DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 5

Design & Detailing For Durability

5.1 Design Engineers consider design of concrete structures to mean
assessing:
i) The size and strength of structural components and concrete
strength grade to meet safety and serviceability limits.
ii) The amount, size and distribution of reinforcements for strength
and control cracks to an acceptable size.
It is anticipated that with good site control and good workmanship, the
structure and its components shall last indefinitely. They have forgotten to
take into account the environmental loads while designing the structures
(Structures are designed adequately for DL & LL, and some times for
erection loads). Environmental factors affect durability of structures. Hundreds
of bridges and structures are collapsing or showing signs of deterioration with
corroding reinforcement all within 25 years of construction. It is, therefore,
necessary for the designer to develop a feel for the problem and design the
structures
to satisfy safety, serviceability and durability requirements
(structural and non-structural loads caused by environment).
5.2 Environmental factors : Critical environmental factors which affect
concrete are carbon dioxide, chlorides, water and temperature as shown in fig
5.1
5.3 Design for carbonation:
5.3.1 The rate of carbonation depends upon the integrates of concrete of the
cover zone. The penetration rate of carbonation in a good concrete structure
remote from the seacoast and not subjected to de-icing salt is given by:
D = k t0.5
k = 1 for M-35 & above (w/c= 0.40)
k = 2 for M-25 (w/c = 0.45)
k = 5 for M-15
D = Depth of carbonation in mm
k = Carbonation coefficient in mm/year depending upon quality of
concrete
t = time of exposure in years.
It is seen that by doubling the cover, quadruples the design life.
Similarly with good quality concrete ( M-35 concrete with w/c ratio 0.4 ) five
times design life can be achieved as compared to poor quality concrete
( M-15 concrete ).

DURABILITY OF CONCRETE STRUCTURES

DURABILITY OF CONCRETE STRUCTURES

5.3.2 The graph shown in fig. 5.2 can be used to select the cover and grade
to meet the required design life.
Example : For 100 years life, if the mix is M-35 or above the minimum cover
requirement is 20 mm. i.e. if the mix is M-15 the cover requirement shall be
between 40 and 60 (say 50 mm).
5.3.3 From the graph in fig. 5.2 it may be concluded that it is always better
to go for richer mixes from durability angle even if it is not required from
strength criteria. In the interior of the buildings the rate of carbonation can be
high and must be considered while designing. Carbonation effect can be
taken care by ensuring adequate cover of good quality concrete. This is
necessary for all the sites in India. It also presupposes that the integrity of
cover concrete (Concrete in cover portion) i.e. both quality and extent, is
assured. Thick cover is of no avail if the concrete is highly penetrable.
5.4 Design for chlorides induced corrosion: For the marine structures,
including buildings within 1 km of coast line, and for bridges exposed to deicing salt, the penetration of chloride is calculated from the following equation:
i)

K.C Clears Life Model:

Life of corrosion on set
(in years)

129 x ( cover-1.22 )
= -----------------------w/c x Cl-0.42

Where cover is in inches and w/c ratio and Cl are in %

ii)

The Chloride penetration curves in fig. 5.3 give a very simple

method for design.

Example : For 100 yrs. design life and 60 mm cover, the minimum conc mix
shall be M-50 or richer.
5.5 Design for sulphate exposure : This is dealt in detail under suitability
of various types of cement in para 6.6 (iv) of chapter 6.
5.6 Design for durability : As durability depends upon permeability. It is
important to control parameters affecting permeability. Therefore, it is
necessary to lay down permissible limits for parameters like minimum
cementitious material content, maximum water cement ratio, maximum crack
width and extent of cover to reinforcement etc. depending upon the exposure
condition. Following values for these parameter are recommended.

DURABILITY OF CONCRETE STRUCTURES

DURABILITY OF CONCRETE STRUCTURES

i) Minimum cementitious material content and maximum water cement

ratio: Recommended values are given in table-5.1
Table 5.1
Minimum cementitious material content and maximum w/c ratio
Exposure
Min.
grade
of
mix

PCC
Min.
cementitious*
material
content
Kg/m

Mild
Mod
Severe
Very severe
Extreme

M-20
M-25
M-25
M-30
M-30

300
350
380
400
400

Max
w/c
ratio

RCC
Min.
grade
of mix

Min.
cementitious*
material
content
Kg/m

0.55
0.50
0.45
0.45
0.40

M-25
M-30
M-35
M-40
M-45

380
400
400
430
430

Max
w/c
ratio

PSC
Min.
grade
of mix

Min.
Cementitious*
material
content
Kg/m

0.45
0.40
0.40
0.38
0.35

M-35**
M-35**
M-45
M-50
M-50

Max
w/c
ratio

400
400
430
440
440

0.40
0.40
0.40
0.35
0.35

The areas covered under different exposure conditions shall be as under:

Mild: Concrete surfaces protected against weather or aggressive conditions.

Moderate: Concrete surfaces sheltered from severe rain or freezing while
wet, concrete continuously under water.
Severe: Concrete surface exposed to severe rain , alternate wetting and
drying or occasional freezing or severe condensation. Concrete exposed to
aggressive sub soil / ground water or coastal environment.
Very severe: Concrete surface exposed to sea water spray, corrosive fumes,
severe freezing.
Extreme: Concrete surface exposed to abrasive action. Surface of members
in tidal zone.
* Min. cementitious material content is for 20mm Max. size aggregate (MSA)
Add extra cementitious material
for 10 mm MSA
= + 20 Kg/m3
for 40 mm MSA
= - 10 Kg/m3
** Minimum grade of concrete mix should be M-40 for pretensioned PSC
bridges.
Note:

The maximum content of cementitious material should be 500 Kg/m3

DURABILITY OF CONCRETE STRUCTURES

ii) Minimum clear cover : Recommended values are given in table-5.2. The
clear cover shall mean cover from the outer most metal /steel, binding wire or
its end.
Table 5.2
Minimum clear cover*
Sr.
No.

Structures
RCC/PSC

1
2
3
4

Slabs
Beams
Columns
Wells, piles
and footings
PSC girders
PSC girder
for
HTS
cables

5
6

Extreme
environment

Very
severe Severe
environment
environment

50
60
75
75

50
50
75
75

25
40
50
75

Mild and
Moderate
environment
25
35
50
50

50
75

50
75

50
75

50
50

*
While designing, it should be ensured that cover does not exceed 2.5
times dia of reinforcing bar. If cover is more, chicken mesh may be provided in
cover concrete to keep the concrete in position.
iii)
Flexural Crack Width : It is necessary to control the crack width to
protect steel rebar against corrosion. The crack width is controlled by reducing
shrinkage, and distributing the reinforcement over the zone of maximum
concrete tension, uniformly, and using smaller dia bars. Cement with low heat
of hydration and not too fine should be used.
Recommended value of
maximum crack width to be considered during design are given in table-5.3.
Design of crack width may be calculated as described in Appendix- I to this
chapter.
Table 5.3
Maximum crack width to be considered during design
Type of structure

Bridges
RCC beams, slabs

Aggressive environment
(Severe, Very severe and
Extreme)
Exposed
0.10mm
0.20mm

Unexposed
0.20mm
0.20mm

Non- aggressive
environment
(Mild and Moderate)

0.20mm
0.30mm

DURABILITY OF CONCRETE STRUCTURES

5.7 Admixtures : Chloride free water-reducing super plastisizers may be

used for RCC & PSC works. However creep effect of plastisizers need to be
considered in design. Air entraining agents may be used in upper Himalayan
regions.
5.8 Temperature: The concreting shall be done only when the temp is
between 5 0C & 32 0C. Preferably temperature variation of concrete during
concreting should be within 5 0C. The special precautions to be taken shall be
laid down by the designer.
5.9 Curing : All properties of concrete improve with extended wet curing.
This is particularly so for permeability, which strongly affects durability and
service life. A minimum wet curing for 7 days by ponding water/continuous
spraying, followed by 3 weeks curing by curing compounds is recommended.
5.10 The form work : The form work is removed too early after obtaining
cube test results to economise the cost of form work. It is not good from
durability point of view. The time recommended is as follows:
Columns
Beams
Slabs

3 days
10 days
14 days

5.11 Detailing : Normally the aspect of congestion of reinforcement at the

junction of beams & column is neglected by design engineer. The drawings
should be prepared by showing the full size of bars, laps, bends, distribution
bars, spacers, cover blocks etc. It should be possible to place & compact
concrete by a 50 mm. dia .needle vibrator. The corners & sharp edges should
be chamfered. Circular sections are preferred. The design detailing should
be such as to ensure effective drainage of water and to avoiding standing pool
or rundown of water towards the critical components. The criteria of
constructibility is of paramount importance. The layout and disposition of
prestressing tendons should be designed for easy placement and vibration of
concrete in the space between tendon ducts. When two or more rows of
ducts are used, the horizontal space between the ducts should be vertically in
line to facilitate proper flow of concrete as shown in Fig. 5.4.
5.12 Design of form work and false work : There is no practice of approval
of design and drawings for form work and false work. With the result, the
contractors use, whatever they like, risking the safety of workers and quality
of concrete. Thus, it is necessary that the design and drawing for these items
are also made, approved in advance and checked at site. For important
works forms of plywood / other similar product which can absorb water are
preferable as compared to steel forms. It is advisable to pay this item
separately.

DURABILITY OF CONCRETE STRUCTURES

5.13 Recommendation:
i Life of a structure may be different under different environmental region.
Hence structure have to be designed for a particular design life. The
structures may be designed for the service life as given in table 5.4.
Table 5.4
Sr. No.
1
2
3
4
5
6

Type of structure
Bridges in sea
Bridges within 1 km of coast line
Bridges in rest of India
Buildings in coastal areas
Buildings in rest of India
F.O.B.Slabs

Design life in years.

50
80
100
80
100
50

ii Each structure should be designed for durability and the design life should
be printed on each drawing, design sheet & method statements.
iii The soil where piles, footings etc. rest, and water in case of marine
structures, should be tested and used in design and selection of type of
cementitious material.
iv The form and false work should be designed in advance, drawings
prepared and paid for separately as an item.
v

The use of nominal mixes should be banned.

vi In place of cement, cementitious material has been used, to bring to focus

that blended cements are superior to pure cements and should be used in all
structures.
vii The specifications of cementitious material should be decided for each
work. Low heat blended cements are preferred for hot weather climate.

DURABILITY OF CONCRETE STRUCTURES

Appendix-I
(Chapter-5 Clause 5.6D)
Design Crack Width Calculation
(Extract of Clause 6.21.A.6 of IRS Concrete Bridge Code 1982)
The design crack width may be calculated by the following formula:
Design surface crack width =

3a cr m
a cmin
1 + 2 cr

h x

Where Cmin - is the minmum cover to the tension steel,

h
- is the overall depth of the member
x
- is the depth of the neutral axis found from analysis to
determine m (see below)
acr
- is the distance from the point considered to surface of the
nearest longitudinal bar.
m
- is the average strain at the level where cracking is being
considered, calculated allowing for the stiffening effect of the
concrete in the tension zone, and is obtained from equation
given below:

12

. bt h a ' x
m = 1
10 3 where f y is in N / mm2
A (h x ) f

y
s

and

12

. bt h a ' x

m = 1
10 2 where f y is in kg / cm2
A (h x ) f

y
s

Where
a' x f s
=
1 dx E
s
d
fs
Es
1

bt
a

As
fY

effective depth of tension reinforcement

actual stress in steel
modulus of elasticity of steel
is the strain at the level considered, calculated ignoring the
stiffening effect of the concrete in the tension zone.
is the width of the section of the centroid of tension steel.
is the distance from the compression face to the point at which
crack width is being calculated, and
is the area of tension reinforcement
is the yield strength of steel in N/mm2 (kg/cm2)

DURABILITY OF CONCRETE STRUCTURES