Bond of steel reinforcement with microwave cured concrete repair mortars

This paper investigates the effect of microwave curing on the bond strength of steel reinforcement in concrete repair. Pull-out tests on plain mild steel reinforcement bars embedded in four repair materials in 100 mm cube specimens were performed to determine the interfacial bond strength. The porosity and pore structure of the matrix at the steel interface, which influence the bond strength, were also determined. Test results show that microwave curing significantly reduces the bond strength of plain steel reinforcement. The reduction relative to normally cured (20 °C, 60% RH) specimens is between 21 and 40% with low density repair materials and about 10% for normal density cementitious mortars. The corresponding compressive strength of the matrix also recorded similar reduction and microwave curing resulted in increased porosity at the interface transition zone of the steel reinforcement. A unique relationship exists between bond strength and both compressive strength and porosity of all matrix materials. Microwave curing reduced shrinkage but despite the wide variation in the shrinkage of the repair mortars, its effect on the bond strength was small. The paper provides clear correlations between the three parameters (compressive strength, bond strength and porosity), which are common to both the microwave and conventionally cured mortars. Therefore, bond-compressive strength relationships used in the design of reinforced concrete structures will be also valid for microwave cured elements.     

Corrosion protection investigation of reinforcement by inorganic coating in the presence of alkanolamine-based inhibitor

Corrosion of reinforced concrete structures is a major problem throughout the world, demanding significant amounts for repair and rehabilitation. Corrosion protection is commonly performed by coating the concrete or by using corrosion inhibitors. This paper describes the comparative evaluation of the effectiveness of an acrylic dispersion and an inorganic coating on silicate basis, of an alkanolamine-based corrosion inhibitor and of their combination, on reinforced mortar specimens partially immersed in 3.5% NaCl solution. The following techniques were used: strain gauges, measurements of the corrosion potential, the mass loss and the EIS of the reinforcing bars and measurements of the chloride diffusion and the carbonation depth in mortars. Results demonstrate that the simultaneous use of the alkanolamine-based corrosion inhibitor with the inorganic coating offers a protection degree comparable to that of the acrylic dispersion, which performs best in the presence of both chloride ions and carbon dioxide.     

Effects of steel fiber reinforcement on surface wear resistance of self-compacting repair mortars

Self-compacting repair mortars (SCRM), as new technology products, are especially preferred for the rehabilitation and repair of reinforced concrete structures. The self-compactability of repair mortars may bring considerable advantages at narrow mould systems. However, due to the high powder content and absence of coarse aggregate, plain SCRMs are susceptible to surface abrasion, especially in case of repair of surfaces under high rates of abrasion (floors, slabs). Steel fiber reinforcement can be an excellent solution for the abrasion resistance problem of SCRMs. However, the optimum amount of fiber reinforcement to sustain self-compactability should be pre-determined. In this study, the optimum superplasticizer dosage and the maximum possible amount of fiber addition, which maintain the self-compactability and stability, was determined for mortars incorporating steel fibers. In addition, the mechanical performance and abrasion resistance of SCRMs prepared by using these fibers were determined. It was concluded that steel fibers can have rheological and mechanical synergistic effects, and that optimised fiber – superplasticizer dosage combinations can better improve the wear resistance while maintaining adequate flow properties for FR-SCRM.     

Structural performance of corroded RC beams repaired with CFRP sheets

Corrosion of reinforcement is a serious problem and is the main cause of concrete structures deterioration costing millions of dollars even though the majority of such structures are at the early age of their expected service life. This paper presents the experimental results of damaged/repaired reinforced concrete beams. The experimental program consisted of reinforced concrete rectangular beam specimens exposed to accelerated corrosion. The corrosion rate was varied between 5% and 15% which represents loss in cross-sectional area of the steel reinforcement in the tension side. Corroded beams were repaired by bonding carbon fiber reinforced polymer (CFRP) sheets to the tension side to restore the strength loss due to corrosion. Different strengthening schemes were used to repair the damaged beams. Test results showed detrimental effect of corrosion on strength as well as the bond between steel reinforcement and the surrounding concrete. Corroded beams showed lower stiffness and strength than control (uncorroded) beams. However, strength of damaged beams due to corrosion was restored to the undamaged state when strengthened with CFRP sheets. On the other hand, the ultimate deflection of strengthened beams was less than ultimate deflection of un-strengthened beams.     

Effectiveness of corrosion inhibitors in contaminated concrete

Four types of corrosion inhibitors (calcium nitrite at two dosages, calcium nitrate at three dosages and two organic inhibitors at their recommended dosages) were evaluated at five different levels of contamination, i.e., 0.8% chloride; 0.8% chloride plus 1.5% SO₃; seawater; brackish water; and unwashed aggregates. Concrete specimens were used to assess the effect of corrosion inhibitors on the compressive strength of concrete and reinforcement corrosion. The results indicated that the corrosion inhibitors investigated in this study did not adversely affect the compressive strength of concrete. Furthermore, calcium nitrite was efficient in delaying the initiation of reinforcement corrosion in the concrete specimens contaminated with chloride, while both calcium nitrite and calcium nitrate mitigated the corrosive effects of chloride plus sulfate salts or sea water. In the concrete specimens prepared with brackish water or unwashed aggregates, all the inhibitors were effective in reducing the rate of reinforcement corrosion. The type and dosage of corrosion inhibitor were observed to be dependent on the nature and level of contamination.     

Chloride redistribution and reinforcement corrosion in the interfacial region between substrate and repair concrete—a laboratory study

One of the most common deterioration mechanisms in concrete structures is reinforcement corrosion caused by chlorides. An often used repair strategy is to remove the damaged concrete and sometimes also undamaged concrete and replace with a repair concrete. The chloride contaminated undamaged concrete and the repair concrete have to be compatible in order to achieve a durable system. This laboratory study has investigated 13-year-old reinforced concrete specimens with both substrate concrete with mixed-in chlorides and an initially chloride free repair concrete. The main objective was to study chloride transport from the contaminated substrate concrete into the repair concrete and establish chloride profiles across the interfacial region and interfacial zone between the two materials. Another objective was to evaluate the location of reinforcement corrosion in the interfacial zone, in the substrate concrete and in the repair concrete. The main results from this laboratory investigation show that reinforcement corrosion occurs in and near the interfacial zone between chloride contaminated and repair concrete. It was found that the corrosion occurs in local areas with passive steel areas between, i.e. macrocell corrosion. The chlorides are transported from the contaminated substrate concrete into the repair concrete. This investigation indicates that there is a risk for reinforcement corrosion around a patch repair when the substrate concrete has chloride contents exceeding 1.0 wt% by weight of cement.     

Compatibility of repair mortars with concrete in a hot-dry environment

Strengthening, maintenance and repair of concrete structures are becoming more recognised in the field of civil engineering. There is a wide range of repair mortars with varying properties, available in the market and promoted by the suppliers, which makes the selection of the most suitable one often difficult. A research programme was conducted at Leeds University to investigate the properties of cementitious, polymer and polymer modified (PMC) repair mortars. Following an earlier publication on the intrinsic properties of the materials, this paper presents results on the compatibility of these materials with concrete. The dimensional stability is used in this study to investigate the compatibility of the repair mortars and the parent concrete. Composite cylindrical specimens (half repair mortar/half concrete) were prepared and used for the measurements of modulus of elasticity and shrinkage. The results of the different combined systems were obtained and compared to those calculated using a composite model. The variations between the measured and calculated values were less than 10%. The paper attempts to quantify the effect of indirect differential shrinkage on the permeability and diffusion characteristics of the different combined systems.     

Effect of polypropylene fibre reinforced mortars on steel reinforcement corrosion induced by carbonation

Low amounts of polypropylene fibres are added to concrete as a secondary reinforcement to control cracking. Whether this addition might improve the corrosion resistance of the concrete reinforcement by increasing the resistance to carbonation, via reducing penetrating paths, is the subject addressed in the present paper. Crack control by the fibres in plastic state mortars and crack evolution with time have been studied. Furthermore, the influence of crack width on the steel bar corrosion induced by carbonation has also been monitored. Circular specimens made of mortar have been employed in the experimental phase of the study, using a water/cement ratio of 0.50 and cement/sand ratio of 2/1. The polypropylene fibre content was 0% and 0.5% by volume. Low modulus polypropylene fibres may control the crack width in specimens subjected to inadequate curing conditions. No relationship between crack width and time for corrosion initiation has been observed. However, a beneficial effect of fibre addition on the corrosion rate was found.     

Corrosion process and abatement in reinforced concrete wrapped by fiber reinforced polymer

The corrosion performance of steel reinforcement embedded in concrete samples encased by carbon fiber reinforced polymer (CFRP) wraps was investigated experimentally. Concrete samples were wrapped with 0−3 fabric layers impregnated with one of two different epoxies. To accelerate corrosion, samples were subjected to an impressed current and a high salinity solution. Current flow measurements dynamically monitored corrosion activity during exposure, while reinforcement mass losses were measured following exposure. Theoretical predictions of total mass loss were compared with actual corrosion mass loss values. Test results indicated that CFRP wrapped specimens had prolonged test life, decreased reinforcement mass loss, and lower corrosion rates. The performance of wrapped specimens was superior to that of either control samples or those coated only with epoxy. Results indicated that the level of corrosion abatement provided by the CFRP wraps was influenced both by the type of epoxy used and the number of wrap layers.     

Studies on corrosion inhibition of steel reinforcement by phosphate and nitrite

This work deals with the effectiveness of sodium phosphates and nitrites used as inhibitors against steel corrosion in concrete reinforcement. First, concrete pore water was simulated with several alkaline solutions. Then, reinforced concrete specimens with inhibitors added in fresh concrete mix are immersed in chloride solution. The effectiveness of inhibitors was assessed by applying electrochemical techniques, namely Electrochemical Impedance Spectroscopy (EIS), Polarisation Curves (PC), and Open Circuit Potential (OCP) measurements. The final concrete condition was analysed with Scanning Electronic Microscopy (SEM), X-Ray Diffraction (XRD) and Infrared Spectroscopy (FT-IR).In solutions simulating concrete contaminated with chloride, the influence of the inhibitors on the steel corrosion was assessed by (PC) and (EIS). The results obtained show that phosphate prevents pitting corrosion when its content is equal to chloride concentration, and that nitrite only contributes to increase the value of pitting potential. Corrosion rate is reduced with both inhibitors at the different contents tested.For reinforced concrete specimens immersed in chloride solution, their conditions were assessed by applying EIS. The results indicate that after 1 year of immersion with the two inhibitors the corrosion rate decreased. Then, after 3 years of immersion no influence of inhibitors on the corrosion rate was observed. However a significant increase in concrete electrical resistance was observed when inhibitors were present. Visual examinations showed that all steel bars were corroded in the presence of chlorides.Results from analytical tests done on the concrete after 3 years of immersion show that as far as the final concrete condition is concerned, the tested inhibitors did not change the type of compounds in concrete. But the final free chloride content remained higher than the critical chloride threshold. The results of FT-IR technique showed that nitrites are likely washed out of concrete during immersion in chloride solution and phosphates interfere with the equilibrium between CO₃ ^2? and HCO₃ ^? in concrete.The main conclusion of this study is: the efficiency of the tested inhibitors decreases with time, after two years of immersion in chloride solution.     

Cathodic protection with localised galvanic anodes in slender carbonated concrete elements

A combined experimental and numerical investigation was carried out with the aim of determining whether few localised galvanic anodes per unit length could protect the reinforcement of slender carbonated concrete elements, exposed to atmospheric conditions, which could not be repaired with traditional methods. Initially, the cathodic behaviour of steel under galvanostatic polarisation was determined on small-size specimens obtained from a real element. A correlation of potential versus applied current was obtained. The current distribution in slender elements was then determined through finite elements simulations, considering various scenarios of carbonation and humidity. Results showed that, in spite of the high electrical resistivity of carbonated concrete, anodes with spacing of 0.45 m are enough to protect corroding reinforcement in most exposure conditions, even in thin parts of element. Estimated anode durations were of the order of several years or even decades; however, it was shown that also reinforcement in dry (carbonated or alkaline) concrete, which does not need to be protected, contributes to anode consumption. Although other aspects play a role on the performance of a cathodic protection system (such as the effectiveness of anode-encasing material and of electrical connection to reinforcement), the results obtained are supportive of a repair strategy based on the use of localised galvanic anodes and can be generalised to slender elements exposed to atmospheric conditions suffering carbonation induced corrosion.     

Corrosion protection performance of High Performance Fiber Reinforced Cement Composites as a repair material

This paper regards the corrosion protection performance of High Performance Fiber Reinforced Cement Composites (HPFRCC) as a repair material. For the purpose of improving workability, the volumetric fiber content in HPFRCC was decreased from its usual rate of 1.5% to as low as 0.75%. The applicability of HPFRCC as a repair material for preventing steel corrosion was investigated using specimens that simulated either surface coating repair or patch repair. The results can be summarized as follows: Patch repair with HPFRCC to depths beyond the backside of the reinforcement effectively suppressed chloride penetration and prevented reinforcement corrosion, whereas surface coating with HPFRCC could not prevent corrosion of the steel in the RC substrate. As long as the fiber content is set so that only fine cracks are formed under service conditions, differences in fiber content did not affect the corrosion preventing performance of HPFRCC as a repair material.     

Effects of phosphate on the chloride-induced corrosion behavior of reinforcing steel in mortars

The influence of phosphate as a corrosion inhibitor on the corrosion behavior of as-received and pre-rusted reinforcing steels in mortar specimens was investigated after 360 days exposure in 3.5% NaCl solution. This involved the use of electrochemical techniques for studying the steel surface reactions and microscopic observations of the steel–mortar interface. The electrochemical methods, including electrochemical impedance spectroscopy (EIS) and measurements of corrosion potential (E_corr) and linear polarization resistance (LPR), were employed to evaluate the corrosion tendency and general corrosion rate of steel. In addition, the pitting corrosion resistance of steel was also determined by cyclic polarization (CP) measurements. The results indicate that different from nitrite, which is generally accepted as an anodic inhibitor, phosphate may be a cathodic inhibitor according to its reduced corrosion rate and more negative E_corr at the same dosage as nitrite in mortar specimens. The study also reveals that the inhibiting efficiency of phosphate against general corrosion of both as-received and pre-rusted specimens is lower than 10%, which is inferior to nitrite in some respects. However, as indicated by cyclic polarization measurements, the presence of phosphate provides slightly higher pitting corrosion resistance in comparison to nitrite. Furthermore, it suggests that the corrosion inhibition mechanism of phosphate in mortars mainly depends on a dual effect occurring at the steel–mortar interface. Furthermore, it is confirmed that phosphate has little effect on the long-term mechanical properties of mortars.     

Inhibitor protection of the steel reinforcement of armored concrete damaged by cracks

For corrosion-electrochemical investigations, we have developed and manufactured original model concrete specimens-cells to identify testing conditions for six reinforcement specimens. We have studied the polarization characteristics of model specimens held in an environment of weak-acid rain, as well as the kinetics and frequency dependences of impedance characteristics. It has been established that, for the rust protection of steel reinforcement, an inhibiting mixture containing equal quantities of sodium molybdate and calcium nitrate is the most efficient. Its inhibiting efficiency is 10 to 12 times as high as the efficiencies of its components separately, which demonstrates the synergetic effect. The mechanism of the synergetic protective action of these inhibitors lies in passing two processes, which mutually strengthen each other, on the metal surface. The addition of inhibitor to the polyurethane injection composition, applied for the repair of armored concrete structures, increases the strength of adherence of reinforcement with concrete, subjected to the long-term action of a corrosive environment, as compared with noninhibited. Using the synergetic effect in developing inorganic inhibiting mixtures, one can reduce significantly the consumption of materials and improve substantially the manufacturability of injection polymeric compositions for the repair of armored concrete structures of long-term operation.     

Performance of silica fume-calcium hydroxide mixture as a repair material

The aim of this experimental work was to investigate the performance of a special concrete repair material. The use of silica fume (SF)-Ca(OH)₂ mixture, with and without cement addition in reinforced mortars has been studied. The examination of the hydration reaction progress by X-Ray Diffraction (XRD), Differential Thermal Analysis-Thermogravimetry (DTA-TG), and Scanning Electron Microscopy (SEM) analysis of SF-Ca(OH)₂ mixture with various cement ratios, shows that calcium silicate hydrate is formed in a desired extent. Damaged specimens repaired by the above-mentioned materials also showed low carbonation depth and the lowest corrosion rate, close to of undamaged specimens. This is attributed to the formation of C–S–H compounds at the interface between these mixtures and cement mortar, resulting in the creation of good binding properties of the repair materials.     

Efficiency of RC square columns repaired with polymer-modified cementitious mortars

This paper regards the axial behavior of reinforced concrete columns repaired by polymer-modified cementitious mortars. Tests were performed on eight columns with square cross-section: six were repaired with three types of polymer-modified cementitious mortars on all faces, two were in non-damaged and non-repaired condition (control elements). Tests were repeated varying mechanical properties (elastic modulus and compressive strength) of repair materials, maintaining the same repair thickness, including the reinforcement bars. Comparisons between repaired and control elements showed that polymer-modified cementitious mortars cannot restore the original load-bearing capacity of columns. In spite of this, selection of mortar mechanical properties plays a significant role. Among the three types of repair mortar tested in this experimental study, using the material with the most similar elastic modulus and higher compressive strength than that of the concrete substrate is recommended.     

Effect of steel manufacturing process and atmospheric corrosion on the corrosion-resistance of steel bars in concrete

This paper presents results of a study conducted to evaluate the effect of steel manufacturing process and the surface condition of reinforcing steel on their corrosion-resistance when embedded in concrete. Steel bars produced by water quenching and air-cooling were utilized. The corrosion-resistance of fresh bars, i.e., those that were clean and shiny, and those exposed to atmosphere and accelerated salt spray, when embedded in concrete, was evaluated. The corrosion-resistance of the clean and corroded reinforcing steel bars was assessed by measuring corrosion potentials and corrosion current density. Accelerated impressed current technique was also utilized to evaluate the corrosion-resistance of clean and corroded reinforcing steel bars in concrete. A longer time-to-initiation and lower rate of reinforcement corrosion was noted in the concrete specimens prepared with water-quenched steel bars compared to similar bars manufactured by the hot-rolling process. Similarly, the rate of reinforcement corrosion in the concrete specimens prepared with corroded steel bars, exposed to atmosphere for 12 months and salt spray, was less than that on the unexposed bars. The data developed in this study also indicate that the surface layer formed on the water-quenched steel bars, due to the cooling process, provides protection to the metal substrate as against the loose mill scale formed on the steel bars produced by the air-cooling process.     

Formation of chloroaluminates in calcium aluminate cements cured at high temperatures and exposed to chloride solutions

The formation of hexagonal chloroaluminates in mortar specimens pre-cured at 20, 40 and 60°C for two weeks and stored in a 0.5 M NaCl solution for up to 255 days has been studied. The appearance of this phase as a function of time has been monitored by X-ray diffraction. In addition, its microstructure has been observed by means of backscattering electron microscopy. The chemical composition was studied by X-ray microanalysis. The formation of chloroaluminate phases in reinforced concrete is related to the immobilization of chloride ions penetrating through the concrete to the reinforcement. Thus the formation of stable chloroaluminates could lower the risk of corrosion. In order to check this point, corrosion rate measurements were performed throughout the experiment. In spite of the high capacity of aluminous hydrates to react with chloride ions to form chloroaluminates, the remaining chloride ions in the pore solution leads over time to reinforcement corrosion. The presence of hexagonal phases in the cement paste ensure a better resistance against the penetration of chloride ions than when cubic phases are present. This effect was attributed to the denser microstructure exhibited, by samples containing the hexagonal phases. This revised version was published online in November 2006 with corrections to the Cover Date.     

Effects of polymer–cement ratio and accelerated curing on flexural behavior of hardener-free epoxy-modified mortar panels

This experimental study reports the applicability of hardener-free epoxy-modified mortar panels to permanent forms as precast concrete products. Hardener-free epoxy-modified mortars are mixed using a Bisphenoal A-type epoxy resin without any hardener with various polymer–cement ratios and steel fiber reinforcement, and subjected to different curings. Hardener-free epoxy-modified mortar panels are prepared with same polymer–cement ratios and steel fiber reinforcement on trial, and tested for flexural behavior under four-point (third-point) loading. The effects of polymer–cement ratios and curings on strength properties of hardener-free epoxy-modified mortars, and on the flexural strength, flexural stress-extreme tension fiber strain relation, flexural load–deflection relation of hardener-free epoxy-modified mortar panels were examined. The adhesion in tension (to placed concrete) of the hardener-free epoxy-modified mortar panels was also tested. As a result, the hardener-free epoxy-modified mortar panels develop a high flexural strength, large extensibility and good adhesion to the placed concrete. The epoxy-modified mortar panels are more ductile and have high load-bearing capacity than unmodified mortar panels and can be used as precast concrete permanent forms in practical applications.     

Influence of coating on short steel fiber reinforcements on corrosion behavior of aluminium base short steel fiber reinforced composites

Steel fiber reinforced aluminium composites are attractive materials of high specific strength but exhibit poor resistance against electrochemical corrosion. The study discusses the electrochemical corrosion behavior of uncoated, copper and nickel coated short steel fiber reinforced aluminium and Al–2Mg matrix composites in 1 (N) NaCl solution. Galvanic corrosion between the steel fiber and aluminium governs the corrosion behavior of these composites. It has been observed that open circuit potential (OCP) is shifted to more negative side with copper coating on the fibers and to the more positive side on coating the fibers with nickel. Compared to the uncoated fiber higher corrosion current density indicates corrosion rate was observed for the copper coated fiber reinforced composites where as a lower current density was noted for the nickel coated fiber reinforced composites was observed. Addition of 2 wt% magnesium to aluminium alloy matrix increased the corrosion current density. The corrosion mechanism in these composites is dominated by galvanic cell formation that is evident from the dissolution of Al matrix near the peripheral region of steel fibers.