O and 3CaO.Fe 2 O 3 .Ca(NO 3 ) 2 .nH 2 O wherein n=0 to 24.  
 
 
     
     
         38 . The concrete structure of  claim 29  including 
 said compound being selected from the group consisting of 
 3Me(II)O.R 2 O 3 .Me(II)(anion) 2 .nH 2 O and 3Me(II)O.R 2 O 3 .Me(II)(anion).nH 2 O  
 wherein Me(II) is one or more cations, R 2  is Al 2 , Fe 2  or Cr 2 , anion is NO 2 , NO 3 , CO 3 , BO 4 , or OH and n is 0 to 24.  
 
 
     
     
         39 . The concrete structure of  claim 38  including 
 said compound being selected from the group consisting of 
 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O and 3CaO.Al 2 O 3 .Ca(NO 3 ) 2 .nH 2 O wherein n=0 to 24.  
 
 
     
     
         40 . A compound capable of sequestering chloride comprising 
 a compound selected from a group consisting of 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O 
 wherein n=0 to 24,  
   3CaO.Al 2 O 3 .Ca(NO 3 ) 2 .nH 2 O; and 3CaO.Fe 2 O 3 .Ca(NO 2 ) 2 .nH 2 O; wherein n=0 to 24.    
     
     
         41 . The compound of  claim 40  including 
 said compound selected from the group consisting of 
 3CaO.Al 2 O 3 .Ca(NO 2 ) 2 .nH 2 O, and 3CaO.Fe 2 O 3 .Ca(NO 2 ).nH 2 O wherein n=0 to 24.  
 
 
     
     
         42 . The method of  claim 1  including 
 employing the following reaction in sequestering said chloride ions  
 3CaO.Fe 2 O 3 .Ca(NO 2 ).nH 2 O+2Cl −   3CaO.Fe 2 O 3 .CaCl 2 .nH 2 O+2NO 2   −   wherein n=0 to 24.

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