DURABILITY OF CONCRETE EXPOSE TO

WEATHER CONDITION
DEFINITION
Concrete durability has been
defined by the American
Concrete Institute (ACI) as its
resistance to weathering action,
chemical attack, abrasion and
other degradation processes

DEFINITION
The durability of concrete depends on its
quality, which can be increased by proper
choice of materials, proportioning,
placing and curing
Concrete with higher strength and lower
permeability is more durable

THESE CAUSES WILL AFFECT THE
DURABILITY OF CONCRETE:
1. Spalling due to corrosion of reinforcement
2. Alkali-aggregate Reaction (AAR)
3. Chemical Attack
4. Surface Deterioration
5. Cracking
6. Freeze/Thaw Action
7. Efflorescence

5
EXPOSURE CONDITIONS AND
DETERIORATION MECHANISMS
Durability Aspect/Exposure Mechanism
Alkali-Aggregate Reaction
Chemical Resistance

Alkali-Silica Reaction

Alkali-Carbonate Reaction
Sulfates

Seawater Acids

6
EXPOSURE CONDITIONS AND
DETERIORATION MECHANISMS (CONTD)
Durability Aspect/Exposure Mechanism

Corrosion of
Reinforcement

Chloride Resistance

Carbonation

Corrosion
Freeze-Thaw
Freezing and Thawing

Deicer Scaling

D-Cracking
7
Durability Aspect/Exposure Mechanism

EXPOSURE CONDITIONS AND
DETERIORATION MECHANISMS (CONTD)
Miscellaneous
Abrasion

Erosion

Fire Resistance

Efflorescence
CONCRETE in MARINE ENVIRONMENT
DURABILITY REQUIREMENTS (ACI 318-08, SEC.4)
Max. water-cement ratios (w/cm) : 0.40 0.50
Recommended f
c
: 27.50 35.00 MPa
The licensed design professional shall assign
exposure classes based on the severity of the
anticipated exposure category according to ACI
318-08 Sec.4.2.1
The Code addresses four exposure categories
that affect the requirements for concrete to
ensure adequate durability, i.e. : Exposure
Category F, S, P and C

EXPOSURE CATEGORIES and CLASSES
Exposure Category F applies to exterior concrete that is exposed to moisture and cycles of
freezing and thawing, with or without deicing chemicals
Category Severity Class Condition Max w/cm Min f'c (MPa) Examples
Not
applicable
F0
Concrete not exposed to freezing-and-
thawing cycles
N/A 17,5
Moderate F1
Concrete exposed to freezing-and-
thawing cycles and occasional
exposure to moisture
0,45 30
Exterior walls, beams,
girder, and slabs not in
direct contact with soil
Severe F2
Concrete exposed to freezing-and-
thawing cycles and in continuous
contact with to moisture
0,45 30
Exterior water tank or
vertical members in
contact with soil
Very severe F3
Concrete exposed to freezing-and-
thawing cycles and in continuous
contact with to moisture and exposed
to deicing chemicals
0,45 30
horizontal members in
parking structures
F
EXPOSURE CATEGORIES and CLASSES
Exposure Category S applies to concrete in contact with soil or water containing deleterious
amounts of water-soluble sulfate ions
Category Severity Class
Water soluble sulfate
(SO
4
) in soil, percent
by weight
Dissolved sulfate
(SO
4
) in water, ppm
Max w/cm Min f'c (MPa)
Not
applicable
S0 SO
4
< 0,10 SO
4
< 150 N/A 17,5
Moderate S1 0,10 < SO
4
< 0,20
150 < SO
4
< 1.500
Seawater
0,5 27,5
Severe S2 0,20 < SO
4
< 2,00 1500 < SO
4
< 10.000 0,45 30
Very severe S3 SO
4
> 2,00 SO
4
> 10,000 0,45 30
S
EXPOSURE CATEGORIES and CLASSES
Exposure Category P applies to concrete in contact with water requiring low permeability

Exposure Category C applies to concrete exposed to conditions that require additional protection against
corrosion of reinforcement
Category Severity Class Condition Max w/cm Min f'c (MPa)
Not
applicable
P0
In contact with water where low
permebility is not required
N/A 17,5
Moderate P1
In contact with water where low
permebility is required
0,50 27,5
Not
applicable
C0 Concrete dry or protected from moisture N/A 17,5
Moderate C1
Concrete exposed to moisture but not to
external sources of chlorides
N/A 17,5
Severe C2
Concrete exposed to moisture and an
external sources of chlorides from
deicing chemicals, salt, brackish water,
seawater, or spray from these sources
0,45 35
P
C
CONCRETE COATING
Another way of enhancing the durability of
concrete is by applying a coating
For many years, coatings have been applied for
aesthetic reasons.
Depending on design and environmental
requirements, weatherproofing treatments have
also been widely used and more durable paints
have evolved.
The increasing use of steel-reinforced concrete in
modern building has led, however, to widespread
deterioration problems associated with
reinforcement corrosion.



CONCRETE COATING
These are related to the specification and quality of
concrete, the depth of protective cover, efficiency in
placing and curing, or to factors in design or
environmental exposure.
Coatings are increasingly being used to protect
reinforced concrete structures against the penetration
of carbon dioxide, water and other aggressive agents,
such as chlorides, to ensure a satisfactory service
life.
Suitable barrier coatings provide a logical option.
The number of cases requiring such protection is
growing.
ADVANTAGES of COATING
Decoration
Cleanability
Dust reduction
Water proofing
Enhanced slip resistance
Protection against reinforcement corrosion
Resistance to chemical attack
Protect from damage caused by frost, abrasion,
mechanical stress, slat penetration, water and
from solar heat
COATING COMPOSITION
The primary ingredients used to formulate coatings
can be placed into one of three basic categories -
solvent, resin, and pigment.
Historically, the first paints utilized fish or vegetable
(e.g., linseed) oils as binders and natural earth
pigments.
The first solvents were from trees (e.g., turpentine).
Now most resins and solvents are derived from
petroleum, and many pigments are derived from
organic synthesis or modification of natural minerals
SOLVENT
Organic solvents are used to dissolve the resin material
and reduce the viscosity of the product to permit easier
application.
They also control leveling, drying, durability, and
adhesion.
The blend must completely dissolve the total binder
system and be balanced to ensure compatibility and
stability during all stages of curing.
Improper blends may result in cloudy films, pigment float
to the wet film surface, or reduced film durability.
Paint solvents evaporate into the air and contribute to the
production of photochemical smog.
Thus, there is a great pressure to reformulate coatings to
reduce the solvent content of paints.
RESIN & PIGMENT
Resins, also called binders, are the filmforming portions of
coatings.
They are usually high molecular weight solid polymers (large
molecules with repeating units) in the cured film.
In some cases, lower molecular weight units in two liquid
components react with each other upon mixing to polymerize into
the higher molecular weight solid.
The pigment constitutes the solid portion of a wet paint.
Pigments are insoluble in the vehicle and are generally heavier
than the liquid vehicle portion.
They may settle to the bottom of a container upon prolonged
standing.
Natural earth pigments are generally much more stable to light
than synthetic organic pigments.
GENERAL TYPES of COATINGS
Alkyds & other Oil-containing coatings
Water emulsion (latex) coatings
Lacquers
Epoxy coatings
Coal-tar epoxy coatings
Polyurethane coatings
Polyester coatings
Inorganic zinc coatings
Zinc-Rich organic coatings
ALKYDS & OTHER OIL-CONTAINING COATINGS

The unmodified drying oil coatings initially developed
were very easily applied, did not require a high level
of surface preparation, and had good flexibility; they
could readily expand and contract with the substrate.
They did, however, have several drawbacks: they
were slow to dry, had residual tack, and provided a
limited period of protection.
They cannot be used in sea water immersion service
or on alkaline substrates (e.g. concrete), because
they are easily hydrolyzed (deteriorated by reaction
with water) by alkalinity.
They are used most on wood and steel surfaces.
ALKYDS & OTHER OIL-CONTAINING COATINGS

Advantages Limitations
Easy to apply/repair/topcoat Relatively high in VOCs
Good initial flexibility possible
Poor performance in severe
environment
Good surface wetting/adhesion Poor chemical/solvent resistance
Good gloss retention Poor immersion resistance
Relatively inexpensive Poor alkali resistance
Based on renewable source Poor heat resistance
Become brittle with extended aging
WATER EMULSION (LATEX)COATINGS
Water emulsion coatings, commonly called latex
coatings, have been successfully used for many
years to coat wood and masonry structures.
The porous nature of their films allows water vapor to
pass through them
This porosity reduces their durability on steel.
Thus, much effort is being made to develop more
durable products because of the great advantages of
their low VOC contents and ease of application and
clean-up.
Water-emulsion coatings have excellent flexibility and
low cost, and are easily topcoated and repaired.
WATER EMULSION (LATEX)COATINGS
Drawbacks include poor solvent and heat resistance (as
with all thermoplastics), poor immersion resistance, and
difficulty in bonding to smooth oil/alkyd coatings and
chalky surfaces.
The poor bonding is due to insufficient content of organic
solvents to soften and wet the binder in the existing paint
film.
Because of this limited adhesion, it is necessary to sand
smooth enamels and/or use a surface conditioner before
topcoating with latexcoatings.
Latex paints do not cure well at temperatures below 50
degrees F, as the emulsion does not coalesce to form a
good film.
WATER EMULSION (LATEX)COATINGS
Advantages Limitations
Environmental acceptability Limited durability
Easy to apply/repair/topcoat Poor chemical/solvent resistance
Excellent flexibility and color and gloss
retention
Poor wetting of surfaces
Low cost Poor immersion service
Available in wide range of color and gloss Must cure above 50 degrees F
LACQUERS
Lacquers (e.g., vinyls, chlorinated rubbers, and acrylics)
form durable films that have good water and chemical
resistance but, being thermoplastics, poor solvent and
heat resistance.
They have a low film build but dry so fast that they can be
quickly topcoated.
When used on steel, they require a blast-cleaned surface,
and in some cases wash priming, for good adhesion.
They are easy to topcoat and repair and can be
formulated for good gloss retention.
The good weathering of acrylic lacquers is duplicated in
acrylic water emulsion coatings.
LACQUERS
Advantages Limitations
Rapid drying and recoating High in VOCs
Good chemical resistance Poor solvent/heat resistance
Good in water immersion Low film build
Good gloss retention possible Blasted surface necessary
Good durability Occasional poor adhesion
Easy to topcoat and repair
Can be applied at low temperatures
EPOXY COATINGS
Epoxy films are tough and relatively inflexible.
Thus, they cannot expand or contract much without
cracking.
However, they bond well and are very durable in most
environments.
They require a blasted steel surface, and they chalk
freely in sunlight.
An aliphatic polyurethane finish coat is usually
applied when the coating is exposed to sunlight.
Epoxies can be formulated to be low in VOCs, some
actually solvent-free.
EPOXY COATINGS
Advantages Limitations
Low in VOCs Limited pot life
Good solvent/water resistance Chalk in sunlight
Tough, hard, smooth film Cure best above 50 degrees F
Good adhesion Top coating is a problem
Good abrasion resistance Blasted surface needed
COAL-TAR EPOXY COATINGS
Coal-tar epoxy coatings are basically epoxies (with all
properties of epoxies) to which coal tar has been
incorporated.
The coal tar reduces cost, improves water resistance,
and provides for greater film builds.
Because of the coal tar, coatings tend to become
brittle in sunlight, and there is great concern about
toxic effects of the coal tar.
They are used primarily on steel piling and other
buried structures.
The catalyst component is usually either a polyamide
or an amine
COAL-TAR EPOXY COATINGS
Advantages Limitations
Low in VOCs Toxic; personal protection needed
Good water/chemical resistance Limited pot life
Good film build Blasted surface needed
Good abrasion resistance Top coating is a problem

Available only in black, dark red, or
aluminum
POLYURETHANE COATINGS
Polyurethane coatings are one or two-package systems.
For two-package systems, one component is an isocyanate and the
other a polyol component.
Polyurethanes are moisture sensitive, and the gloss may drop when the
wet film is exposed to high humidity.
The toxicity of the isocyanate component is of great concern, and
personal protection, including respirators, must be used when applying
them.
They require skilled applicators.
Polyurethane coatings are available in a variety of formulations, giving
rise to a variety of properties (e.g., may be tough or elastomeric).
They perform well in most environments.
Aliphatic polyurethanes have excellent weathering in sunlight; aromatic
polyurethanes do not, but they have better chemical resistance.
Both types can readily be formulated to be low in VOCs.
POLYURETHANE COATINGS
Advantages Limitations
Low in VOCs Highly toxic; need personal protection
Good solvent resistance Moisture sensitive; gloss may drop
Good hardness or flexibility Skilled applicator needed
May have excellent gloss Limited pot life
Good durability Blasted surface required
Good abrasion resistance High cost
POLYESTER COATINGS
Polyester coatings are used most with
fiberglass or glass flake reinforcement.
They can be very tough and durable but are
seldom used today except with glass
reinforcement.
INORGANIC ZINC COATINGS
Inorganic zinc coatings usually have a silicate resin
The silicate film is very hard and abrasion resistant.
They provide cathodic protection to steel, require greater steel
surface cleanliness, and must be applied by a skilled applicator
Inorganic zinc silicate coatings frequently do not bond well to
each other, and it is safest to repair them using a zinc-rich organic
coating.
Inorganic zinc coatings are extremely durable in an atmospheric
environment, the steel preferentially receiving cathodic protection
from the zinc.
The zinc is attacked, however, by acid and alkali
Inorganic zinc coatings have not been used often in continuous
water immersion because of concern for their limited period of
protection.
INORGANIC ZINC COATINGS
Advantages Limitations
Can be low in VOCs Needs clean, blasted surface
Excellent abrasion resistance Requires skilled applicator
Excellent heat resistance Constant agitation needed
Good atmospheric durability Difficult to topcoat
Useful as shop primer Attacked by acid and alkali

ZINC-RICH ORGANIC COATINGS
Zinc-rich organic coatings utilize an organic resin
rather than an inorganic silicate binder.
Zinc-rich organic coating films can be of the
thermoplastic (e.g., utilize vinyl or chlorinated rubber
resins) or the thermosetting type (e.g., utilize epoxy
or polyurethane resins).
Film properties of zinc-rich organic coatings are
similar in most respects to those of zinc-free organic
coatings using the same resin.
Organic zinc-rich coatings do not require as high a
level of blast-cleaned steel surface as do zinc-rich
inorganic coatings, and they are easier to topcoat.
ZINC-RICH ORGANIC COATINGS
Advantages Limitations
Can be low in VOCs Requires skilled operator
Good durability Constant agitation necessary
Relatively easily topcoated Unsuitable for acid or alkali
Moderate surface preparation needed Costly
SELECTION of SURFACE TREATMENT
SURFACE PREPARATION
Surface treatments are designed to provide lasting
protection in any number of environments.
This, almost inevitably, will mean that the choice and
application of surface treatment may vary
considerably from one locale to another.
Concrete is not any different in terms of preparation
than, say, timber or steel.
The surface must be clean, free from grease, flaking
paint, eflorescence, fungal growth, corrosion
products, mould release agents, curing membranes
and, most importantly, be in a good state of repair.
SURFACE PREPARATION
Most signs of degradation will be apparent
from the general surface appearance, such
as reinforcement corrosion, spalling or
mechanical damage.
The level of breakdown must be assessed
before attempting to decide on the final
surface preparation.
SURFACE PREPARATION
Some suggested methods for cleaning are:
1. For small areas, mechanical wire brushing.
2. High-pressure water jetting (provided adequate,
suitable drainage is present).
3. A fungicidal wash.
4. Wet, dry or vacuum abrasive blasting.
5. Mechanical impact techniques, such as needle
gunning or bush hammering.
6. Mechanical abrasion.
SURFACE PREPARATION
Mechanical abrasion methods of cleaning are
effective for removing deeply ingressed
contamination but may remove unacceptable
quantities of surface concrete.
Needle gunning and bush hammering are extremely
effective but are often too aggressive and lead to
micro-cracking and form deep textures in previously
smooth concrete, thus rendering the final surface
unacceptable for coating without carrying out
expensive skimming.
The use of washing techniques may also be flawed,
as the correct choice of detergent is not always
obvious and an incorrect material may just spread
surface contaminants.
SURFACE PREPARATION
Using solvent-based or sodium hydroxide-based
products are often more effective, but may lead to
health and safety problems for operatives and
surrounding periphery such as alumunium and glass.
Removal of these products efficiently is also vital, as
remaining traces may interfere with the application of
surface treatments at a later stage.
Whichever method appears to be the most suited to
any project, it is always advisable to carry out trials
on sample areas, with reference to material suppliers,
contractors and or applicators before proceeding.
APPLICATION METHODS
No matter what choice of coating has been
made, there are three main methods of
application to post-fabricated concrete
structures; brush, roller or spray.
Environmental considerations, surface area
to be coated, accessibility and final choice of
finish will be the main criteria to be
considered when making a decision on the
method of application.
APPLICATION METHODS
The environment is of increasing concern and many
owners or local councils are beginning to move away from
solvent-based products in favor of waterborne or high
solids systems in enclosed areas or town centers
Due to solvent emissions from the atomized paint, this is
of increasing importance if a sprayed finish is desired.
These emissions will be reduced if a roller is used but the
method will be very labor intensive if large areas require
coating and the use of a brush in such circumstances is
not recommended.
Textured coatings may be sprayed or rolled to a desired
pattern as required and the emissions from such systems
are generally much lower than standard paint products.
APPLICATION METHODS
When spraying smooth coatings, either an airless or
air assisted unit may be used.
Most contractors favor the use of airless systems
which are quicker touse, reduce wastage and almost
eliminate over-spray if set correctly.
Spray equipment is now available to apply two-pack
materials without the necessity of pre-mixing the
components, as all mixing takes place in the nozzle
prior to atomization.
Whichever spray system is used, the final
environmental consideration is the immediate locale
and great effort must be made to mask off all
surrounding areas.
APPLICATION METHODS
Brushing and rolling may be used on small
surface areas, for cutting-in or where access
is limited and spraying is impossible.
Where a two-pack epoxy of polyurethane has
been specified and the use of specialized
spray equipment is impracticable, the
utilization of a roller is recommended, but
only sufficient product should be mixed at
one time as can be applied within the pot
life.