09/03/2011 1

SILANES
Sydney Opera House
protected with MASTERSEAL 360 TE
John Halsall
Regional Business Segment
Manager
Repair & Grouts
09/03/2011 2
What are Silanes?
Chemical Compound of Silicone and Hydrogen
Used as an Adhesion Promoter in
- Adhesives and sealants
- Coatings
- Fillers and Pigments
Hydrophobic Treatment for Building / Structure
Protection
Silane
RSi(OR)
3
09/03/2011 3
Small Reactive Molecules
Penetrate Deep Into The Substrate
Chemically Bond With The Concrete
Form A Water Vapour Permeable Protective Barrier
Against Harmful Waterborne Substances
Si
O
O
O
S i
O
S i
X
O
R
Si
Si
O
O
O
S i
O
H
f
R
f
Substrate e.g. concrete Substrate e.g. concrete Substrate e.g. concrete Substrate e.g. concrete
Silane Molecule Silane Molecule Silane Molecule Silane Molecule
What are Silanes?
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Si
Consider Silanes As Umbrella Protecting The
Substrate
What are Silanes?
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Silanes Make The Surface Of the Substrate Hydrophobic.
They Penetrate Deeply Into Substrate And React With The Surface
Of The Pore System.
dissolved
chlorides
water vapor
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capillary pore
OH-function
silanized
capillary pore
alkylsiloxane
How Do Silanes Work?
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Due To The Protective Function (Umbrella) Silanes Change The
Surface From Hydrophilic To Hydrophobic.
Non Modified Hydrophilic
Mineral Substrate Causes
Capillary Suction
Silane Treated Hydrophobic
Porous Mineral Substrate.
No Ingress Of Water
How Do Silanes Work?
09/03/2011 7
Water Absorption On Structural Concrete
0
1
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0 1 2 3 4 5 6 7
Immersion [days]
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Masterseal 360/
Protectosil CIT
untreated
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Masterseal 360 TE (Protectosil BHN)
Field Study Zeebrugge Harbour Wall 1993 -
2005
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Silanes Vs Siloxanes
Silanes are small molecules and Penetrate Deeply into the Substrate and
chemically react with the pore surface (3-10mm deep). This chemical
reaction and deep penetration give a life > 10 years
Siloxanes are big molecules which form a film within the outer pores
system that creates a water barrier on any mineral building material with
pores (Bricks, roof tiles, concrete). This material is eventually washed out
of the pores and thus has a life of around 5 years..
Silane
RSi(OR)
3
Siloxane
Si O
OR
RO Si O Si O Si OR
OR OR OR
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No significant penetration
of a siloxane resin based
water repellent
Siloxane Treated
Silanes Vs Siloxanes
Penetration of the silane
into dense concrete
HIGH PENETRATION DEPTH = LONG SERVICE LIFE
Surface modification
can cause less adhesion
of a succeeding coating
No change in surface appearance
Silane Treated
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Clear Liquids (Cream)
Low Viscosity (10 times less than water)
Simply Applied
Highly Water Vapour Permeable
No Change Of Surface Appearance
Silane Protection of Buildings / Structures
MASTERSEAL 360TE
09/03/2011 12
Advantages of Silanes
They can avoid damage caused by
- Chloride induced corrosion of reinforcement
- Carbonation induced corrosion
- Freezing / thawing
- Acid Rain
- Alkali silica reaction
(Na,K)-Si-OH gel reacts with Ca solidification water absorbtion and
swelling
- Sulfate Attack
- Reduce Efforvescence
09/03/2011 13
Storebaelt Bridge
Sydney Opera House
Zeebrugge Harbour
References
09/03/2011 14
Summary - Silanes
Very effective for reduction of water absorption
Excellent penetration depth
Completely water vapour permeable
Long-term stability over decades, proved in various field
studies
Does not change surface and thus will accept
subsequent coatings
Coated surfaces have a longer service life
Repels various dissolved pollutants
Easy spray application
Available in various forms (is available in liquid, gel and
water dispersed forms
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Silane Based Corrosion Protection
09/03/2011 16
TYPES OF CORROSION PROTECTION
Mechanical Methods
Coating Of The Steel Reinforcement (Emaco Nanocrete AP)
Coating Of Concrete Surface (Masterseal Acylics)
Non Corrodeable Reinforcement (SS, Carbon , Fibreglass)
Electrochemical Methods
Chloride Ion Extraction
Galvanic Cathodic Protection (
Impressed Current Cathodic Protection
Chemical Methods
CORROSION INHIBITORS (PROTECTOSIL CIT)
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What Is Protectosil

Cit ?
Silane Based Corrosion Inhibitor To Reduce Active But Not Yet Visible
Corrosion (Ie Rusting Has Not Yet Resulted In Cracks, Spalling, Rust
Stains Etc)
Protectosil CIT Consists Of Small, Reactive Molecules, That
Penetrate Deeply Into The Concrete And React With The Concrete
Pore Walls
Prevents Ingress Of More Water, Chloride Ions And Other
Pollutants
Can React With The Oxide Layer Of The Rebar
Strengthening Of The Passivation Layer
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Incipient Anodes (Ring Anode Effect)
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Corrosion In Reinforced Concrete
anode
cathode
cathode
4 Fe 4 Fe 4 Fe 4 Fe 4 Fe 4 Fe 4 Fe 4 Fe
2+ 2+ 2+ 2+
+ 8 e + 8 e + 8 e + 8 e- -- -
4 Fe 4 Fe 4 Fe 4 Fe
2+ 2+ 2+ 2+
+ O + O + O + O
2 22 2
+ 8OH + 8OH + 8OH + 8OH- -- - 4 FeOOH + 2 H 4 FeOOH + 2 H 4 FeOOH + 2 H 4 FeOOH + 2 H
2 22 2
O OO O
2 O 2 O 2 O 2 O
2 22 2
+ 4 H + 4 H + 4 H + 4 H
2 22 2
O + 8 e O + 8 e O + 8 e O + 8 e- -- - 8 OH 8 OH 8 OH 8 OH- -- -
e
- -- -
e
- -- -
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Specimen Set Specimen Set Specimen Set Specimen Set- -- -up For Laboratory up For Laboratory up For Laboratory up For Laboratory
Testing Of Corrosion Testing Of Corrosion Testing Of Corrosion Testing Of Corrosion
Inhibitors Inhibitors Inhibitors Inhibitors
FHWA TEST METHOD
25 mm 25 mm 25 mm 25 mm
25 mm 25 mm 25 mm 25 mm
PONDED SALTWATER
HUMIDITY PROBE
DRAWING NOT TO SCALE
09/03/2011 21
Test Set-up
Filled with
15 % NaCl
concrete
humidity
Acrylic glass edging
Sensor for
Steel rebars
Steel
rebars
The idea is to cycle the salt water ponding to drive the salt into the
concrete to initiate corrosion much faster than in real life
09/03/2011 22
Decrease in Corrosion Current Following
Application Of Protectosil Cit
Days ponding Days ponding Days ponding Days ponding
0 00 0
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800 800 800 800
untreated
After CIT application After CIT application After CIT application After CIT application
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wetting/drying cycles wetting/drying cycles
Concrete sepcimen according to FHWA (30x30x17,5 cm), 15 % NaCl solution, Total
corrosion current
(macro- + microcell corrosion) measured,
> 90 % reduction of corrosion current > 90 % reduction of corrosion current > 90 % reduction of corrosion current > 90 % reduction of corrosion current
09/03/2011 23
Performance On Cracked Concrete Performance On Cracked Concrete Performance On Cracked Concrete Performance On Cracked Concrete
Cracks are 0.3 mm wide
and 25 mm deep
Corrosion Corrosion Corrosion Corrosion
products products products products
visible visible visible visible
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PROTECTOSIL

CIT PREVENTS CORROSION ON

CRACKED CONCRETE
0 00 0
100 100 100 100
200 200 200 200
300 300 300 300
400 400 400 400
500 500 500 500
600 600 600 600
0 00 0 1 11 1 5 55 5 10 10 10 10 15 15 15 15 20 20 20 20 25 25 25 25 30 30 30 30 35 35 35 35 40 40 40 40 45 45 45 45 48 48 48 48
Time Time Time Time - -- - Weeks Weeks Weeks Weeks
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Untreated Untreated Untreated Untreated
Protectosil CIT Protectosil CIT Protectosil CIT Protectosil CIT
09/03/2011 25
Protectosil Protectosil Protectosil Protectosil

Cit Reduces Cit Reduces Cit Reduces Cit Reduces
Existing Active Existing Active Existing Active Existing Active Corrosion On Corrosion On Corrosion On Corrosion On
Cracked Concrete Cracked Concrete Cracked Concrete Cracked Concrete
0 00 0
100 100 100 100
200 200 200 200
300 300 300 300
400 400 400 400
500 500 500 500
600 600 600 600
0 00 0 1 11 1 5 55 5 10 10 10 10 15 15 15 15 20 20 20 20 25 25 25 25 30 30 30 30 35 35 35 35 40 40 40 40 45 45 45 45 48 48 48 48
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Weeks of Salt Water Exposure Weeks of Salt Water Exposure Weeks of Salt Water Exposure Weeks of Salt Water Exposure
Slabs Treated Slabs Treated Slabs Treated Slabs Treated
with CIT with CIT with CIT with CIT
Untreated Untreated Untreated Untreated
Protectosil Protectosil Protectosil Protectosil
CIT CIT CIT CIT
09/03/2011 26
Application Of Protectosil

Cit
Spalled concrete and delaminations are repaired; totally corroded
reinforcement has to be replaced; the surface has to be cleaned from
dust, effluorences and oil
Protectosil

CIT should be applied to ALL concrete using low-pressure

pumping equipment
09/03/2011 27
Field Performance of Field Performance of Field Performance of Field Performance of
Protectosil Protectosil Protectosil Protectosil

CIT CIT CIT CIT
Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water
20 Year Old Building Located in Florida, USA 20 Year Old Building Located in Florida, USA 20 Year Old Building Located in Florida, USA 20 Year Old Building Located in Florida, USA
Total Repairs = US $ 1.2 million Total Repairs = US $ 1.2 million Total Repairs = US $ 1.2 million Total Repairs = US $ 1.2 million
Repairs Made and Protectosil Repairs Made and Protectosil Repairs Made and Protectosil Repairs Made and Protectosil

CIT Applied in 1994 CIT Applied in 1994 CIT Applied in 1994 CIT Applied in 1994
09/03/2011 28
Spalls and Delaminations were repaired using standard methods Spalls and Delaminations were repaired using standard methods Spalls and Delaminations were repaired using standard methods Spalls and Delaminations were repaired using standard methods
Protectosil Protectosil Protectosil Protectosil

CIT was applied to all the exposed concrete CIT was applied to all the exposed concrete CIT was applied to all the exposed concrete CIT was applied to all the exposed concrete
Corrosion testing was performed annually to verify performance Corrosion testing was performed annually to verify performance Corrosion testing was performed annually to verify performance Corrosion testing was performed annually to verify performance
Field Performance of Field Performance of Field Performance of Field Performance of
Protectosil Protectosil Protectosil Protectosil

CIT CIT CIT CIT
Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water
09/03/2011 29
0 00 0
0 00 0. .. .2 22 2
0 00 0. .. .4 44 4
0 00 0. .. .6 66 6
0 00 0. .. .8 88 8
1 11 1.0 .0 .0 .0
1 11 1. .. .2 22 2
1 11 1. .. .4 44 4
1 11 1. .. .6 66 6
1994 1994 1994 1994 1994 1994 1994 1994 1995 1995 1995 1995 1996 1996 1996 1996 1997 1997 1997 1997 1998 1998 1998 1998 1999 1999 1999 1999 2000 2000 2000 2000 2001 2001 2001 2001
Corrosion Rate Before CIT Corrosion Rate Before CIT Corrosion Rate Before CIT Corrosion Rate Before CIT
Corrosion Rate After CIT Corrosion Rate After CIT Corrosion Rate After CIT Corrosion Rate After CIT- -- - steel steel steel steel
remains in passive condition for remains in passive condition for remains in passive condition for remains in passive condition for
at least 8 years at least 8 years at least 8 years at least 8 years
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2 22 2
> >> >1.0 1.0 1.0 1.0 A A A A/cm /cm /cm /cm
2 22 2
= < 2yrs to defects = < 2yrs to defects = < 2yrs to defects = < 2yrs to defects
< 0.2 < 0.2 < 0.2 < 0.2 A A A A/cm /cm /cm /cm
2 22 2
= passive conditions = passive conditions = passive conditions = passive conditions
Field Performance of Field Performance of Field Performance of Field Performance of
Protectosil Protectosil Protectosil Protectosil

CIT CIT CIT CIT
Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water Balconies Near Salt Water
09/03/2011 30
Field Performance of Protectosil

CIT
Bridge Deck Exposed to Deicer Salts
1.8 miles long bridge
98,000 m
2
of concrete deck
Built in 1970
Corrosion damage due to
chloride
ingress & transverse
cracking
GeCor 6
Linear
Polarisation
test
apparatus
09/03/2011 31
Commodore Barry Bridge - Corrosion Rate
Measurements from 1997 to 2000
0 00 0
0 00 0. .. .1 11 1
0 00 0. .. .2 22 2
0 00 0. .. .3 33 3
0 00 0. .. .4 44 4
0 00 0. .. .5 55 5
0 00 0. .. .6 66 6
0 00 0. .. .7 77 7
0 00 0. .. .8 88 8
0 00 0. .. .9 99 9
B Gantry B Gantry B Gantry B Gantry E Gant E Gant E Gant E Gantr rr ry yy y F Gantry F Gantry F Gantry F Gantry
Treated Treated Treated Treated
Untreated Untreated Untreated Untreated
Actual core
showing
nature of
transverse
cracks
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> > > > 0.5 0.5 0.5 0.5 - -- - 1.0 1.0 1.0 1.0 A A A A = 3 = 3 = 3 = 3- -- -10yrs to deterioration 10yrs to deterioration 10yrs to deterioration 10yrs to deterioration
< 0.2 < 0.2 < 0.2 < 0.2 A A A A/cm /cm /cm /cm
2 22 2
= passive conditions = passive conditions = passive conditions = passive conditions
09/03/2011 32
Protectosil

CIT Independant testing

J Bennett Associates - USA
Protectosil by Degussa Corporation effectively reduced
corrosion of reinforcing steel in ASTM G109.
Mott MacDonald - UK
..an effective alternative to the existing methods of durability
enhancement for reinforced concrete and the avoidance of
secondary effects such as incipient anode behavior.
SGK - Switzerland
.Protectosil CIT treatment resulted in a clear decrease
in corrosion current, and even repassivation is observed
on the sensors initially showing active corrosion.
09/03/2011 33
SUMMARY
Protectosil CIT should be considered as an solution in part of A long
term repair package
- Effective preventative measure to prevent incipient anodes
- Excludes of water borne chlorides
- Strengthens the passive layer on the steel surface
- Simply applied
- Cost effective
- Proven track record
- Backed up by independent testing
09/03/2011 34
END