Manufacturing Errors of Concrete Cover as a Reason of Reinforcement Corrosion in a Precast Element—Case Study

Abstract

The article concerns the assessment of technical condition of the precast loggia wall in a large panel building after 25 years of use as well as the cause of its damage. As a result of the study, cracks and losses of the concrete cover were found. Corrosion products were visible on exposed reinforcing rods. The reinforcement distribution and concrete cover thickness in loggia wall were estimated using a rebar detector. The corrosion assessment of reinforcement was performed using a semi non-destructive galvanostatic pulse method that allows the location of areas of corrosion and estimate the reinforcement corrosion activity. The phase composition of the concrete cover was analyzed. The test results showed an insufficient thickness of the concrete cover as the main cause of loggia wall damage. The research indicated that manufacturing errors made in the prefabrication plants affect the technical condition of precast elements and may lead to the damage of the structure well before the expected of its service life. In the case of manufacturing errors causing the implementation of an element with a concrete cover that does not meet the standard requirements for thickness and tightness, it is recommended to use protective coatings to increase the element’s durability to the designed level.