Chloride threshold for rebar corrosion in concrete with addition of silica fume

The effect of silica fume on the chloride threshold for the initiation of pitting corrosion of steel in concrete was investigated. Laboratory tests were carried out in concrete specimens made with ordinary Portland cement and with 10% of silica fume. Chloride contents up to 2% by mass of cement were added to the mixes, in order to investigate the corrosion rate of embedded bars made of both strengthened and mild steel. A lower chloride threshold was observed in the bars which were embedded in concrete with silica fume compared to those embedded in concrete made of Portland cement.     

On the penetration of corrosion products from reinforcing steel into concrete due to chloride-induced corrosion

Reinforced concretes were corroded to varying degrees by exposing to cyclic NaCl spray and 40 °C drying. The amount of corrosion products and induced damage were measured using image analysis. We found that corrosion products can accumulate at steel-concrete interface as well as penetrate cement paste and deposit within hydration products, relicts of reacted slag, and air voids. As corrosion increases, the products tend to accumulate at the steel-concrete interface, while the amount penetrating cement paste remains relatively constant. Only a small amount of corrosion is needed to induce visible cover cracking. Implications on modelling time to cover cracking are discussed.     

Use of a 3D optical measurement technique for stochastic corrosion pattern analysis of reinforcing bars subjected to accelerated corrosion

The 3D corrosion patterns of 23 reinforcing bars subjected to accelerated corrosion are characterised using an optical surface measurement technique. A stochastic signal processing methodology is employed for corrosion pattern analysis of the measured data. The statistical analysis of corrosion pattern data shows that a lognormal distribution model can represent the non-uniform distribution of pitted sections along the corroded bars. It was observed that the frequency of corrosion is independent from the mass loss ratio and the length of the bars. Finally, a set of probabilistic distribution models for the geometrical properties of corroded bars is developed.     

Non-uniform distribution of rust layer around steel bar in concrete

The thickness of rusted layers at steel/concrete interface from a chloride-exposed reinforced concrete specimen was observed by digital microscopy. The non-uniform corrosion front is presented by a Gaussian function, the parameters in the model, including the non-uniformity coefficient, the spread coefficient, and the uniformity coefficient, are studied to describe the non-uniform distribute characters of rust layer. Comparing with the models proposed by other researchers, the Gaussian model can describe the non-uniform rust layer better. The location of corrosion peak along the perimeter of rebar and the condition for corrosion spreading across the entire circumference of rebar are discussed.     

Damage analysis and cracking model of reinforced concrete structures with rebar corrosion

The damage of concrete cover in reinforced concrete structures induced by reinforcing steel corrosion is investigated in this study. The damage process of the concrete cover can be divided into two distinct stages: the non-cracking stage and the partial cracking stage. An analytical model based on damage mechanics and elastic mechanics is developed to predict the concrete cracking due to steel corrosion. Based on this model, the expansive pressure and the radial loss of steel bar are discussed. Parametric studies are carried out to examine the effects of the correlative factors on the expansive pressure and the steel loss.     

Modelling sea-salt transport and deposition in marine atmosphere zone - A tool for corrosion studies

Atmospheric corrosion of metals and corrosion of reinforcements in concrete structures are influenced by salt concentration of marine aerosol inland. This work presents a model that represents marine aerosol behaviour in marine atmosphere zone. The model has the distance from the sea and wind speed as the major variables and takes into account changes in marine aerosol due to settlement of salts when being transported inland. The proposed equations M=M₀e^{(vdep₀/αh)[e(-αx/v)-1]}, D=D₀e^{(vdep₀/αh)[e(-αx/v)-1]} show good consistency with literature data and well represent the results obtained. This model can be a useful tool to indicate the salinity level expected at different distances from sea in marine atmosphere zone.     

3D Numerical modelling of steel corrosion in concrete structures

The paper deals with a 3D numerical model for transient analysis of processes after depassivation of reinforcement in concrete, which are relevant for calculation of corrosion rate. The aim of the study is to investigate the influence of the concrete quality, cracking and water saturation in concrete on the current density. The results show that the corrosion rate is higher in poor quality concrete than in good quality concrete. The model predicts that cracks do not influence corrosion rate for the case where the only influence of the crack is on the rate at which oxygen can reach the steel.     

Reinforcement corrosion-induced cover cracking and its time prediction for reinforced concrete structures

A relation between the radial pressure induced by expansion corrosion products and weight loss percentage of corroded steel was developed and simplified by investigating the influence of the mechanical properties of corrosion layer on cover cracking. By taking account of the penetration of the rusts into open cracks, a mathematical model that predicts the cover cracking time was proposed based on Faraday’s law. Some experimental observations were compared with the predictions made by the proposed model and two existing models, which indicates that the presented model is more suitable for predicting cracking time for both accelerated and long-term corrosion conditions.     

The effect of temperature on the corrosion of steel in concrete. Part 2: Model verification and parametric study

A comprehensive model for predicting the corrosion rate of steel in concrete has been developed using the concept of simulated polarization resistance experiments. This model is developed by carrying out a nonlinear regression analysis on data obtained from numerical experiments that are based on the solution of Laplace’s equation in a domain determined by the polarized length of the rebar. This part of the paper provides a comprehensive verification of the developed model and illustrates the application of the model to investigate the coupled effects of parameters affecting corrosion of steel in concrete. The results of the verification study show that the model predictions are in good agreement with the experimental data.     

The effect of temperature on the corrosion of steel in concrete. Part 1: Simulated polarization resistance tests and model development

The effect of temperature on the corrosion rate of steel corrosion in concrete is investigated through simulated polarization resistance experiments. The simulated experiments are based on the numerical solution of the Laplace’s equation with predefined boundary conditions of the problem and have been designed to establish independent correlations among corrosion rate, temperature, kinetic parameters, concrete resistivity and limiting current density for a wide range of possible anode/cathode (A/C) distributions on the reinforcement. The results, which successfully capture the resistance and diffusion control mechanisms of corrosion as well as the effect of temperature on the kinetic parameters and concrete/pore solution properties, have been used to develop a closed-form regression model for the prediction of the corrosion rate of steel in concrete.     

Assessing corrosion risk in reinforced concrete using wavelets

Corrosion potential measurements were analyzed using the continuous wavelet transform (CWT). The corrosion potentials estimate the probability of corrosion of steel embedded in concrete. The CWT of the corrosion potential data estimates the behaviour in time of the energy distribution associated with the corrosion process. The results obtained indicate that CWT-based ratios can be successfully applied to better understand the different processes involved in the corrosion phenomenon, such as the cracking of concrete.     

Chloride induced reinforcement corrosion: Electrochemical monitoring of initiation stage and chloride threshold values

Reinforcement steel embedded in six different concrete mixes was exposed to chloride by wetting/drying cycles. Various parameters were continuously monitored during more than 1 year. Cement replacement with fly ash had beneficial long-term effects regarding chloride penetration resistance. Concerning corrosion performance, by far the most dominant influencing parameter was the steel/concrete interface since corrosion initiated on the lower side of the rebar (with respect to casting direction) regardless of binder type and w/b ratio. In many cases, after the first signs of depassivation, a marked increase in chloride content was required to prevent repassivation and to enable stable pit growth.     

Quantum chemical study of some cyclic nitrogen compounds as corrosion inhibitors of steel in NaCl media

Corrosion inhibition efficiencies of 3-amino-1,2,4-triazole (3-ATA), 2-amino-1,3,4-thiadiazole (2-ATDA), 5-(p-tolyl)-1,3,4-triazole (TTA), 3-amino-5-methylmercapto-1,2,4-triazole (3-AMTA) and 2-aminobenzimidazole (2-ABA) as corrosion inhibitors on steel in sodium chloride media were investigated by using semiempirical PM3 and density functional theory (DFT) methods. Quantum chemical parameters such as highest occupied molecular orbital energy (E_HOMO), lowest unoccupied molecular orbital energy (E_LUMO), energy gap (ΔE) and dipole moment (μ) have been calculated for these compounds by using semiempirical PM3 and 6-31G(d), 6-311G(d,p) DFT methods. It was found that theoretical data support the experimental results.     

A numerical study of damage caused by combined pitting corrosion and axial stress in steel pipes

Localized pipe wall damage accounts for many failures. Numerical modelling of pipes under increasing axial load and constant internal pressure when there is corrosion pits on the exterior surface of the pipe is reported herein. It is shown that for the assumed ideal elastic–plastic material the shape and volume of the plastic field depend on pit depth and its geometry. Pipe wall fracture around a pit can be associated with a critical plastic section. The results reported herein should be relevant for estimating of the risk of perforation and of loss of contents for steel pipes under different loading.     

Modeling the cracking of cover concrete due to non-uniform corrosion of reinforcement

In situations when external chloride penetration is the cause of depassivation, the corrosion process may start from the outer region of a rebar, which might expand non-uniformly. Therefore, the main objective of the present work is to explore the effect of non-uniform corrosion on cracking behavior of cover concrete. The influences of concrete heterogeneities and the porous layer generated at the rebar/concrete interface on the failure patterns and the corrosion level of cover concrete are considered. The random aggregate structures of concrete are built, and the concrete is regarded as a composite composed of three phases, i.e. the aggregate, mortar matrix, and the interfacial transition zones (ITZs). The plasticity damaged model is employed to describe the mechanical properties of the mortar matrix and the ITZs, and it is assumed that the aggregate is elastic. Non-uniform radial displacement with a half ellipse shape is adopted to describe the expansion distribution of the corrosion products. The failure pattern and the corrosion pressure of cover concrete, and the critical corrosion level when the cover concrete cracks due to non-uniform corrosion expansion are studied based on the meso-scale numerical method. The comparison of the simulation results with the available test results on the failure pattern of cover concrete shows fairly good agreement. Moreover, the influence of meso-structural heterogeneities is explored, and the cracking behavior obtained under non-uniform and uniform expansion conditions are compared. Finally, the influences of cover thickness, rebar diameter and the location of rebar (namely side-located rebar and corner-located rebar), on the failure pattern and the corrosion level are examined.     

Polarisation behaviour of steel bar samples in concrete in seawater. Part 2: A polarisation model for corrosion evaluation of steel in concrete

In the companion paper [Z.T. Chang, B. Cherry, M. Marosszeky, Polarisation behaviour of steel bar samples in concrete in seawater, Part 1: Experimental measurement of polarisation curves of steel in concrete, Corrosion Science 50(2) (2008) 357-364], influences of the experimental procedure on measured polarisation curves of steel in concrete in seawater were investigated. It was found that an undistorted full polarisation curve of a steel sample in concrete can be obtained by the two-test procedure to conduct separate anodic and cathodic polarisation tests and combine the two partial curves into one curve. However, polarisation curves of steel samples in concrete in seawater were found not to fit with the theoretical curves based on the kinetics of charge transfer reactions. This was considered to be due in the main to the influence of a passive film on the steel surface in concrete. This paper proposes an empirical model for the polarisation behaviour of steel in concrete based on the assumption of two major electrochemical processes taking place at the interfaces of steel/passive-film/concrete: one is the active corrosion process and the other is the passive film growth or dissolution process. Typical curve-fit results are presented using the proposed model to simulate the polarisation behaviour and to evaluate the corrosion rate and Tafel parameters of three types of steel corrosion in seawater: steel bars in concrete, new steel bars and corroded steel bars.     

Influence of pH on the nitrite corrosion inhibition of reinforcing steel in simulated concrete pore solution

Measurements of corrosion rate of reinforcing steels have been carried out in solutions simulating electrolytic chloride environments in corrosion pits in the propagation period with sodium nitrite. A significant corrosion inhibition has been observed at relatively low chloride contents of 0.045 M due to the presence of nitrite in these systems, but its efficiency decreases when the pH is reduced. The corrosion intensity seems to be related to the [Cl⁻]/[OH⁻] ratio. Three different pH regions from acid to alkaline have been observed in terms of corrosion activity. An explanation on the behaviour of nitrite at different pH is given.     

Effect of surface condition on the initial corrosion of galvanized reinforcing steel embedded in concrete

The present work was aimed at determining the effect of coating surface condition on the initial corrosion of hot-dip galvanized reinforcing steel bar (HDG rebar) in ordinary Portland cement (OPC) concrete. During zinc corrosion in OPC concrete, calcium hydroxyzincate (CHZ) formed on untreated HDG steel provided sufficient protection against corrosion. Therefore, it is concluded that treating HDG rebar with dilute chromic acid is unnecessary as a method of passivating zinc. A layer of zinc oxide and zinc carbonate formed, through weathering, on HDG bars increased the initial corrosion rate and passivation time compared with the non-weathered rebar exposed to concrete. HDG steel with an alloyed coating, i.e. containing only of Fe-Zn intermetallic phases, required a longer time to passivate than those with a pure zinc surface layer. The lower zinc content of the surface limited the rate of CHZ formation; hence, delayed passivation. Regardless of the surface condition, the coating depth loss after two days of embedment in ordinary Portland cement concrete was insignificant.     

Throwing power of cathodic prevention applied by means of sacrificial anodes to partially submerged marine reinforced concrete piles: Results of numerical simulations

The paper deals with the determination of current and potential distribution in reinforced concrete elements partially submerged in seawater aimed at predicting the throwing power of cathodic prevention applied by means of sacrificial anodes. Experimental results from previous laboratory tests showed that the throwing power of cathodic prevention is higher compared to that of cathodic protection [1]. In order to extend the results obtained on small-scale specimens to elements of higher dimensions, FEM numerical simulations of potential distribution were carried out. Several cases were considered, representative of conditions differing in electrochemical behaviour of steel bars, geometry of the pile and of sacrificial anodes, concrete resistivity. The results allowed to discuss the role of different factors on the throwing power that can be reached by using sacrificial anodes immersed in the seawater to protect reinforcing steel bars in the emerged part of a pile.     

Comparison of uniform and non-uniform corrosion induced damage in reinforced concrete based on a Gaussian description of the corrosion layer

A Gaussian function is proposed to describe the non-uniform spatial distribution of corrosion products as measured from chloride-exposed reinforced concrete specimens using backscattered electron imaging and image analysis. The model provides a good fit to the observed data and limited data sets reported in the literature. Subsequently, it is used as an input into a finite element analysis to provide a qualitative comparison of the damage induced on concrete from idealized uniform corrosion and more realistic non-uniform corrosion. The spatial distribution of corrosion is shown to have a major impact on the propagation phase, directly influencing residual service life.