International Journal of Civil Engineering and Technology (IJCIET)

Volume 8, Issue 10, October 2017, pp. 988–1000, Article ID: IJCIET_08_10_103
Available online at http://http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=8&IType=10
ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

STUDY ON CORROSION RESISTANCE IN

CONCRETE BY MINERAL ADMIXTURE
ADDITION AND FRP WRAPPING OF
REINFORCEMENT BARS
Varun Kumar K and Mini K.M
Department of Civil Engineering, Amrita University,
Coimbatore, Tamilnadu, India

ABSTRACT
Corrosion is a major concern in structural applications due to its detrimental
effect which reduces the lifespan of the structures, particularly in coastal areas. The
main sources of corrosion in concrete are chloride intrusion and carbonation. Due to
corrosion, the spalling and delamination of the concrete due to the expansion of steel
is unavoidable. Hence, the steel reinforcement bars are to be protected from corrosion
so that the structure remains safe. In the present paper, modifications are done for
steel using Fiber Reinforced Polymer (FRP) wrapping and the concrete is modified by
doping with Zeolite and Micro Silica. The corrosion resistance offered by the
specimens is monitored by Half-cell potential method, Open circuit potentials (OCP),
Linear Polarization Resistance (LPR) and Tafel Polarization techniques. As there are
modifications in steel and concrete, water absorption , compressive strength and bond
strength of the specimens are checked and are compared with control specimens.
Key words: Corrosion, Zeolite, Micro-silica, Open circuit potential (OCP), half-cell
potential, LPR, Tafel Polarization, FRP Wrapping.
Cite this Article: Varun Kumar K and Mini K.M, Study on Corrosion Resistance in
Concrete by Mineral Admixture Addition and FRP Wrapping of Reinforcement Bars.
International Journal of Civil Engineering and Technology, 8(10), 2017, pp. 988–
1000.
http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=10

1. INTRODUCTION
Concrete is a versatile composite material which has been used over century in the
construction area due to its economical, ecological and technical advantages. But, the
corrosion of steel reinforcement bars in the concrete is a longstanding global problem being
faced by many technical engineers which causes damage to the concrete structures [1]. In case
of adverse environments, numerous structures have experienced unacceptable loss in safety or
serviceability far earlier than expected due to corrosion of reinforcing steel bars and therefore
there is a need for replacement. Corrosion is mainly caused by the chloride intrusion (passage
of aggressive chloride ions from marine environments, deicing salts, and use of chloride

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 Varun Kumar K and Mini K.M

contaminated aggregates) and carbonation. When chloride ions react with steel, corrosion
products such as rust is formed which involves a substantial increase in volume which results
in expansion of the concrete and thus spalling and delamination of concrete takes place. In
general, these are repaired using Fiber reinforced Polymer (FRP) patches and in case of harsh
environments associated with marine and coastal regions, partial or full delamination of these
patch repairs due to continued corrosion is unavoidable. These repairs won't last for a longer
duration and thus concrete starts to crack and spall. So, it is necessary to stop the corrosion at
the initial stage itself, so that the life of the structure is improved which indirectly reduces the
maintenance cost.
Several studies were carried out by mixing mineral admixtures like nano-silica, micro-
silica and micro-zeolite for improving the compressive strength and reducing the water
absorption of concrete [2-4]. But the addition of mineral admixtures for resisting corrosion is
still under investigation. The effect of mineral admixtures like nano-silica, nano calcium
carbonate, micro-silica and micro zeolite on water absorption are studied out in controlling
the corrosion [5]. The effect of silica fume on CNT based cement composite was carried out
by K.M.Mini et.al [6] which also shows reduced water absorption and thus can reduce
corrosion. Different corrosion inhibitors are added to the concrete to reduce the corrosion of
steel bar. The effect of different inhibitors like fly ash, zeolite, diatomite, leaf-extract of
morindalucida, imidazoline based inhibitors, high volume fly ash, nano-calcium carbonate etc
is studied and concluded that all the inhibitors are good at resisting corrosion when compared
to the normal traditional concrete without any admixtures [7-12].
Several studies were carried out using FRP wrappings for concrete [13] which are mainly
focused on improving the compressive strength, fatigue and flexural behavior of concrete
[14,15], retrofitting large scale corrosion damaged RC beams[16-20]. Nimrat Pal Kaur [21]
conducted a study on CFRP as active protection of corroded steel rebar embedded in FRP
wrapped concrete by using nondestructive monitoring techniques. Less and Adeli [22]
investigated the structural behavior and corrosion resistance of hybrid FRP wrapped steel
reinforcement bars in concrete and life cycle cost analysis as performed to assess the
economic advantages and disadvantages of hybrid bars.
Several studies were carried out on corrosion of rebar using different type of coatings like
basaltic pumice, colemanite, barite and ground granulated blast furnace slag (GGBS), out of
which colemanite offers a best corrosion resistant [23]. Several other coatings like inorganic
zinc, epoxy, polyurethane, molybdenum disulfide and other anti-corrosion resistant alloy
coatings were developed in the past few years [24-28] and are still under investigation.
The effect of corrosion on the bond strength between reinforcement steel bars and
concrete, stress distribution and bond-slip behavior is studied by varying the level of
corrosion, with and without the confinement of steel. Pull-out tests were conducted on
different specimens and the study concluded that bond strength was very sensitive to the bars
without confinement when compared to the bars with confinement [29-31].
There are different methods for measuring the rate of corrosion. Weight loss is one of the
best ways to represent the corrosion exactly but it takes a long time and hence it is represented
by the electrochemical methods and their importance is studied by many researchers [32, 33].
In the present paper, two modifications are carried out, one for steel and one for concrete.
Micro-silica and zeolite are the mineral admixtures which are added to the concrete by
replacing the cement, due to which small pores are replaced by the admixtures thus reducing
the water absorption of the concrete which indirectly reduces the corrosion. The water

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 Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of
Reinforcement Bars

absorption of the concrete is checked as per ASTM C642-06 [34]. As the concrete is modified
by adding the mineral admixtures, the compressive strength of the concrete is studied by
using compression testing machine as per IS 516-1959 [35]. The steel rebars are wrapped with
CFRP and GFRP sheets using epoxy and hardener in different layers with different
combinations. These sheets act as a secondary barrier and reduce the passage of water, which
indirectly results in reduction of corrosion. The bond strength between the steel and the
concrete is checked by using the pull-out test as specified in the IS 2770(Part 1)-1967 [36].
The rate of corrosion is measured by using different methods like half cell potential method,
open circuit potentials (OCP), Linear Polarization Resistance (LPR) and Tafel Polarization
methods to have a proper check on corrosion monitoring.

2. METHODOLOGY
2.1. Cement, Steel and Aggregates
All the experimental specimens are cast using OPC (Ordinary Portland Cement) of Grade 53
with a specific gravity of 3.15.
All the steel reinforcements used are of TMT (Thermo Mechanically Treated) bars of Fe
415 grade. The density of the steel is 7850 kg/m3, elastic modulus is 200GPa and Poisson's
ratio is 0.28.
The coarse aggregate used in the preparation of the specimens has a specific gravity of
2.75 and the specific gravity of fine aggregates is 2.62.The water absorption of the coarse
aggregate and fine aggregates are 2% and 1.6% respectively.

2.2. Micro Silica & Zeolite

Micro-silica and zeolite are the pozzolonic materials that are added to the concrete by
replacement of cement. The properties of Micro-silica and Zeolite are listed in Table 1.The
cement is replaced with different percentages of micro-silica and zeolite namely 0%, 10%,
20%, and 30%.
A study is conducted on the water absorption of the concrete as per ASTM C642-06 [34]
by replacement of cement with different compositions of Micro-silica and Zeolite. Cubes of
size 100mm × 100mm ×100 mm are considered for the study and the specimens are cast as
per the percentages mentioned above and cured for 28 days. Then the water absorption of the
concrete is determined and the study concluded that 10% replacement of cement with Micro-
silica and Zeolite resulted in less water absorption and is shown in Fig. 1.

2.3. Fiber-Reinforced Polymer (FRP)

Fiber-reinforced polymer (FRP) (also fiber-reinforced plastic) is a composite material made of
a polymer matrix reinforced with fibers. The fibers are usually glass, carbon, aramid and
basalt. FRP has seen an increased use in structural engineering applications in recent years
due to a number of advantageous qualities, including a high ultimate strength, light weight,
corrosion resistance, and formability. In this paper, bidirectional CFRP and multidirectional
GFRP are used for wrapping the reinforcement bars and the properties of FRP’s are listed in
the Table 2.

2.4. Specimen Preparation

For studying the corrosion of steel in the concrete, a cylindrical specimen of 100mm diameter
and 200mm height is considered and a 10mm diameter TMT steel bar is embedded inside the

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 Varun Kumar K and Mini K.M

concrete up to a depth of 150mm from the top so that uniform cover is maintained from all the
sides. By taking the characteristic compressive strength (fck) of concrete as 25MPa, the
quantity of materials used in the preparation of control specimens are calculated using IS
10262:2009 [37] and are listed in Table 3.

Table 1 Properties of Micro-silica and Zeolite

Physical Zeolite Microsilica
Bulk density 0.8-1.1gm/cc 0.76gm/cc
Specific gravity 2.63 2.63
Loss on ignition 14% Max 0.015%
Ph 4.5 to 6.5 6.9
Moisture 1% max 0.058%
Melting point 1735oC 1600oC
Chemical Zeolite Microsilica
Silica 45.17 99.886
Ferric oxide 0.5 (Max) 0.04
Alumina 37.59 0.043
Titanium dioxide 0.5 0.001
Calcium oxide 0.22 0.001
Magnesium oxide 0.12 0.0
Sodium oxide 0.31 0.003
Potash 0.07 0.001

7
Water absorption

6.5

5.5

4.5

4
0 10 20 30 40

% Replacement of cement

Microsilica Zeolite

Figure 1 Water absorption for micro-silica and zeolite

Table 2 Properties of FRP

Property CFRP GFRP
Ultimate tensile strength (MPa) 600 440
Modulus of Elasticity (GPa) 70 25
Poisson’s Ratio 0.1 0.2
Shear Modulus(GPa) 5 4
Nominal thickness 0.23 0.21
Thermal coefficient 2.1 11.6

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 Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of
Reinforcement Bars

As per the study conducted on micro-silica and zeolite (Fig.1), the cement is replaced with
10% of micro-silica and zeolite and are noted as MS,Z respectively and the conventional
concrete without any modifications for steel and concrete is noted as CS. The reinforcement
bars are wrapped with CFRP and GFRP sheets using epoxy and hardener. At first the epoxy
and hardener are mixed well in the ratio of 1kg: 150ml respectively and applied on the FRP
sheet. The steel bar is wrapped with the FRP and kept in oven at a temperature of 45 oC for
approximately 14 hours to get it hardened. In case of FRP wrappings the modifications and
their notations are given as follows:
CS-Control Specimen
MS-Micro-silica
Z-Zeolite
2C- CFRP wrapped in two layers
3C-CFRP wrapped in three layers
2G-GFRP wrapped in two layers
3G-GFRP wrapped in three layers
2G+2C-GFRP wrapped in two layers over which CFRP is wrapped in two layers
For each type of combination a total of six specimens are casted (3 specimens for pull-out
test and 3 specimens for corrosion test) and cured for 28 days and are subjected to accelerated
corrosion by immersing them in 0.5M NaCl + 0.5M H2SO4 for 120 days.

Table 3 Materials used in preparation of concrete For one cum concrete, w/c ratio=0.48
Material Quantity
Cement 370 kg
Sand 691 kg
Coarse aggregate 1179 kg
Water 212 L

2.5. Experimental Setup

2.5.1. Compressive Strength
The cement in the concrete is replaced with 10% micro-silica and zeolite to reduce its water
absorption property. As there is a change in the composition of materials used in the concrete,
compressive strength is determined for the specimens with 10% replacement of micro-silica,
zeolite with cement and no replacement of cement (control specimens).The specimens are
checked for compressive strength using the compressive testing machine as per IS 516-1959
[35].

2.5.2. Pull-out Test

As the cement and steel in the concrete are modified by adding different admixtures and
wrappings respectively, the bond strength between the steel rebar and concrete is checked by
conducting pull-out test as specified in IS: 2770 (Part 1) -1967 [36].

2.5.3. Corrosion Testing

The rate of corrosion can be expressed in many ways. Among all the different ways, Loss of
weight is the best way to measure the rate of corrosion accurately which takes a long time. As
the corrosion involves the electro-chemical reactions, the rate of corrosion can be obtained
easily by using Half-cell Potential method, Linear Polarization resistance (LPR) method,

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 Varun Kumar K and Mini K.M

Open circuit potentials (OCP) and Tafel Polarization method. In the present study, these four
methods are used for corrosion monitoring to have a proper check on the corrosion resistance
offered due to modifications in steel and concrete. The rate of corrosion is measured for 0th
day (after curing for 28days), 40th day, 80th day and 120th day respectively and the readings
are noted down.

2.5.4. Polarization Techniques

The corrosion measurement using electrochemical techniques are currently experiencing
increasing popularity among corrosion engineers, primarily due to the rapidity with which
these measurements can be made. Long term corrosion studies, such as weight loss
determinations may require some weeks to complete while an electrochemical experiment
will requires only several hours. The speed of electrochemical measurements is especially
useful for those metals or alloys that are highly corrosion resistant. In this study, all the
readings were taken using the CHI604E electrochemical analyser. Here, the working electrode
is steel bar, the counter electrode is platinum wire and the reference electrode is silver-silver
chloride electrode.

3. RESULTS AND DISCUSSION

3.1. Compressive Strength
The compressive strength is checked for the specimen as mentioned in the code IS 516-1959
[35] and the results of the compressive strength are tabulated in Table 4.

Table 4 Compressive strength for different specimens

Notation Characteristic Compressive strength (MPa)
Control specimens (CS) 31
Micro-silica(MS) 39
Zeolite(Z) 34

From the above results, it is clear that both micro-silica and zeolite induced specimens
have increased compressive strength when compared to the control specimens.

3.2. Pull-out Test

In this test, the concrete specimen is fixed to the lower end of the testing machine and the
steel rebar is being pulled out and the corresponding deflections are noted down. The testing
of a specimen is shown in Fig. 2. The bond strength for different types of combinations is
shown in Fig. 3. The load deflection curves for the specimens are shown in Fig. 4. The bond
strength for different specimens is tabulated in Table 5.

Table 5 Bond strength values

Notation Bond-strength (MPa)
CS 0.87004
MS 0.89126
Z 1.46422
2C 1.16714
3C 1.72948
2G 1.93108
3G 2.66319
2G+2C 1.78254

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Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of
Reinforcement Bars

Figure 2 Testing of a specimen for pull-out load

Bond Strength
3
2.5
2
1.5
1
0.5
0
1 2 3 4 5 6 7 8
Bond Strength

1-CS, 2-MS, 3-Z, 4-2C, 5-3C, 6-2G, 7-3G, 8-2G+2C

Figure 3 Bond strength of the specimens

12
Bond Strength (MPa)

10

0
0 1 2 3 4 5 6
Deflection (mm)
CS MS Z 2C 3C 2G 3G 2G+2C

Figure 4 Bond Strength -deflection graph

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 Varun Kumar K and Mini K.M

From the above results, it is clear that all the specimens have sufficient bond strength
when compared to the control specimens and highest bond strength is accounted for 3G
specimen.

3.3. Half-Cell Electrical Potential Method

In this method, the negative charge is obtained by measuring the concrete surface electric
potentials relative to that of the standard electrode. Copper-copper sulfate electrode is used as
the reference electrode in this method. At half-cell, electrons transform Cu+2 ions in the
copper sulfate solution to Cu atoms and deposit on the rod in the half-cell, thus voltmeter
indicates a negative value. The higher the negative value, higher is the corrosion. According
to ASTM C876-91 [38], the criteria for the probability of corrosion are given in Table 6.

Table 6 Criteria for corrosion of rebar in concrete for different half-cells[38]

Cu/CuSO4 electrode Ag/AgCl electrode Likely corrosion condition
> -200 mV > -106 mV Low(10% risk of corrosion)
-200 to -350 mV -106to -256 mV Intermediate corrosion risk
<-350 mV < -256 mV High(>90% risk of corrosion)
<-500 mV <-426 mV Severe corrosion

The half-cell potential values (in mV) for different days are given in Fig. 5
0
-100 0 40 80 120
-200
Potential (mV)

-300
-400
-500
-600
-700
-800
-900
Time (days)
CS MS Z 2C 3C 2G 3G 2G+2C

Figure 5 Half-cell potentials

From the above figure, it is understood that till 80 days both zeolite and micro-silica have
offered very good resistance as their potential lies in the range of low and intermediate
corrosion risk, and at the range of 120 days both zeolite and micro-silica have severe
corrosion. But, at 40 days itself, all the remaining specimens are lying under high risk of
corrosion and at 120 days all these specimens are having severe corrosion, whereas the
control specimen lies in the severe corrosion at all the time.

3.4. Open Circuit Potential Method

In this method, Ecorr will be obtained directly from the electrochemical analyzer which gives
qualitative information about the risk or degree of corrosion. The more negative potential
indicates more active corrosion, and the open circuit values (mV) of different samples on
different days are given in Fig. 6. The criteria for the probability of corrosion are illustrated in
Table 5.

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 Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of
Reinforcement Bars

100

0
0 20 40 60 80 100 120 140
-100
Potential (mV)

-200

-300

-400

-500

-600
Time (days)

CS MS Z 2C 3C 2G 3G 2G+2C

Figure 6 Open circuit Potentials

So, from the above figure, it is clear that in the initial days, all the specimens are lying
under low corrosion risk, but as the days passed it is clear that zeolite offers higher resistance
than all the specimens.

3.5. Linear Polarization Resistance Method

In this method the potential is changed about 10-20mV from Ecorr and the corresponding
current is measured. When a plot is drawn for current vs potential, the slope of the plot gives
the Polarization Resistance.
The corrosion current (icorr) can be calculated from the equation icorr = B / Rp
Where Rp is polarization resistance obtained from the slope, B is considered as 26mV for
concrete [19]
The corrosion rate in terms of corrosion density (Icorr) is given by Icorr= icorr/A, where A is
the polarized area.
The corrosion density for all the days is plotted and shown in Fig. 7.

3.5E-09
Corrosion density (μA/cm2)

3E-09
Hundreds

2.5E-09
2E-09
1.5E-09
1E-09
5E-10
0
-5E-10 0 20 40 60 80 100 120 140
Time (days)
CS MS Z 2C 3C 2G 3G 2G+2C

Figure 7 Corrosion rate calculated from LSV method

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 Varun Kumar K and Mini K.M

In the initial days, the corrosion rate is almost same for all the specimens, but as the days
passed the trend is changed and zeolite has very low corrosion density and thus it offers very
high corrosion resistance when compared to remaining specimens.

3.6. Tafel Polarization Method

A Tafel plot is performed on a metal specimen by polarizing the specimen about 300 mV
anodically (positive-going potential) and cathodically (negative going potential). The
corrosion current, Icorr, is obtained from a Tafel plot by extrapolating the linear portion of the
curve. After extrapolation the corrosion current and potential are obtained directly and will be
shown by electrochemical analyzer. The corrosion density obtained for different specimens
are plotted and shown in Fig. 8.
1E-08
Corrosion density (μA/cm2)

8E-09
Hundreds

6E-09

4E-09

2E-09

0
0 40 80 120
-2E-09
Time (days)
CS MS Z 2C 3C 2G 3G 2G+2C

Figure 8 Corrosion rate calculated from Tafel Polarization method

From the above plot, it is clear that in the initial days all the specimens except 3C are
having low corrosion density, but as the days passed zeolite offered best corrosion resistance
at all the time.
In the present paper, the corrosion resistance offered by the modifications in steel and
concrete is studied. As per the study conducted on water absorption of the micro silica and
zeolite, it is revealed that 10% replacement of cement with micro silica and zeolite resulted in
less water absorption. This is because all the small voids are filled up by the micro-silica and
zeolite admixtures which make the concrete impermeable. From the compressive test results,
it is clear that both micro-silica and zeolite induced specimens have higher compressive
strength than the control specimens and the highest compressive strength is accounted for
micro-silica.
As per the study conducted on the pull-out strength of different specimens, it is concluded
that all the specimens have higher bond strength when compared with the control specimen.
The highest bond strength is accounted for 3G specimen. So, by the addition of admixtures
and wrapping the steel, there is no adverse effect on the bond strength.
Based on the different methods that are used to measure corrosion rate for different
samples, it is clear that from half-cell electrical potential method and open circuit potential
method; zeolite offers higher corrosion resistance as it has very low negative potential when
compared to remaining specimens. From Linear Polarization Resistance (LPR) and Tafel
Polarization methods, it is understood that in the initial stages, all the specimens are having

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 Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of
Reinforcement Bars

less corrosion current but as the days passes the trend is changed and lowest corrosion current
is offered by zeolite when compared with remaining specimens.

4. CONCLUSIONS
The present paper reports a study on the modifications in concrete and steel to reduce the rate
of corrosion of steel reinforcement bars. The concrete is modified by replacing cement with
micro-silica and zeolite admixtures which fills all the small pores present in the cement and
makes concrete impermeable. In case of steel modification, CFRP and GFRP sheets are
wrapped around the steel bar which acts as a secondary reinforcement (barrier) for the
passage of water.
From the experiments conducted on water absorption, the lowest water absorption is
obtained for specimens with 10% replacement of cement with micro-silica and zeolite.
Based on the test results on compressive strength, it is clear that micro-silica induced
specimens have higher compressive strength when compared to control specimens and zeolite
induced specimens.
From the pull-out test conducted on all the different type of specimens, specimens
wrapped with 3 layers of glass fiber showed highest bond strength when compared to
remaining specimens.
From all the electrochemical methods conducted for measuring the rate of corrosion, it
can be concluded that zeolite offers better corrosion resistance when compared to remaining
specimens.
So, from all the above results it is clear that addition of 10% zeolite gives less water
absorption, good compressive strength, appreciable bond strength, better corrosion resistance
when compared with different specimens.

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