MAB 1033

Structural Assessment and Repair

1. CORROSION OF REINFORCEMENT

Professor Dr. Mohammad bin Ismail

C09-313
 Learning Outcome
At the end of the course students should be able
to understand
• Mechanism of corrosion of reinforcement
• Factors that influence corrosion propagation
• Differences general and pitting corrosion
• Method of rectification
 Effect Cause
Leakage
Design
Defect Materials
Settlement
Construction
Deflection
Overloading
Wear Chemical spill
Damage
Earthquake
Spalling Fire

Disintegration Erosion
Corrosion of
Cracking Deterioration metals
AAR
Delamination
Sulphate Attack
MAB 1033 Structural Assessment & Repair 3
Scaling
 INTRODUCTION
• Corrosion of reinforcement is indeed one of the
major cause of deterioration to concrete structures
in many parts of the world
• The main cause is largely related to :
– The use of de-icing salts
– Chloride :
a) Exposure chloride containing environments (marine
environments)
b) Previous use of chloride based accelerator
c) Chloride contaminated materials
– Due to reduction in alkalinity of concrete as a result of
carbonation of concrete from exposure to CO2 in the
atmosphere
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 MECHANISMS OF CORROSION OF
STEEL IN CONCRETE (1)
• Definition of corrosion : Degradation of metals by an
electrochemical reaction with the environment
• The electrochemical corrosion cell has 4 components :
– Anode : Site where corrosion occurs and electrons flow from
– Cathode : Site where no corrosion occurs and electron flow
to
– Electrolyte : the aqueous environment, in contact with both
the anode and cathode to provide a path for ionic
conduction
– The electrical connection between the anode and the
cathode to allow electrons to flow between them
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 MECHANISMS OF CORROSION OF
STEEL IN CONCRETE (2)

Electron
Flow

Salt
Water

Zinc Copper
(Anode) (Cathode)

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 MECHANISMS OF CORROSION OF
STEEL IN CONCRETE (3)
Cracking, Spalling and Delamination

Reinforcement Cracking

Reinforcement Spalling

Reinforcement Delamination
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Structural Assessment & Repair
 MECHANISMS OF CORROSION OF
STEEL IN CONCRETE (4)

Fe Volume Change
Fe3O4
Fe(OH)2
Fe(OH)3
Fe(OH)3. H2O

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 MECHANISMS OF CORROSION OF
STEEL IN CONCRETE (5)
In order for corrosion to occur the 4 basic elements
(anode, cathode, electrolyte & electrical connection)
are required plus the supply of O2 & H2O
If any of these required elements is absent,
corrosion will not occur
Corrosion cell :

Anodic reaction : Fe (solid)  Fe2+ (ions) + 2e

Cathodic reaction : O2 + 2H2O + 4e  4OH-

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Structural Assessment & Repair
 Corrosion Process
• Concrete high alkalinity material (pH 12-13)
• Passive film protect Steel γ-Fe2O3
• When passive film disrupted, corrosion may take
place
• Corrosion is defined as the deterioration of metal by
reaction with species in the environment to form
chemical compound
• Corrosion is a electrochemical process requiring an
anode, a cathode an electrolyte

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 The Three-Stage
Model of Corrosion Damage

Initiation Propagation Accelerated

Period Period Period

No
Extent of Damage

evidence of
Damage

Corrosion initiated by Corrosion

chlorides or carbonation with minor Widespread cracking
damage and spalling of cover

0 15 30
Age of Structure (Years)

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 Corrosion Corrosion Promoters:
Inhibitors - Oxygen.
High quality - Water
concrete - Stray electrical
High pH (Alkalinity) currents.
concrete protects - Uneven chemical
steel surface from environment around
corrosion reinforcement.
- Environments that
lower
the pH (alkalinity).
- Chlorides.

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 Carbonation
• Carbonation is a reaction between acidic gases in the
atmosphere and the products of cement hydration
CO2 + H2O H2CO3
H2CO3 + Ca(OH)2 CaCO3 + 2H2O
• Carbon dioxide diffuse in concrete react with calcium
hydroxide and reduce pH value (pH < 10)
• Protective layer of the steel destroyed

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 0.8
Acidic Alkaline

0.7

0.6

0.5

0.4
Corrosion
Rate 0.3
mm/yr
0.2

0.1

0
0 2 4 6 8 10 12 14
pH of Concrete Relationship
between pH & Corrosion rate
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 CARBONATION – Induced corrosion
CO2 from the atmosphere Presence of O2 & H2O
penetrates the concrete

1. CO2 react with Ca(OH)2 to form

CaCO3
Alkalinity < 12.5 – 8.5

Passive oxide layer lost its ability to protect the steel

Steel reinforcement
Reinforcement - corroded

MAB 1033 Reinforcement concrete

Structural Assessment & Repair 15
 Carbonation process
Delamination

H 2O
CO2

Y
e
a
r
s

Corrosion takes
place faster when
the pH is lowered.
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 Corrosion of Reinforcement
(Carbonation)

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 Chloride penetration
• Chloride in concrete may arise from external and
internal source
• External – ingress from sea-water, salt laden mist,
deicing salt
• Internal – added as admixture (accelerator)
• Chloride attack the passive layer on steel
• As rust layer builds, tensile forces generated by
expansion of the oxide cause concrete to crack and
delaminate

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 CHLORIDE – Induced corrosion
Chloride penetrate the concrete
Presence of O2 & moisture
from de-icing salts / seawater

Existing chloride – admixtures /

contaminated aggregates etc.

Passive oxide layer lost its ability to protect the steel

Steel reinforcement
Reinforcement - corroded

MAB 1033 Reinforcement concrete

Structural Assessment & Repair 19
 Chloride penetration

When chlorides penetrate to

Delamination/Sp reinforcing steel corrosion
all begins.

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 Cast-in Chloride
• Introduced deliberately as an accelerator
• Natural ingredient found in some aggregates
• Concrete made from beach sand or mix using
sea-water
• Chlorides occur in either water soluble or acid
soluble

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 Corrosion of Reinforcement
(Chloride)

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 Limit of chloride ion in concrete

Service condition % of Cl to weight

of cement
Prestressed concrete 0.06

Conventionally reinforced concrete in 0.10

a moist environment and exposed to
chloride
Conventionally reinforced concrete 0.15
not exposed to chloride
Above-ground building construction No limit
where concrete will stay dry
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24
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 Cracks and Chloride
• Cracks and construction joints permit corrosive
chemicals to access reinforcement
• ACI 224R-90 present the following table of tolerable
crack width
Exposure Condition Tolerable crack Width
Dry air, protective membrane 0.41mm
Humidity, moist air, soil 0.3
De-icing chemicals 0.18
Seawater, seawater spray 0.15
Water retaining structures 0.1

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 Corrosion induced
cracking and spalling
• Cracking and spalling is a function of
– Concrete tensile strength
– Quality of concrete cover
– Bond/condition of interface between rebar and
surrounding concrete
– Diameter of reinforcing bar
– Percentage of corrosion by weight of reinforcement
C/D Ratio Cover Bar size Corrosion % to
(mm) cause cracking
7 89 #4 4%
3 38 #4 1%
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 Reduction in Structural Capacity
• The structural capacity of a concrete member
is affected by bar corrosion and cracking of
surrounding concrete
• Steel with more than 1.5% corrosion, the ult
load capacity began to fall, and at 4.5%
corrosion, the ult load reduced by 12%.

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 Dissimilar metal Corrosion
(galvanic)
• Corrosion can take Note: shaded area denotes level of
place in concrete moisture penetration and active
electrolyte. If chlorides are present,
when two different the process is accelerated.

metals are cast into a

concrete structure Electron Flow
_
+
1. Zinc Cathode Anod
e
2. Aluminium
Ion OH Flow
3. Steel
4. Iron
5. Nickel

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 Post-Tension Strand Corrosion
• Unbonded post-tension strands are protected
by protective grease and sheathing
• Aggressive agents can penetrate when
inadequate cover damage by heavy loads
• Common problem - poor corrosion protection
of the end anchorages due to porous or
cracked anchorage plug grout

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MAB 1033 Structural Assessment & Repair 33
 Unprotected Strand
without Protective
Leakage Paths Sheathing
into Strand
System

7 Wire
Strand Protective Sheathing
Anchorage Grease
Types
Individual Wires
Plug Grout (typical)
Wedge
s
End Anchor
Casting Heat-
Breakout Push-Thru Sealed Extruded
Bars

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 Structural Steel Member
Corrosion
• Steel beam cast into concrete to form a
composite member
• To provide fire protection
• Top flange of beam is susceptible to corrosion
when a crack or construction joint intersect
the flange

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 Aggressive
Crack or Construction
Environmen
Joint over Embedded .. ..... . . t
Structural Steel . . ..
.. .. .

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 CONSEQUENCES OF CORROSION

Reduction in the steel cross-sectional area

Cracking, spalling & delamination of the concrete
cover (due to expansive nature of the iron oxides)
A decrease of the steel/concrete bond
Possible reduction in load carrying capacity of
structural member

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Structural Assessment & Repair
 ASSESSMENT OF CORROSION DAMAGED
CONCRETE STRUCTURES
Objectives – to find the causes/as well as the extent of the corrosion problem

Normally done in 2 stages :

Visual inspection + limited testing

Detailed testing
Testing :

Covermeter survey

Carbonation depth measurement

Chloride ion content measurement

Half-cell potential measurement

Resistivity measurement

Degree of corrosion

Other tests (rate of corrosion, analyses for cement content)

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Structural Assessment & Repair
 REPAIR OF CORROSION DAMAGED
CONCRETE
Patch repair

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Structural Assessment & Repair
 REPAIR OF CORROSION DAMAGED
CONCRETE (Cont.)
Guniting / Shotcreting

Shotcreting on R.C. wall

Preparing slab for guniting

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 REPAIR OF CORROSION DAMAGED
CONCRETE (Cont.)
Pressure grouting

Confuse.
.
Hardworking

Before In progress After

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 REPAIR OF CORROSION DAMAGED
CONCRETE
Another repair options

Preplaced aggregates & Pressure grouting

Preventive measures

Surface protection

Electrochemical methods

Strengthening

Plate bonding (steel, CFRP)

Jacketing

External prestressing

Give up – Demolish and rebuild to new & improved specification

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Structural Assessment & Repair
 CORROSION PREVENTION FOR
CONCRETE STRUCTURES (1)
Use of sufficient cover
Use of impermeable good quality concrete

Lower water binder ratio

Use of mineral admixtures

Use of optimum cement content

Optimum compaction

Early and comprehensive curing

Apply surface treatments

Use of durability related tests for compliance (gas &
water permeability, chloride permeability, chloride
diffusion)
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Structural Assessment & Repair
 CORROSION PREVENTION FOR
CONCRETE STRUCTURES (2)
Isolation of reinforcement from the chemical
effect of corrosion by means of physical barrier or
chemical inhibition

Use of epoxy coated reinforcement

Use of galvanised reinforcement

Use of stainless steel reinforcement

Use of bar primer

Use of zinc rich paint

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Structural Assessment & Repair
 CORROSION PREVENTION FOR
CONCRETE STRUCTURES (3)

Reversing the effect of corrosion by cathodic

protection (CP)
It works based on the principles of eliminating the
anodic sites (corrosion sites) by progressing the
steel to a cathodic state

Sacrificial anodes CP

Impressed current (CP)

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Structural Assessment & Repair
 CORROSION PREVENTION FOR
CONCRETE STRUCTURES (4)
Preserving or restoring passivity (reserving the
effect carbonation and chloride attack by
electrochemical processes)

Realkalization : Technique to introduce alkaline
solution into concrete to arrest and prevent further
deterioration due to carbonation. Produce hydroxyl ions
& restoring pH levels

Chloride extraction (Desalination) : Technique to
remove ingressed or cast in chlorides in order to arrest
deterioration due to carbonation

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Structural Assessment & Repair
 CONCLUSION
The risk of reinforcement corrosion occuring in new
construction could be reduced by understanding the cause
and mechanism of corrosion and taking appropriate
preventives measures in the planning and construction
stages
The most appropriate measure to reduce the risk of
corrosion is to produce durable concrete in the first place
by choosing proper materials and mix proportions as well
as appropriate construction practices
Successful repair to deteriorated concrete also require an
understanding of the causes and mechanism of the
deterioration, so that the most appropriate repair materials
and techniques could be applied
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Structural Assessment & Repair
Department of Structures and Materials,
Faculty of Civil Engineering 49
UTM