Use of polymer-impregnated concrete permanent form in marine environment: 10-year outdoor exposure in Saudi Arabia

Chloride diffusion is one of the main factors that affect concrete durability in harsh Arabian Gulf environment. This happens due to severe ground and ambient salinity and large fluctuations in temperature and humidity regimes and shortening the life span of the concrete structures. To study the performance of polymer-impregnated concrete permanent form (PICPF) to prevent chloride penetration, polymer-impregnated concrete panels (450 × 900 × 25 mm) were prepared as permanent forms for large-scale retaining reversible T-shaped reinforced concrete walls (Standard concrete wall and concrete wall covered with PICPF) and exposed to extremely aggressive environment site of the port city, Al Jubail, Saudi Arabia for more than 10 years. The foundation and lower half part of concrete walls were embedded into ground near the sea. This study focused on the use of PICPF in marine environment to prevent chloride ions penetration from atmosphere, ground and sea. The performance of PICPF to protect large-scale concrete walls from chloride attack from ground, atmosphere and sea was evaluated; core specimens were taken from concrete walls after 1.5-year, 5.4-year and 10.6-year outdoor exposure, and tested for carbonation depth, chloride ions penetration depth, and compressive strength. It was found that covering all surfaces of concrete walls with PICPF proved to be much effective in controlling water evaporation from concrete walls to atmosphere and to protect chloride attack from atmosphere, underground water and sea.

► PICPF protects and retrofits old and new concrete structures in severe marine environment.
► Huge reinforced concrete walls (Standard and PICF covered) exposed to aggressive Middle East environment for a decade.
► The performance of PICPF to protect concrete walls from chloride attack from ground, atmosphere and sea was evaluated.
► Carbonation and chloride ions penetration depths and compressive strength tested after 1.5, 5.4 and 10.6-year exposure.
► PICPF cover effectively controlled evaporation and prevented chloride attack from atmosphere, underground water and sea.