Section-14 Durability r1

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NEW UNIFIED CONCRETE CODE
Limit State Version (IRC:112-2011)
SECTION 14 : DURABILITY PROVISIONS
ALOK BHOWMICK
MANAGING DIRECTOR,
B& SENGINEERING CONSULTANTS PVT. LTD.
315-316, VISHAL CHAMBERS, SECTOR 18, NOIDA U.P
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IRC:112-2011
CONTENT OF PRESENTATION
1. Historical Perspective, Definitions
2 D t i ti M h i 2. Deterioration Mechanism
3. Design for Durability
4. Good Detailing practice from Durability
Considerations
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IRC:112-2011
Considerations
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Untill about 30 years ago, durability was
not seen as a serious issue for concrete.
Durability became an issue only when
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HISTORICAL PERSPECTIVE
Durability became an issue only when
following problems were noted all over
the world :
1. Very serious deterioration of bridge decks in
USA, UK and all other countries due to corrosion
of reinforcement, due to use of de-icing salt in
bridge decks in winter.
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2. Major deterioration in problems in the Middle
East due to chloride induced corrosion in a
particularly aggressive environment.
IRC:112-2011
3. Severe cracking in structures in many countries
resulting from alkali-silica reaction
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IRC:112-2011
Deterioration
in Bridges
from
durability
reasons
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IRC:112-2011
Durability of concrete is its ability to
resist weathering action, chemical
WHAT IS DURABILITY ?
attack, abrasion or any process of
deterioration. The cause may reside
inside the concrete itself, or be
present in the service environment
to which the concrete structure is
exposed.
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IRC:112-2011
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Durability Requirements :
Fulfilment of the requirements of
t t l f t d i bilit structural safety and serviceability,
within the planned use and the
foreseeable actions, without
unforeseen expenditure on
maintenance and repair.
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IRC:112-2011
WHY DURABILITY CONSIDERATIONS ARE
IMPORTANT FOR CONCRETE ?
Concrete property changes with time.
It is no longer sufficient for the structure to have only
Strength. The structure shall last also.
So far the practice had been to provide a few deemed
to satisfy clauses in the code to ensure durability (e,g.
On minimum cover, crack width control, maximum spacing
of rebars, minimum concrete grade, minimum cement
content, maximum w/c ratio etc.)
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IRC:112-2011
1. DEEMED TO SATISFY CLAUSE SUFFERS FROM
FOLLOWING :
Fails to acknowledge that structures deteriorate
progressively. p g y
Takes limited account of impact of conceptual &
detailed design, construction quality and methods.
Has limited flexibility.
2. The new code has defined the end of service life,
which demands that structure must be designed for
durability.
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IRC:112-2011
The LS code has given more importance to durability, in
line with the present international practices. The
structure has to be designed for durability. Durability is
covered exclusively in a separate chapter now (section
14).
Classification of Service Environment Four classes
defined now as against Two earlier.
Design Service life has been accounted for in the
provisions of durability.
Additional provisions for specific mechanism of
deterioration added.
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Factors affecting Durability
Service Environment
Detailing (Cover Shape & Size)
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Detailing (Cover, Shape & Size)
Construction Method (Workmanship)
Type & Quality of Materials used
Cement Content & W/C ratio
Repair & Maintenance
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IRC:112-2011
Considerations
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IRC:112-2011
DETERIORATION MECHANISM
Concrete Deterioration
Mechanism
Mechanical & Reinforcement / Chemical /
Most serious form of
degradation of Concrete
Mechanical &
Physical
Deterioration
Reinforcement /
Prestressing Steel
Corrosion
Abrasion
Sulphate
Attack
Alkali - Aggregate
Reaction Carbonation Chlorides
Depassivation
Chemical /
Biological
Deterioration
Acid
Attack
Frost
Attack
Plastic
Shrinkage
Thermal
Effects
Impact Erosion
Chloride CO
2
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IRC:112-2011
1. Since the maximum damage caused in
RCC structures worldwide is primarily
due to corrosion of reinforcement, the
environmental classification in IRC code environmental classification in IRC code
is based on specific mechanism of
duration (i,e. corrosion only).
2. However, relative importance of the
various mechanism of deterioration will
vary from region to region.
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IRC:112-2011
3. Most of the reactions in concrete, which
causes deterioration are expansion -
producing and presence of water or
moisture is required moisture is required.
4. For ensuring durability, It is therefore
important that ingress of moisture in
concrete is restricted to the extent
possible.
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The deterioration process can be divided
into two phases :
During the initiation phase no weakening
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During the initiation phase no weakening
of the concrete or of the function of the
structure occurs.
During the propagation phase active
deteriorations proceeds rapidly and in
many cases with acceleration.
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1. A durable
concrete
structure has a
long initiation
phase and a slow
propagation
IRC:112-2011
t
o
f

a
c
c
e
p
t
a
b
le

d
a
m
a
g
e
DESIGN SERVICE LIFE
p p g
phase.
2. The ideal
situation by
design of new
structure is if the
initiation phase
goes upto say 50
years !
L
im
it
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IRC:112-2011
WHAT IS DESIGN SERVICE LIFE OF A STRUCTURE ?
The assumed period for which a structure is to be used for
its intended purposes with anticipatory maintenance, but
without major repair being necessary.
What is the end of Service Life ?
(Not defined properlyin IRC:112-2011)
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IRC:112-2011
There is need to precisely define
the condition which can be treated
as end of service life.
This can be either in the form of %
depassivation or surface cracking
or spalling of concrete cover.
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IRC:112-2011
Mechanism
Mechanical & Reinforcement / Chemical Mechanical &
Physical
Deterioration
Reinforcement /
Prestressing Steel
Corrosion
Abrasion
Sulphate
Attack
Alkali - Aggregate
Depassivation
Chemical
Deterioration
Acid
Attack
Frost
Attack
Plastic
Shrinkage
Thermal
Effects
Impact Erosion
Chloride CO
2
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Effects of Physical Deterioration :
ABRASION / EROSION / CAVITATION :
IRC:112-2011
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ABRASION / EROSION / CAVITATION :
IRC:112-2011
RESISTANCE TO ABRASION CAN BE OBTAINED BY :
USING HIGH STRENGTH CONCRETE
USINGABRASION RESISTANT AGGREGATES
GOOD CURING
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GALVANISATION / EPOXY COATINGS IN
REBARS SHALL BE ABRASION RESISTANT
SO THAT THERE ARE NO DAMAGE CAUSED
DURING HANDLING / PLACEMENT.
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COATINGS IN PRESTRESSING STEEL SHALL
ALSO BE ABRASION RESISTANT.
ABRASION RESISTANCE IS ALSO A
REQUIREMENT FOR THE SHEATHING DUCTS
BEING USED.
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Abrasion Damage in
Concrete
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Effects of Physical Deterioration :
FROST ATTACK :
1. Capillary pore water in concrete expands by 9%
IRC:112-2011
p y p p y
after freezing, and produces strong pressure which
causes failure, rupture and scaling.
2. Saturation of water is formulated due to repeated
freezing and thawing. When it reaches the critical
saturation, concrete will be destroyed by freezing.
3. The effective way to prevent freezing and thawing
destruction is to add chemical air-entraining agent.
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IRC:112-2011
FROST ATTACK .contd.
4. With the addition of an air
entrainment admixture,
concrete is highly resistant to
freezing and thawing.
5. During freezing, the water displaced by ice
formation in the paste is accommodated so that
it is not disruptive; the microscopic air bubbles
in the paste provide chambers for the water to
enter and thus relieve the hydraullic pressure
generated.
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IRC:112-2011
FROST ATTACK .contd.
6. Concrete with a low water-cement ratio
(0.40 or lower) is more durable than
concrete with a high water-cement ratio concrete with a high water-cement ratio
(0.50 or higher).
7. Air-entrained concrete with a low water-
cement ratio and an air content of 5 to 8%
will withstand a great number of cycles of
freezing and thawing without distress.
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IRC:112-2011
Freeze & Thaw Effect
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Mechanism
Physical
Deterioration
Reinforcement /
Prestressing Steel
Corrosion
Abrasion
Sulphate
Attack
Alkali - Aggregate
Depassivation
Chemical
Deterioration
Acid
Attack
Frost
Attack
Plastic
Shrinkage
Thermal
Effects
Impact Erosion
Chloride CO
2
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Effects of Chemical Deterioration :
ALKALI AGGREGATE REACTION (AAR) :
CERTAIN CONSTITUENTS IN AGGREGATES CAN
REACT HARMFULLY WITH ALKALI HYDROXIDES IN
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CONCRETE CAUSING SIGNIFICANT EXPANSIONS.
THERE ARE THREE FORMS OF THIS REACTION:
1. ALKALI SILICA REACTION (ASR)
2. ALKALI CARBONATE REACTION (ACR)
3. DELAYED ENTRINGITE FORMATION (DEF)
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Effects of Chemical Deterioration : AAR
ALKALI SILICA REACTION (ASR):
ASR is chemical reaction between alkali in cement
and silica in aggregates
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and silica in aggregates.
Alkali is sodium or potassium
A gel is formed and expansion takes place in
presence of moisture, which comes from rain water.
Concrete forms surface cracks called map cracking
Deterioration is caused by spalling.
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IRC:112-2011
Mechanism :
The reaction can be visualized as a two-step
process: process:
Alkali hydroxide + reactive silica gel
alkali-silica gel
Alkali-silica gel + moisture expansion
The reaction has great affinity for moisture
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CONTROL OF ASR:
USE OF LOW ALKALI PORTLAND CEMENT (LESS
THAN 0.6% EQUIVALENT Na
2
O) WHEN ALKALI SILICA
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THAN 0.6% EQUIVALENT Na
2
O) WHEN ALKALI SILICA
REACTIVE CONSTITUENTS ARE SUSPECTED TO BE
PRESENT IN THE AGGREGATE.
IF LOW ALKALI CEMENT IS NOT AVAILABLE, THE
TOTAL ALKALI CONTENT CAN BE REDUCED BY
REPLACING A PART OF HIGH ALKALI CEMENT WITH
SUPPLEMENTARY CEMENTITIOUS MATERIALS SUCH
AS FLY ASH, GROUND BLAST FURNACE SLAG AND
SILICA FUME, OR USE BLENDED CEMENT.
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IRC:112-2011
Alkali Silica Reaction Alkali Silica Reaction
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IRC:112-2011
Photographs showing repair of Bridges affected by Alkali Photographs showing repair of Bridges affected by Alkali--
Silica Reactions Silica Reactions
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IRC:112-2011
Utilization of silica
fume, fly ash, and blast
furnace slag as partial
replacement of cement replacement of cement
will reduce the
expansion.
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ALKALI CARBONATE REACTION (ACR):
THE AGGREGATES [DOLOMITE - CALCIUM
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MAGNE-SIUM CARBONATE] HAVE SPECIFIC
COMPOSITION THAT IS NOT VERY COMMON.
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ALKALI CARBONATE REACTION (ACR):
ACR IS A CHEMICAL REACTION BETWEEN
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HYDROXYL IONS ASSOCIATED WITH THE ALKALIS,
SODIUM AND POTASSIUM IN THE CEMENT AND
CERTAIN DOLOMITIC TEXTURES IN THE
AGGREGATE RESULTING IN EXPANSION AND
EVENTUALLY CRACKING OF THE HARDENED
CONCRETE. (ACR is not as widespread as ASR)
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ACID ATTACK
IRC:112-2011
Concrete is susceptible to acid attack because of p
its alkaline nature. The components of the cement
paste breaks down during contact with acids.
Sulphuric acid is very damaging to concrete as it
combines an acid attack and a sulfate attack.
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Sulphate Attack
IRC:112-2011
Sulfate attack can be external or internal.
External: due to penetration of sulfates in solution,
in groundwater for example, into the concrete from
outside.
Internal: due to a soluble source being incorporated
into the concrete at the time of mixing, (e,g.
gypsum in the aggregate, for example).
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DELAYED ENTRINGITE FORMATION
SPECIAL TYPE OF INTERNAL SULPHATE ATTACK
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IS CALLED DELAYED ENTRINGITE FORMATION.
THE RELATED EXPANSION PRODUCES CRACKING,
SPALLING & STRENGTH LOSS, SINCE IT OCCURS
IN HARDENED CONCRETE.
ITS DAMAGING EFFECT IS RELATED TO INTERNAL
SULPHATE SOURCE
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IRC:112-2011
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Effects of Chemical Deterioration : Sulphate Attack
IRC:112-2011
External Sulfate attack is possibly the most common
and widespread form of chemical attack on concrete.
In case soluble sulphates is >0.1% in soil, it will have
detrimental affect on concrete More than 0 5% is very detrimental affect on concrete. More than 0.5% is very
dangerous.
Damage caused by sulfate attack normally occurs as
cracking, crumbling and scaling of the concrete. In
addition to physical deterioration, sulfate attack may
also destroy the binding capability of the cement,
thus affecting the mechanical properties of the
concrete (strength, elastic modulus).
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IRC:112-2011
Sulfate attack occurs as a chemical reaction of
sulfate ions (aggressive substance) with the
aluminate component of the hardened concrete
(reactive substance).
Sulfate attack may also occur as a physical
attack on concrete due to the crystallization of
sulfate salts within the cement matrix. Regions
of concrete structures experiencing sulfate
attack normally display a characteristic whitish
appearance.
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IRC:112-2011
Damage is usually initiated in areas most
susceptible to the ingress of contaminants, such
as corners and edges of concrete elements. As
g
the attack progresses, extensive cracking and
spalling of the concrete may occur.
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IRC:112-2011
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IRC:112-2011
Mechanism
Physical
Deterioration
Reinforcement /
Prestressing Steel
Corrosion
Abrasion
Sulphate
Attack
Alkali - Aggregate
Depassivation
Chemical
Deterioration
Acid
Attack
Frost
Attack
Plastic
Shrinkage
Thermal
Effects
Impact Erosion
Chloride CO
2
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IRC:112-2011
Corrosion
occurs due to
de-passivation
of iron-oxide
Corrosion Most serious form of deterioration in Concrete
layer alkaline
environment
surrounding the
reinforcement.
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IRC:112-2011
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1. Passivity can be destroyed by chlorides and
carbonation.
2. Once the passivity of steel has been eroded, corrosion
will continue if there is sufficient moisture and oxygen yg
present at the reinforcement.
3. Corrosion requires both water and oxygen. When
concrete is wet, oxygen penetration is inhibited In very
dry conditions, where oxygen levels are sufficient,
moisture levels are low.
4. The greatest risk of corrosion is therefore in members
subjected to cyclic wetting and drying.
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IRC:112-2011
Chlorine ions penetrate to the surface of reinforcing bars
from the protective layer,destroy passive film, and change
bars from passive state into active state.
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IRC:112-2011
Cracking
De-lamination
Spalling of cover
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Carbonation :
1. Atmospheric CO
2
is converted to carbonic acid (H
2
CO
3
) in
the presence of moisture, which attacks hydrated cement
t thi i ll d b ti
IRC:112-2011
paste; this is called carbonation.
2. Carbonation lowers the pH value of concrete and reduces
the protection to steel by the alkalinity of the surrounding
medium.
3. Rate of Carbonation depends upon the concrete grade,
relative humidity & integration of concrete in cover zone
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IRC:112-2011
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Graph showing variation
of Carbonation Depth
with Time
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IRC:112-2011
CORROSION PROTECTION MECHANISM & METHODS
Prevent entry at
concrete surface.
If penetrates
concrete surface,
prevent reaching
the reinforcement
If reaches reinft.,
control corrosion
Best is to avoid
reactive substance
itself !
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2 D t i ti M h i d F t
IRC:112-2011
2. Deterioration Mechanism and Factors
influencing Durability
Considerations
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IRC:112-2011
DESIGN FOR DURABILITY
1. The first step is to establish the
aggressiveness of the service environment
(exposure conditions).
In deciding the appropriate class of service
environment, the following factors are to be
taken into account (fib, 2009):
a. The general environmental conditions of the
area in which the structure is situated,
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b. The specific location and orientation of the
concrete surface being considered and its
exposure to prevailing winds, rainfall etc.,
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c. Localised conditions such as surface
ponding, exposure to surface runoff and
spray, aggressive agents, regular wetting,
condensation etc.
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IRC:112-2011
2. To select the type of structure suitable for the
chosen service environment.
3. To select the appropriate materials, mix
proportions, workmanship, design and
detailing, including minimum cover to steel
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4. There are four categories :
Moderate,
Severe,
Very Severe and
IRC:112-2011
y
Extreme;
This is in increasing order of likelihood of
chloride-induced corrosion and
carbonation - induced corrosion, depending
on the chances of carbonation and ingress of
chloride ions from outside.
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IRC:112-2011
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Moderate category is for situations where the
Not Sea Water !!
IRC:112-2011
g y
chances of carbonation are insignificant because
the pores of concrete are either saturated or dry.
No ingress of chloride from external sources is
anticipated. Inadequate workmanship can lead to
corrosion of steel. Provision is also made against
attack by other deleterious chemical agents,
which are facilitated by the presence of moisture.
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1. Severe category is for situations, where presence
of moisture (wet, rarely dry) and some carbonation
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under humid conditions can lead to corrosion of
steel.
2. Wet, rarely dry includes concrete surfaces subject
to long term water contact and many foundations.
Concrete exposed to coastal environment can have
access to chloride ions increasing the risk of
chloride-induced corrosion.
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3. Concrete components exposed to industrial
t t i i hl id ill b i l d d i thi
IRC:112-2011
waters containing chloride will be included in this
category.
4. In spite of presence of significant amount of
chloride ions in sea water, risk of corrosion in
concrete completely submerged in sea water
below mid-tide level is comparatively less
because of paucity of oxygen.
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1. When the relative humidity is between 50 to 70 percent,
the chances of carbonation are very high. Exposure to
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air-borne chloride ions in marine environment add
significantly to the risk of chloride-induced corrosion.
2. Such exposure conditions are termed very severe.
Saturated concrete subjected to cyclic freezing and
thawing is prone to effects of expansion due to
formation of ice, leading to spalling. Such conditions
are anticipated in few areas in the colder regions of the
country.
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1 Extreme category is for conditions where the risk
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1. Extreme category is for conditions, where the risk
of corrosion of steel and sulphate attack are the
highest in concrete exposed to tidal, splash and
spray zones in sea, because of accumulation of
salts in the pores and accompanied by damage due
to wave action.
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2. Concrete in direct contact with aggressive sub-
soil/ground water can lead to severe attack to
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soil/ground water can lead to severe attack to
concrete in foundations, without being accessible to
periodic inspection and maintenance.
3. If harmful effluents from nearby chemical industries
are discharged into the water body, where the bridge
is situated, it poses serious threat to the durability of
concrete. Cyclic wet and dry conditions allow
accumulation and build up of deleterious agencies.
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IRC:112-2011
Example of
a structure
in
Extreme
climatic
condition
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Clear cover to any reinft.
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Cover can be
reduced by
opting for HPC
(M30 to M90)
In case of
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In case of
blended
cement.
Reinft. has
secondary
role in PCC
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IRC:112-2011
1. The values of minimum strength grade in
Table 14.2 are those which can be
generally expected with the
corresponding water cement ratio and corresponding water cement ratio and
with the cements or binders available in
India.
2. So, the minimum strength grade specified
is an indirect control on the durability
parameters.
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Adjustment for other Aggregate size
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UNIFIED CONCRETE CODE
PART 4 : DURABILITY PROVISIONS
2 D t i ti M h i d F t 2. Deterioration Mechanism and Factors
influencing Durability
Considerations
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GOOD DETAILING PRACTICE
Detailing to improve Durability :
1. Structural Scheme
2. Geometry, Size & Shape of Structure (to promote good drainage)
3. Drainage, Detailing for better Drainage
4. Reinforcement Detailing
5. Use of Controlled Permeability Formwork (CPF)
6. Protective Coatings in Concrete
7. Choice of Rebar Coating
8. Corrosion protection of Prestressing Steel
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Structural Scheme :
Example: Avoid Permanent Joints and Bearings, e.g. Integral Bridges
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Geometry, Size & Shape effects Durability :
Pier with lesser surface area / volume ratio is preferred
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Drainage : Most Important for Durability
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Drainage :
Avoid Horizontal Surface in Substructure Detail to
promote quick run-off
(e,g top of pier cap to be sloped outside)
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Poor Drainage :
Severe distress due to
corrosion induced by defective
expansion joint detail
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Reinforcement Detailing :
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Controlled Permeability Formwork :
1. The properties of surface skin (the cover),
which is the first line of defence to
protect reinforcement, remain poorer.
2. Conventional steel or timber formwork is
essentially impermeable and traps the
entrapped air and water that migrate
towards the formwork during compaction.
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Controlled Permeability Formwork :
3. The resultant water/cement ratio in the
cover zone is higher than in the bulk, and
forms a weak link; having lower resistance
to the ingress of air, water and CO2 etc.
from the service environment.
4. Use of CPF helps to improve durability.
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Concrete Formwork: With Zemdrain Vs Conventional
Reduced W/C of 0.20 - 0.25 from Bulk W/C of 0.35,
In another case, reduced w/c to- 0.40 / 0.35 from 0.50 bulk.
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Coatings in Concrete :
1. Coatings are sometimes given :
To protect it from chemical and physical attack.
To protect it from chemical and physical attack.
To protect products stored or processed indirect
contact with the concrete from contamination caused
by dust from the substrate.
To improve its appearance, case of maintenance.
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Coatings in Concrete :
2. With the advancement in the polymer technology,
materials are available which can be used as protective
coatings in concrete.
coatings in concrete.
3. Some of the polymers available are Epoxy resin,
Polyurethane resin, Acrylic resin, Polyester resin,
silicone resin, silane / siloxane acrylic blend primer with
a pigmented acrylic top coat..
4. Suitability of the coating system and cost are important
factors in deciding about coatings.
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Material Cost Ratio
COATING ON REBAR :
COST COMPARISON ON REBAR COATING
Material Cost Ratio
Rebar without Coating 1.0
Rebar with FBEC 1.3
Rebar with Hot-dip
Galvanized Coating
1.5
Solid Stainless Steel
Rebar(316)
5.0
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As per MORTH
Guideline issued in
J an-2000, for regions
within 15 Km radius of
Corrossivity
Map of India
the coast, FBEC bars
shall be used for
Bridges.
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Protection Levels for pt-tendons based on aggressivity /
exposure vs. structural protection layers
Source:
fib bulletin 33
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THANK
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