DURABILITY

Time for Corrosion by Carbonation and Chlorides

tL = t i + t P

ti period of corrosion initiation

tP propagation period

d = K (t)0.5

d penetration depth for an age t

K coefficient depending on agressiveness process

1) Carbonation Model

t = (d/Kc)2

d = depth in mm
t = Time in years
Kc = Cenv * Cair * a * fcmb (Carbonation coefficient)

fcm = fck + 8 (fcm = avg concrete strength at compressi

Cenv = Coefficient of environment
Cair = Coefficient of aeration
a, b = Function parameters of the type of binder

Environment Cenv
Protected from the rain 1
Exposed to the rain 0.5

Air occluded (%) Cair

< 4.5% 1
>= 4.5% 0.7

Binder Cements Instruction RC03 a b

CEM I
CEM II/A
CEM II/B-S
Portland Cement CEM II/B-L 1800 -1.7
CEM II/B-LL
CEM II/B-M
CEM/V
CEM II/B-P
Portland Cement + CEM II/B-V
360 -1.2
28% FLY ASH CEM IV/A
 Portland Cement +
360 -1.2
28% FLY ASH
CEM IV/B

Portland Cement +
CEM II/A-D 400 -1.2
9% SILICA FUME

Portland Cement + CEM III/A

65% BLAST 360 -1.2
FURNACE SLAG CEM III/B

Equivalent Class IIa (high humidity) following EHE08:

Corrosion of origin other than chlorides.
interiors subject to high relative humidity (> 65%) or condensation
external in the absence of chlorides, and exposed to rain in areas with an average annual rainfall above 60
buried or submerged elements

Equivalent Class IIb (medium humidity) following EHE08:

Corrosion of origin other than chlorides
external in the absence of chlorides, subjected to the action of rainwater, in areas with annual mean rainf

Equivalent Class IIIa (medium humidity) following EHE08:

Corrosion by chlorides
elements of marine structures, above the tide level
external elements of structures situated in the vicinity of the coastline (less than 5 km)

fcm = 40 (cylindrical sample) + 8 = 48 N/mm2

Cenv 1=
Cair =1

For Portland cement, a = 1800, b= -1.7

Kc = Cenv * Cair * a * fcmb
2.4955

dnominal = 50 mm

ti (d/Kc)²
401.43 > 120 years for working life

For Portland cement + 28% Fly Ash, a = 360, b= -1.2

Kc = Cenv * Cair * a * fcmb
3.45790

dnominal = 50 mm

ti (d/Kc)²
209.08 > 120 years for working life

2) Chloride Penetration Model

t = (d/Kcl)²

where,
d = depth in mm
t = time in years

α unit conversion factor

D(t) coefficient of effective diffusion of chlorides, for age t, expressed in cm²/s
Cth Critical concentration of chlorides, expressed as % by weight of cement = 0.4% weight of cement
Concentration of chlorides on the concrete surface, expressed in% by weight of cement. Since this chlorid
concentration is usually obtained in% by weight of concrete, its weight equivalent of cement can be calcul
from the concrete content of the concrete (in kg / m3) as: Cs (% weight of cement) = Cs (% weight of conc
Cs (2300 / cement content)

Chloride content contributed by the raw materials (aggregates, cement, Water, etc.), at the time of manuf
Cb of the concrete = 0,05% aggregate mass + 1gr/l of water used in a m3 of concrete = 0.05% x 6 x 300 + 1 / (
300) = (0.9 gr + 0,006 gr) / m3 of concrete = 0,906 gr per 300 kg of cement = 0,0003% weight of cement

Diffucsion coefficient of chlorides

n = age factor (can be taken as 0.5)

Coefficient of d(t0) (x10-12 m²/s)

Cement Type w/c = 0.40 w/c = 0.45 w/c = 0.50 w/c = 0.55 w/c = 0.60
CEM I 8.9 10 15.8 19.7 25
CEM II/A-V 5.6 6.9 9 10.9 14.9
CEM III 1.4 1.9 2.8 3 3.4

For CEM I » for w/c = 0.55 » D(t0) = 19.7

for t = 120 years

D(t) 0.49805 x10-12 m²/s

For CEM II/A-V » for w/c = 0.55 » D(t0) = 10.9

for t = 120 years

D(t) 0.27557 x10-12 m²/s

For exposure IIa (high humidity):

there is not assigned value for D (to) because no chloride agressiveness is expected/
For exposure IIIa (aerial marine exposure):

Cs (% weight of concrete) = 0.07

Cs (% weight of cement) = Cs (% weight of concrete) * (2300 / cement content)

0.5367 % weight of cement

In the case of Cth-Cb > Cs, the Limit State shall be deemed to have been Need to perform any numerical
checking. But: Cth-Cb = 0.4% - 0.0003% = 0,3997% < Cs=0.5366%

For exposure IIIa

For CEM I , for w/c = 0.55 → D(to) = 19.7
for t = 120 years

D(t) 0.49805 x10-12 m²/s

0.000000004981 cm²/s

KCI 1.87767893489298

t 709.083436026582 years

For exposure IIIa

For CEMII/A-V → For w/c = 0.55 → D(to) = 10.9
for t =120 years,

D(t) 0.27557 x10-8 m²/s

0.000000002756

KCI 1.39669465120887

t 1281.55446694713 years

3) Period of Propagation

tP = (80/φ) * (d / vcorr)

tP Propagation time, in years

d Coating thickness in mm
φ Dia of reinfrocement in mm
vcorr Corrosion rate in μm / year

Class IIa → vcorr = 3 µm/year

Class IIIa → vcorr = 20 µm/year
For class IIa:
Φ =12 mm
d=50 mm

vcorr = 3 µm/year
tP 111.11 years
For class IIIa:
Φ =12 mm
d=50 mm

vcorr = 20 µm/year
tP 16.67 years

4) Time for corrosion by carbonation and chlorides: tL = ti + tP

ti period of corrosion initiation

tP propagation period
Class IIa or IIIa

Carbonation time and chlorides worst case: tP= 16.66 years

For Portland cement CEM I, a = 1800, b= -1.7

Kc = Cenv * Cair * a * fcmb
2.49553
dnominal = 50 mm

ti (d/Kc)²
401.43 > 120 years for working life

tL 418.10 > 120 years

For Portland cement + 28% fly ash, a=360, b=-1.2

Kc = Cenv * Cair * a * fcmb
3.45790
dnominal = 50 mm

ti (d/Kc)²
209.08 > 120 years for working life

tL 225.75 > 120 years

CONCLUSION
The above note briefly describes the strategy indicated in the tender document and its conformity with requirements
of the BS code and available IS codes for achieving the desired service life of 120 years.
Hence,it is felt that the minimum requirements recommended regarding grade of concrete,crack widths, cover to
reinforcement, permeability and RCPT limits, etc will be applicable to achieve the desired 120 years Design life of the
tunnel segments. The concrete mix shall be designed as per the recommendations given in this design note and the
tests results of same shall be approved by designer and engineer in charge of employer.
ete strength at compression N/mm²)
e annual rainfall above 600 mm

as with annual mean rainfall less than 600 mm

weight of cement
cement. Since this chloride
nt of cement can be calculated
nt) = Cs (% weight of concrete) *

etc.), at the time of manufacture

e = 0.05% x 6 x 300 + 1 / (0.55 x
003% weight of cement
ty with requirements
 widths, cover to
ars Design life of the
esign note and the