MECHANISM OF CORROSION IN REINFORCED CEMENT CONCRETE

CORROSION

Corrosion

Corrosion

Reinforcement Corrosion Process

Corrosion Promoters
0.8
Acidic Alkaline

Oxygen Water Stray electrical currents Uneven chemical environment around reinforcement Environments that lowert the pH (alkalinity) Chlorides

0.7 0.6 0.5

Corrosion Rate mm/yr

Corrosion Inhibitors
High quality concrete High pH (Alkalinity) concrete protects steel surface from corrosion

0.4 0.3 0.2 0.1 0 0 2 4 6 8 10 12 14

pH of Concrete Relationship between pH and corrosion rate

Corrosion-Induced Cracking and Spalling

Cracking and spalling of concrete induced by steel corrosion is a function of the following variables :

1. Concrete tensile strength 2. Quality of concrete cover over the reinforcing bar 3. Bond or condition of the interface between the rebar and surrounding concrete 4. Diameter of the reinforcing bar 5. Percentage of corrosion by weight of the reinforcing bar

Reduction in Structural Capacity

Loss of section

The structural capacity of a concrete member is affected by bar corrosion and cracking of surrounding concrete. A research conducted on flexural beams found that in steel with more than 1.5 percent corrosion, the ultimate load capacity began to fall, and at 4.5 % corrosion, the ultimate load was reduced by 12%. In compressive members, cracking and spalling of concrete reduces the effective cross section of the concrete, thereby reducing the ultimate compressive load capacity considerably.

Chlorides can be introduced Chloride Penetration

Moisture and Oxygen Chlorides penetrate into concrete with the help of surface moisture

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into concrete by coming into contact with environments containing chlorides, such as sea water or de-icing salts. Penetration of the chlorides starts at the surface, then moves inward. Penetration takes time, depending upon :

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Delamination spall Chlorides penetrate into concrete with the help of surface moisture

When chlorides penetrate to reinforcing steel corrosion begins

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1. The amount of chlorides coming into contact with the concrete 2. The permeability of the concrete 3. The amount of moisture present

Further penetration of chlorides results in further corrosion, delamination and spalling

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Crack or Construction Joint

Cracks and Chlorides

Cracks and construction joints in concrete permit corrosive chemicals such as de-icing salts to enter the concrete and access embedded reinforcing steel.

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Surface Introduced Chlorides

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ACI 224R presents following tolerable crack widths: Exposure condition Tolerance Crack Width (mm) 0.41

alt

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Dry air, protective membrane

Humidity, moist air, soil

De-icing chemicals Seawater and seawater spray; wetting and drying Water-retaining structures

0.30
0.18 0.15

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0.10

Deep spalling

Concrete with Cast-in water soluble chlorides

Cast-in Chlorides
Chlorides can be found in reinforced concrete even before the structure is in service. Chlorides may be introduced deliberately as an accelerator, or in the form of natural ingredients found in some aggregates. ACI 201.2R suggests following limits for chlorides in concrete prior to placing concrete:
Service condition % of Cl to weight of cement 0.06 0.10

Note : shaded area denotes level of moisture penetration.

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Delamination Corrosion

Prestressed concrete
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Conventionally reinforced concrete in a moist environment and exposed to chloride Conventionally reinforced concrete in a moist environment not exposed to chloride

Chloride content is generally the same throughout the cross section

0.15

Carbonation
pH is lowered by the reaction... CO2 + H2O + Ca(OH)2 --> CaCO3 + H2O Acidic gases CO2 H2O

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Carbonation front H2O CO2 Delamination

Carbonation of concrete is a reaction between acidic gases in the atmosphere and the products of cement hydration. The level of carbon dioxide in industrial atmospheres is, as a rule, higher. Carbon dioxide penetrates into the pores of concrete by diffusion and reacts with the calcium hydroxide dissolved in the pore water. As a result of this reaction, the alkalinity of concrete is reduced to a pH value of about 10, and, consequently, concrete protection of the reinforcing steel is lost. The passivity of the protective layer on steel is destroyed. In good quality concrete, the carbonation process is very slow. The process requires constant change in moisture levels from dry to damp to dry. Carbonation will not occur when concrete is constantly under water.

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Corrosion takes place faster when the pH is lowered

CO2

CO2

Carbonation takes place within crack

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Corrosion

Crack

Structural Steel Member Corrosion

Embedded Stuctural Member

Crack or Construction Joint over Embedded Structural Steel

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Aggressive Environment

Embedded Stuctural Member

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+ Lifting of slab from top of flange by expanding corrosion products.

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Corrosion of embedded metals includes structural members such as steel beams cast into concrete to form a composite member, or to provide fire protection. The top flange of a beam is susceptible to corrosion when a crack or construction joint intersects the flange. Moisture and corrosive salts are trapped on the flange, providing an ideal environment for corrosive activity. Corrosion on the top flange exerts a jacking force on the concrete above the flange. When the force is sufficient, delamination occurs. Evidence of slab separation from the beam then becomes apparent from the underside of the slab.

Steel

Aluminium

Dissimilar Metal Corrosion

Aluminium in contact with fresh concrete liberates hydrogen gas, thereby creating localized porosity.

Corrosion can take place in concrete when two diffeent metals are cast into a concrete structure, along with an adequate electrolyte. A moist concrete matrix provides for a good electrolyte. This type of corrosion is known as galvanic. Below is a list of metals in

Note : shaded area denotes level of moisture penetration and active electrolyte. If chlorides are present, the process is accelerated.
Electrode flow

Cathode
Ion OH Flow

Anode
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order of increasing activity : Zinc < Aluminium < Steel < Iron < Nickel < Tin < Lead < Brass < Copper < Bronze < Stainless Steel < Gold

Corrosion occurs here. Aluminium oxide causes expansion and cracking of surrounding concrete

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Unbounded Post-Tension Strand

Post-Tension Strand Corrosion

Aggressive Environment
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Broken protective sheathing allows exposure to corrosive environment. Strand corrodes and breaks

Corrosion of unbonded post-tension strands has become a common problem for structures exposed to aggressive environments. Buildings exposed to ocean salt spray and parking structures exposed to de-icing salts are typical strand locations for

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Collapsing broken strand may exit the structure at points of low cover or at ends

unbonded

corrosion. strands are

Unbonded post-tension

protected
Leakage paths into strand system 7-wire strand Anchorage plug grout Wedges End anchor casting Breakout bars
Push-thru Heat Extruded Sealed Protective Sheathing Types Individual Grease wires (typical)

from

corrosion

by

Unprotected strand without protective sheathing

protective grease and sheathing.