14.01-TEC-V-AAA-DIV-06856 - Rev.0 - Technical Note - Rebar Steel Corrosion Risk Assessment Due To Embankment Environment

ROYAUME DU MAROC
AGENCE SPECIALE DE TANGER MEDITERRANEE Ministère de l’Equipement et du transport

Tél : 212 (0)37 76 55 79
Fax : 212 (0)37 76 37 79
INGEMA
INGEMA 4, Rue Zalagh, Agdal, Rabat
Tél : 212 (0)37 68 78 00
Fax : 212 (0)37 67 30 89
Halcrow Group Limited

Burderop Park Swindon Wiltshire SN4 0QD
Tel : +44 (0)1793 812479
Fax : +44 (0)1793 812089
SOCIETE DE REALISATION DU PORT DE TANGER MEDITERRANEE
1 avenue Eugène Freyssinet 1/7 avenue San Fernando Bd de la Corniche – El Hank –

78065 St Quentin en Yvelines FRANCE 78884 St Quentin en Yvelines FRANCE BP 16013 – Casablanca MAROC
NOUVEAU PORT DE TANGER MEDITERRANEE

Premier Lot
Marché N° 1/2003 TMSA
0 2 First Issue FCA 01/03/10 ABO 01/03/10
Rev. Statut Raison pour la révision Nom Date Nom Date Nom Date
REDACTEUR VERIFICATEUR APPROBATEUR
Code de statut : 1- en Développement ; 2- Emis ; 3- Disponible sur e-doc ; 4 – Bon pour exécution ; X – Annulé
TECHNICAL NOTE - REBAR STEEL CORROSION RISK ASSESSMENT

DUE TO EMBANKMENT ENVIRONMENT
Page: 1 / 41
Index Emetteur Lot Phase Type Doc N° Rev.
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REVISION PAGE
Revision Description of the Revision
0 First Issue
New Mediterranean Port of Tangier

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REVISION TABLE
REVISION REVISION REVISION

PAGE PAGE ANNEX
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
1 26 A
2 27 B
3 28 C
4 29 D
5 30 E
6 31 F
7 32 G
8 33 H
9 34 I
10 35 J
11 36 K
12 37 L
13 38 M
14 39 N
15 40 O
16 41 P
17 42 Q
18 43 R
19 44 S
20 45 T
21 46 U
22 47 V
23 48 W
24 49 X
25 50 Y

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TABLE OF CONTENTS
1 INTRODUCTION .......................................................................................................................................... 6
2 SCOPE OF THE DOCUMENT ..................................................................................................................... 6
3 DEFINITION AND ABBREVIATIONS ......................................................................................................... 6
3.1 DEFINITIONS ........................................................................................................................................... 6
3.2 ABBREVIATIONS ...................................................................................................................................... 6
4 REFERENCES ............................................................................................................................................. 6
4.1 CONTRACTOR DOCUMENTS ..................................................................................................................... 6
4.2 NORMATIVE REFERENCES ....................................................................................................................... 7
4.2.1 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ........................................................... 7
4.2.2 EUROPEAN NORM (EN)................................................................................................................. 7
4.2.3 FRENCH STANDARDS (NF) ............................................................................................................ 7
4.2.4 MOROCCAN STANDARDS (NM) ...................................................................................................... 7
4.3 LITERATURE REFERENCES....................................................................................................................... 7
5 DESCRIPTION OF THE PORT.................................................................................................................... 9
6 DESIGN DATA........................................................................................................................................... 10
6.1 DESIGN LIFE ......................................................................................................................................... 10
6.2 MATERIALS OF CONSTRUCTION: REINFORCED CONCRETE ...................................................................... 10
6.2.1 CEMENT ..................................................................................................................................... 10
6.2.2 SILICA FUME ............................................................................................................................... 10
6.2.3 SUPERPLASTICIZER ..................................................................................................................... 11
6.2.4 RETARDANT ................................................................................................................................ 12
6.2.5 REINFORCING BARS (REBARS) ..................................................................................................... 12
7 CORROSION ASSESSMENT.................................................................................................................... 13
7.1 MECHANISMS OF REINFORCED CONCRETE DEGRADATION ...................................................................... 13
7.1.1 REINFORCED CONCRETE DEGRADATION DUE TO CORROSION OF REINFORCING STEEL .................. 13
7.2 STEEL PASSIVITY IN CONCRETE ............................................................................................................. 13
7.3 MECHANISMS OF REBARS STEEL CORROSION IN CONCRETE ................................................................... 14
7.3.1 MORPHOLOGY OF REBARS STEEL CORROSION IN CONCRETE ....................................................... 15
7.3.2 CARBONATION OF CONCRETE...................................................................................................... 15
7.3.2.1 Carbonation Penetration Rate .................................................................................. 16
7.3.2.2 Propagation and Corrosion Rate .............................................................................. 17
7.3.2.3 Presence of Low Concentrations of Chlorides.......................................................... 18
7.3.3 CHLORIDE-INDUCED CORROSION OF STEEL IN CONCRETE ............................................................ 18
7.3.3.1 Chloride-induced Corrosion Mechanism................................................................... 19
7.3.3.2 Critical Content of Chloride ....................................................................................... 19
7.3.3.3 Modellization of Chloride Penetration ....................................................................... 20
7.3.3.4 Propagation............................................................................................................... 22
8 CALCULATIONS ....................................................................................................................................... 23
8.1 CALCULATION OF CHLORIDES PENETRATION PROFILES ........................................................................... 23
8.1.1 INPUT DATA ................................................................................................................................ 23
8.1.1.1 Environmental Data................................................................................................... 23
8.1.1.2 Concrete Data ........................................................................................................... 23
8.1.2 ASSUMPTIONS ............................................................................................................................ 23
8.1.3 RESULTS OF CALCULATIONS........................................................................................................ 24
8.1.3.1 Calculation of Chlorides Diffusion Coefficient ........................................................... 24
8.1.3.2 Calculation of Chlorides Penetration Profiles............................................................ 25
9 DISCUSSIONS........................................................................................................................................... 26

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9.1 CORROSION DUE TO CARBONATION ....................................................................................................... 26

9.2 CORROSION DUE TO CHLORIDES ........................................................................................................... 26
9.2.1 CONCRETE QUALITY IN RESPECT TO DURABILITY ......................................................................... 26
9.2.2 CONCRETE CHLORIDE DIFFUSION COEFFICIENT: TIME TO CORROSION INITIATION .......................... 26
9.2.3 CORROSION PROPAGATION ......................................................................................................... 28
10 CONCLUSIONS AND RECOMMENDATIONS ......................................................................................... 29
10.1 CONCLUSIONS ...................................................................................................................................... 29
10.2 RECOMMENDATIONS ............................................................................................................................. 30
ANNEX A - CEMENT TECHNICAL DATA SHEET ........................................................................................ 31
ANNEX B - SILICA FUME TECHNICAL DATA SHEET ................................................................................ 33
ANNEX C - SUPERPLASTICIZER TECHNICAL DATA SHEET ................................................................... 36
ANNEX D - RETARDANT TECHNICAL DATA SHEET................................................................................. 39

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1 INTRODUCTION
SRPTM (standing for Société de Réalisation du Port de Tanger Méditerranée) has been awarded the
contract for the design and construction of the new commercial port of Tangier on the Mediterranean façade
on behalf of the Tangier Mediterranean Special Agency (TMSA). SRPTM is a consortium made of Bouygues
Travaux Publics, Bymaro and Saipem S.A.
2 SCOPE OF THE DOCUMENT
This report presents the rebar steel corrosion risk assessment for the reinforced concrete caissons caused
by long term exposure of the concrete caissons to the embankment environment.
Other degradation mechanisms such as chemical attack by acids or sulphates, alkali-aggregate reactions,
physical and/or mechanical degradation mechanisms have not been consider to the aim of this study. Also
risk of rebars steel corrosion due to seawater for the caissons sides exposed to seawater and due to marine
environment for the caissons section exposed to marine atmosphere has not been considered.
3 DEFINITION AND ABBREVIATIONS
3.1 DEFINITIONS
The following definitions are applicable throughout this document:

COMPANY: Tangier Mediterranean Special Agency (TMSA);
CONTRACTOR: SRPTM (standing for Société de Réalisation du Port de Tanger Méditerranée),
responsible for the design and construction of the Tangier Mediterranean Port. SRPTM is
a consortium made of Bouygues Travaux Publics, Bymaro and Saipem S.A.
3.2 ABBREVIATIONS
The following abbreviations are applicable throughout this document:

• ACI: American Concrete Institute;
• AIM: Associazione Italiana di Metallurgia;
• ASTM: American Institute for Testing and Materials;
• EN: European Norm;
• GGBF: Ground Granulated Blast Furnace (Concrete);
• NF: Norme Française (French Standards);
• NM: Norme Marocaine (Moroccan Standards);
• PSD: Particle Size Distribution;
• RH: Relative Humidity;
• SCE: Standard Calomel Electrode;
• SRPTM: Société de Réalisation du Port de Tanger Méditerranée;
• TM: Trade Mark;
• TMSA: Tangier Mediterranean Special Agency (Agence Spéciale Tanger Méditerranée);
• w/c: Water to cement (ratio).
4 REFERENCES
4.1 CONTRACTOR DOCUMENTS
[1]
14.02-TEC-E-PED-DIC-03882 Rev. 1 Digue Principale a Caissons - Etude de Faisabilité d’un
Système de Protection Cathodique des Superstructures -

14.01 TEC V AAA DIV 06856 0 7 of 41
Rapport Final
[2]
14.02-TEC-E-PED-DIC-03892 Rev. 2 Digue Principale a Caissons - Protection Cathodique a
Posteriori des Superstructures - Système de Surveillance
[3]
14.02-TEC-V-PED-PLA-06841 Rev. 0 Protection Cathodique du Quai Céréalier - Principe
General d’Alimentation Electrique des Transformateurs
4.2 NORMATIVE REFERENCES
4.2.1 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
[4]
ASTM C1556 Standard Test Method for Determining the Apparent Chloride Diffusion Coefficient
of Cementitious Mixtures by Bulk Diffusion
4.2.2 EUROPEAN NORM (EN)
[5]
EN 480-8 Methods of Testing Admixtures for Concrete, Mortar, and Grout - Part 8:
Determination of the Conventional Dry Material Content
4.2.3 FRENCH STANDARDS (NF)
[6]
NF A35-016 Reinforcing Steel - Weldable Ribbed Steel - Part 1: Bars and Coils
4.2.4 MOROCCAN STANDARDS (NM)
[7]
NM 10.1.004 Liants Hydrauliques - Composition, Spécifications et Critères de Conformité de
Ciments Courants
[8]
NM 10.1.157 Liants Hydrauliques - Ciment à Faible Chaleur d'Hydratation Initiale et à Teneur en
Sulfures Limitée
4.3 LITERATURE REFERENCES
[9]
ACI Committee 226. Silica fume in concrete: Preliminary report. ACI Materials Journal. Pages 158 -
66. (Mar./Apr. 1987).
[10]
M. D. Luther. High-performance silica fume (microsilica) - Modified cementitious repair materials.
69th Annual Meeting of the Transportation Research Board. Paper no. 890448. (Jan. 1990).
[11]
R. J. Detwiler, C. A. Fapohunda, J. Natale. Use of supplementary cementing materials to increase
the resistance to chloride ion penetration of concretes cured at elevated temperatures. Materials
Journal. (Jan. 1994).
[12]
R.J. Detwiler, P.K. Mehta. Chemical and physical effects of silica fume on the mechanical behaviour
of concrete. Materials Journal. (Nov. 1989).
[13]
G. Bianchi, F. Mazza. Corrosione e protezione dei metalli. Ed. AIM, Third Edition. Pag. 38. (2005).
[14]
K. Tuutti. Service life of structures with regard to corrosion of embedded steel. Performance of
concrete in marine environment. ACI SP-65, American Concrete Institute. Pages 223 - 236. (1980).
[15]
P. Pedeferri, L. Bertolini. La durabilità del calcestruzzo armato. Mc Graw-Hill. (2000).
[16]
D. A. Jones. Principles and Prevention of Corrosion. Prentice Hall, Second Edition. Pag. 214
[17]
M. Collepardi, A. Marcialis, R. Turriziani. Penetration of chloride ions into cement pastes and
concrete. Journal of the American Ceramic Society. Pages 534 - 535. (1972)
[18]
K. Sergi, S. Yu, C. Page. Diffusion of chloride and hydroxyl ions in cementitious materials exposed
to a saline environment. Magazine of Concrete Research. Pages 63 - 69. (1992).

14.01 TEC V AAA DIV 06856 0 8 of 41
[19]
L. Nilsson. The effect of non-linear binding on chloride diffusivities and chloride penetration. A
theoretical approach. Chloride penetration into concrete structures. Nordic Miniseminar Sweden.
Pages 310 - 320. (1993).
[20]
A. Saetta, R. Scotta, R. Vitaliani. Analysis of chloride diffusion into partially saturated concrete. ACI
Materials Journal. Pages 441 - 451. (1993).
[21]
R.D. Browne. Design prediction of the life of reinforced concrete in marine and other chloride
environments. Durability of Building Materials, Vol. 3, Elsevier Publishing. (1982).
[22]
N. Buenfeld, M. Shurafa-Daoudi, I. McLoughlin. Chloride transport due to wick action in concrete.
Chloride penetration into concrete. Proceedings of the International RILEM Workshop. Pages 315 -
324. (1995).
[23]
D. P. Bentz. Influence of silica fume on diffusivity in cement-based materials. II. Multi-scale
modeling of concrete diffusivity. Cement and Concrete Research, Volume 30, No. 7. Pages 1121 –
1129. (July 2000).
[24]
D. P. Bentz, E. J. Garboczi, l and E. S. Lagergrenì. Multi-scale microstructural modelling of concrete
diffusivity: identification of significant variables. Journal of Cement, Concrete, and Aggregates.
(June 1998).
[25]
D. P. Bentz, C. J. Haecker. An argument far using coarse cements in high-performance concretes.
Cement and Concrete Research. Pages 615 - 618. (1999).
[26]
ACI 201.2R-92. Guide to durable concrete. American Concrete Institute. (1992).
[27]
B. Kerkhoff. Effects of substances on concrete and guide to protective treatments. Portland Cement
Association. (2001).
[28]
ACI 318-02. Building code requirements for structural concrete. American Concrete Institute.
(2002).
[29]
J. Crank. The Mathematics of diffusion. Clarendon Press, 2nd Ed. (1975).

14.01 TEC V AAA DIV 06856 0 9 of 41
5 DESCRIPTION OF THE PORT
The mediterranean Port of Tangier is the second port facility in Tangier and it’s located in the Mediterranean
Sea in correspondence of the Strait of Gibraltar.
The port is consisting of two 1,230 m long breakwaters, 8 berths for ferries, and a 42-hectare logistics area.
The main breakwater will comprise forty precast concrete caissons for which foundations exceed 20 meters
deep and Accropodes™. The use of precast concrete caissons has permitted not only to diminish the
environmental impact by reducing the project footprint and the volume of construction materials required, but
also has reduced the construction time.
The quay object of the study of this report is the quay of the Bulk and Miscellaneous Materials Terminal,
which will serve for import and export cargo traffic particularly for the industries established in the port area
and will be equipped to receive cereal traffic.
The quay is constructed with 21 concrete caissons, namely R0 and V1 to V20. Caisson V20 is entirely
surrounded by seawater and has not been considered to the purpose of this study. The rebars steel of the
R0 and V1 to V19 caissons sides exposed to seawater and the entire reinforcing steel bars of caisson V20
are protected by an impressed current cathodic protection system.
Following Fig. 1 shows the plan of the quay of the Bulk and Miscellaneous Materials Terminal and part of the
main breakwaters.
Embankment
Seawater
Metres
Fig. 1 - Plan of the quay of the Bulk and Miscellaneous Materials Terminal and part of the main breakwaters [3]

14.01 TEC V AAA DIV 06856 0 10 of 41
6 DESIGN DATA
6.1 DESIGN LIFE
The design life of the reinforced concrete caissons quay is 100 years.
6.2 MATERIALS OF CONSTRUCTION: REINFORCED CONCRETE
The caissons used for the construction of the quay are constructed of reinforced concrete. The composition
of the concrete for a cubic meter of dry aggregate concrete is reported in following Table 1.
Component Denomination SUPPLIER/Origin Nominal Composition
Cement CPJ 45 (V) PM LAFARGE/Tanger 455 Kg
Silica fume S95 DM CONDENSIL 25 Kg
Fine sand ‐ Quarry Haft Lebnate 450 Kg
Coarse sand ‐ Quarry Haft Lebnate 220 Kg
Gravel GI 3.5 ‐ 12 mm Quarry Haft Lebnate 520 Kg
Coarse gravel GII 10 ‐ 20 mm Quarry Haft Lebnate 650 Kg
Active water ‐ ‐ 162 Kg
Superplasticizer Optima 175 CHRYSO/Sermaises 6.2 Kg
Retardant ChrysoTard CHR CHRYSO/Sermaises 0.0 Kg
Table 1 - Composition of the caissons concrete for a cubic meter of dry aggregate [1]
6.2.1 CEMENT
The cement CPJ 45 (V) PM (where PM stands for “Prise Mer”) manufactured by LAFARGE meets both the
following Moroccan Standards:
- NM 10.1.004: Hydraulic Binders [7];
- NM 10.1.157: Cement for Offshore Operations [8].
The CPJ 45 (V) PM cement contains at least 65% of clinker, the rest consisting of additions (lime, fly ash and
pozzolans). The chemical constituents of the clinker and the maximum percentage of different additions are
defined by the standard NM 10.1.157. This cement is intended for the manufacture of high performance
concrete which allows to better withstand the chemical elements present in aggressive environments such
as marine waters, sulphate waters and brackish waters.
The technical data sheet of the cement is reported in Annex A.
6.2.2 SILICA FUME
The silica fume CONDENSIL DM S95 is a super fine, mechanically densified silica for high performance and
high durability concretes. The CONDENSIL DM S95 silica fume is a by-product of the silicon and ferrosilicon
alloys production industry.
[9], [10]
Silica fume is a very effective pozzolanic material due to its extreme fineness and high silica content
and it is added to cement concrete to improve its mechanical properties, in particular:
- increases the compression, bending and tensile strengths;
- increases the modulus of elasticity;
- reduces the creep susceptibility;
- improves resistance to abrasion and erosion.
and to improves its durability in aggressive environments. In particular, addition of silica fume also reduces

14.01 TEC V AAA DIV 06856 0 11 of 41
the permeability of concrete to chloride ions [11].

These improvements derive from both the mechanical improvements resulting from addition of a very fine
powder to the cement paste mix as well as from the pozzolanic reactions between the silica fume and free
calcium hydroxide in the paste [12].
The main properties of the CONDENSIL DM S95 silica fume are reported in following Table 2.
Property Value
Apparent density 0.45 ± 0.1
Real density (helium) 2.24
Content of SiO2 ≥ 85%
Content of elemental Si ≤ 0.4%
Content of Na2O equiv. ≤ 1.0%
Content of SO3 ≤ 2.0%
Content of CaO ≤ 1.0%
2
Specific Surface BET (m /g) 15 ‐ 35
loss on ignition ≤ 4.0%
‐
Content of Cl ions ≤ 0.1%
Table 2 - CONDENSIL DM S95 silica fume main properties
The technical data sheet of the silica fume is reported in Annex B.
6.2.3 SUPERPLASTICIZER
The CHRYSO®Fluid Optima 175 is a superplasticizer based on polycarboxylate and modified phosphonate.
It is developed to reduce water contents considerably and/or increase the workability of the concrete, yet
maintain the workability of fresh concrete without compromising the setting time.
Superplasticizers (also called high range water reducers or dispersants) are chemical admixtures that can be
added to concrete mixtures to improve workability. Since the strength of concrete is inversely proportional to
the amount of water added (or water-cement - w/c ratio), in order to produce stronger concrete, less water is
added which makes the concrete mixture very unworkable and difficult to mix, necessitating the use of
plasticizers, water reducers, superplasticizers or dispersants.
Superplasticizers are also often used when pozzolanic ash is added to concrete to improve strength. This
method of mix proportioning is especially used when producing high-strength high performance concrete.
Adding 1-2% superplasticizer per unit weight of cement is usually sufficient.
The main properties of the CHRYSO®Fluid Optima 175 superplasticizer are reported in following Table 3.
Property Value
Nature Liquid
Colour White / yellow
Bulk density (20°C) 1.055 ± 0.010
pH 6 ± 1
Na2O equiv. ≤ 1 %
‐
Dry extract (EN 480‐8) 30.5 ± 1.5
Dry extract (24h, 105°C) 30.0 ± 1.5
Table 3 - CHRYSO®Fluid Optima 175 superplasticizer main properties

14.01 TEC V AAA DIV 06856 0 12 of 41
The technical data sheet of the superplasticizer is reported in Annex C.
6.2.4 RETARDANT
CHRYSO®Tard CHR retardant slows down the hydration of cement by momentarily blocking the surface of
the cement particles. At the end of setting, the concrete hardens rapidly and high compressive strength is
obtained after 28 days.
Retardants are commonly used in hot weather conditions in order to overcome accelerating effects of higher
temperatures and large masses of concrete on concrete setting time. Because most retardants also act as
water reducers, they are frequently called water-reducing retardants. Retarding admixtures consists of both
organic and inorganic agents. Organic retardants include unrefined calcium, sodium, NH4, salts of
lignosulfonic acids, hydrocarboxylic acids, and carbohydrates. Inorganic retardants include oxides of lead
and zinc, phosphates, magnesium salts, fluorates and borates.
The main properties of the CHRYSO®Tard CHR retardant are reported in following Table 4.
Property Value
Nature Liquid
Colour Brown
Density (20° C) 1.06 ± 0.01
pH 10.5 ± 1.0
Freezing point ‐1° C
‐
Na2O equiv. ≤ 0.5%
Dry extract (24h, 105° C) 14.7% ± 1.0%
Dry extract (EN 480‐8) 15.0% ± 1.0%
Table 4 - CHRYSO®Tard CHR retardant main properties
The technical data sheet of the retardant is reported in Annex D.
6.2.5 REINFORCING BARS (REBARS)
The reinforcing bars (rebars) of the concrete caissons are made of mild carbon steel of grade FeE500
according to French Standard NF A35-016. The chemical composition (ladle analysis) of such grade is
reported in following Table 5.
C P S Cu N Ceq.
Grade
Max. Max. Max. Max. Max. Max.
FeE500 0.22 0.050 0.050 ‐ 0.012 0.50
Table 5 - Chemical composition of grade FeE500 according to NF A35-016
The mechanical properties of grade FeE500 according to French Standard NF A35-016 are reported in
following Table 6.
(1)
YS TS El.
Standard Grade 2 2
TS/YS
N/mm N/mm %
NF A35‐016 FeE500 500 ‐ ≥ 1.03 ≥ 2.5
Notes:
(1)
El.: Elongation under max. load
Table 6 - Mechanical properties of grade FeE500 according to NF A35-016

14.01 TEC V AAA DIV 06856 0 13 of 41
7 CORROSION ASSESSMENT
7.1 MECHANISMS OF REINFORCED CONCRETE DEGRADATION
Any reinforced concrete structure can be subject to different degradation mechanisms which can be
classified as follows:
- physical (caused by natural temperature variations, such as freeze-thaw or artificial temperature
variation such as those produced by fires);
- mechanical (such as abrasion, erosion, cavitation, impact);
- chemical (such as chemical attack by acids or sulphates, alkali-aggregate reactions - AAR);
- biological (such change in local environmental conditions created by biofouling);
- structural (such as overloads, loss of supports, cycling loads);
- corrosion of reinforcing steel.
In reality the above classification is purely indicative since different degradation mechanisms can overlap
producing combined effects. The latter mechanism is the leading cause of deterioration in concrete and it is
the subject to the assessment of this Section. The other mechanisms have not been considered to the
purpose of this document.
7.1.1 REINFORCED CONCRETE DEGRADATION DUE TO CORROSION OF REINFORCING STEEL
When rebar steel corrodes, the resulting corrosion products (iron oxides) occupy a greater volume than the
iron they originate from (from 2 to 6 times depending on the hydratation state of the oxide which is formed).
This expansion at the interface rebar-concrete creates tensile stresses in the concrete than can eventually
cause cracking, delamination and spalling with can seriously impair the structural integrity of the concrete. In
some particular conditions and only with rebars made of high yield steels, sudden structural failures can
occur due to stress corrosion cracking.
As long as the rebar corrosion rate is below 1.5 - 2 μm/year, the effects of rebar corrosion on the structural
integrity of the concrete are negligible.
When the corrosion rate exceeds 2 μm/year, corrosion products pile up at the interface between rebar and
concrete causing firstly loss of adhesion between rebars and concrete. When the corrosion penetration
reach a depth of 20 to 200 μm (depending on thickness of rebars concrete cover, rebars diameter,
environmental conditions, type of corrosion and corrosion rate, type of corrosion products, etc.) corrosion
products can cause failures in the concrete.
7.2 STEEL PASSIVITY IN CONCRETE
The rebar steel corrosion in concrete is an electrochemical process which involves the formation of an
electrochemical cell. The electrochemical cell is by definitions composed by four components: an anode, a
cathode, an electrical conductor and an electrolyte (e.g. a solution capable of transporting ions). In the
reinforced concrete the anode and cathode form on the surface of the reinforcing steel which acts as a good
electrical conductor, as the majority of metals. Finally the fourth component needed to establish an
electrochemical cell, e.g. the electrolyte, is the aqueous solution which fills the macro and micro pores of the
concrete matrix.
The corrosion occurs in the anodic region, where metallic iron (Fe) is oxidized to ion Fe2+ releasing electrons
(e) according to the following reaction:
2Fe → 2Fe2+ + 4e- (1)
2+ -
In proximity of the anodic region, the ions Fe react with the ions OH producing ferrous hydroxide Fe(OH)2
(e.g. rust) according to the following reaction:
2Fe2+ + 4OH- → 2Fe(OH)2 (2)
In the cathodic region, the oxygen (O2) reacts with the water (H2O) and the electrons (e) released from the
anodic region and transported to the cathodic region through the rebar steel which acts as an electrical
conductor. The cathodic reaction is according to the following reaction:

14.01 TEC V AAA DIV 06856 0 14 of 41
O2 + 2H2O + 4e- → 4OH- (3)

-
The ions OH migrate from the cathode to the anode through the aqueous electrolyte which fills the macro
and micro pores of the concrete matrix to sustain the formation of Fe(OH)2 in the anodic region where iron is
corroding. The sum of the anodic and cathodic reactions gives:
2Fe + O2 + 2H2O → 2Fe(OH)2 (4)
In reality, in the highly alkaline concrete environment (pH ≥ 13) produced by calcium carbonate (lime) and
alkaline hydroxides which saturate the aqueous solutions filling the macro and micro pores of the concrete
matrix, corrosion reaction rate is negligible due to the formation on the rebar steel surface of a thin oxide
layer of ferric oxide (γ-Fe2O3) which reduces the anodic reaction rate to almost zero. This phenomenon is
called passivation.
Thus, in the local pore environment of a sound concrete, the macro and micro pores solution has a pH from
12.6 to 13.8. In this interval of pH, the rebar steel results to be passivated as it is also possible to observe in
the Pourbaix diagram for iron reported on following Fig. 2
Fig. 2 - Diagram potential-pH (di Pourbaix) for iron [13]
7.3 MECHANISMS OF REBARS STEEL CORROSION IN CONCRETE
It has been determined that the iron is passivated by a thin layer of oxide (with a thickness of a few Å) in
alkaline aerated solutions when pH > 11.5. These conditions are met for the steel rebars in a sound concrete
structure correctly poured. However, with time, the passivating conditions responsible for corrosion
protection the steel rebars can be altered. This can happen for three reasons:
- starting from the exterior layers, the alkalinity of the concrete can be neutralized by reaction with the
carbon dioxide (CO2) coming from the external environment (atmosphere) so that the pores solution
passes from pH > 13 to pH < 9 destroying the oxide film and with that the passivity conditions. This
phenomen is called carbonation.
- In contact with environments containing chlorides, chlorides ions can penetrate the concrete and
reach the rebar steel. If at the rebar steel surface, a critical content of chlorides is reached the
passive film can be locally destroyed.
- Finally, in case of structure subject to electrical fields and thus where possible stray currents can
interfere with the reinforcement bars (e.g. in some regions the current is passing from the concrete to
the steel rebars and in other regions from the steel rebars to the concrete), the passive film can be
destroyed where the current is exiting the steel rebars.
Once the passive film has been destroyed, corrosion proceeds only if at the rebar steel surface water and
oxygen are available or, in case of stray currents, until the interference is present. The destruction of the
passive film is a condition necessary but not sufficient to promote corrosion of the rebar steel.

14.01 TEC V AAA DIV 06856 0 15 of 41
In the design life of any reinforced concrete structure, it is possible to distinguish two different phases in
respect to degradation due to rebar steel corrosion (see following Fig. 3):
- initiation of the corrosion, e.g. when the different phenomena responsible for loss of the passivity
conditions take place, resulting in a local or general destruction of the passive film;
- propagation of the corrosion, at different corrosion rates, starting from the moment when the passive
film is destroyed.
Corrosion
penetration
Max. acceptable
corrosion penetration
Initiation Propagation Time
Design Life
Fig. 3 - Tuutti model for initiation and propagation of corrosion [14]
7.3.1 MORPHOLOGY OF REBARS STEEL CORROSION IN CONCRETE

Carbonation destroys completely the passive film on the rebars steel while chlorides causes only a localized
damage, unless they are present at very high concentrations. Stray currents destroy the passive film where
leaving the rebars steel to enter into the concrete. Thus:
- Corrosion due to concrete carbonation is a general corrosion spread all over the rebar steel
surfaces.
- Corrosion caused by chlorides is a localized form of corrosion with penetrating damage taking the
form of pits surrounded by uncorroded areas (so called pitting corrosion). Only in case of very high
chlorides concentrations (specially with decreasing pH), the passive film can be destroyed over large
areas, resulting in a more general form of corrosion.
- Corrosion caused by stray currents appears as a localized corrosion damage where currents leave
the rebars steel to enter into the concrete.
On rebars made of high yield steel used especially for pre-compressed concrete, in specific environmental,
potential, metallurgical and mechanical conditions, it is possible to experience cracks due to stress corrosion
(generally due to hydrogen embrittlement) leading to brittle failure of the steel.
7.3.2 CARBONATION OF CONCRETE.
The carbon dioxide (CO2) present on the atmosphere (at different concentrations from 0.04% in rural
environments up to 0.2% in urban areas) when in contact with the concrete tends to neutralize the alkaline
components of the concrete, starting form the external layers.
Also acid substances such as sulfur dioxide (SO2) (with is present in concentration up to 5-10 mg/l in acid
rains) or nitrogen oxides (NOx) can neutralize the alkalinity of the concrete but their contributions result
negligible compared to CO2.
Carbonation reaction can be written as follows:
CO2 + Ca(OH)2 (in the presence of H2O and NaOH) → CaCO3 + H2O (5)

14.01 TEC V AAA DIV 06856 0 16 of 41
although the reaction precedes through different intermediate reactions involving sodium and potassium
hydroxides.
The carbonation reaction itself is not creating damages in the concrete; actually, at least for concrete made
with Portland cement, the carbonation reaction reduces the concrete porosity and increases the mechanical
properties. On the contrary, the carbonation reaction reduces the pH of the pore solution from the initial
value between 13 and 14 to values close to neutrality, so that the steel rebars of carbonated concrete
become exposed to a pore solution made essentially of pure water with a pH far lower than 11.5 which is the
value needed to maintain the passivity conditions, in absence of chlorides.
7.3.2.1 Carbonation Penetration Rate
The carbonation reaction starts at the external surface of the concrete and then proceeds towards the
internal. The carbonation penetration with time follows a mathematical law of the following type:
s = K · t 1/n [1]
where:
s is the thickness of the carbonate layer and t is the time.
The penetration rate, ds/dt = (K/n) · t (1-n)/n, tends to decrease with time. In porous concretes, the exponent n
is approximately 2 and the carbonation penetration has a parabolic law of the type s = K · √ t. In compact
concretes, the decreasing with time of the carbonation rate is higher and n is > 2. In impervious concretes,
the carbonation rate tends to decrease to zero with time.
The coefficient K, which represents the carbonation penetration rate, depends on several factors, e.g.
environmental factors (humidity, temperature, carbon dioxide concentration) and factors linked to the
concrete quality (such as alkalinity and porosity).
In addition to the parabolic law of Equation [1], other empirical formulas have been formulated taking into
account the main factors affecting the carbonation: environmental factors such as humidity and temperature
and other factors relative to the concrete (e.g. type of cement, w/c ratio and curing). The main factors are
discussed here below.
Relative Humidity
The carbonation penetration rate varies with concrete humidity for two reasons, as follows:
- Mass transport of CO2 across the concrete pore is facilitated across pores filled with air (e.g. in the
gaseous phase) while mass transport is much slower in pores filled with water (the ratio between the
diffusion rate in the two conditions is approximate 104). Consequently, the CO2 diffusion rate
decreasing while increasing the relative humidity (especially at RH > 80%) up to almost zero for
water saturated concrete. This means that when the concrete in wet the CO2 penetration stops.
- On the other hand, the carbonation reaction requires the presence of water, so that for RH < 40%
the reaction rate is negligible.
For the above two reasons, the most critical relative humidity interval for the carbonation of concrete is
between 50 and 80%.
The value of K can be subject to change with time (e.g. because for instance the concrete structure is
subject to wetting and drying) or passing from one region to another of the structure (for instance passing
from one region exposed to rain to one dry the penetration rate can result considerably lower) or from the
external to the internal layers of concrete (the external layers becomes dryer than the internals during drying
so that the skin has different properties that the core) or from a rainy and wet to a dry region.
From the practical point of view, it is of extreme importance the microclimate e.g. the local conditions of
temperature ad humidity which the different part of a concrete structure are exposed to due to also the
geometry of the structure itself.
CO2 Concentration
Increasing the CO2 concentration in atmosphere, the penetration rate of the concrete carbonation increases.
Temperature
An increase in temperature at the same relative humidity increased the carbonation penetration rate.

14.01 TEC V AAA DIV 06856 0 17 of 41
Concrete Alkalinity
The capacity of concrete to fix the CO2 is proportional to the alkalinity of the paste, and consequently
depends on the quantity of cement used. The alkalinity depends also from the cement type. In the portland
cement approximately 64% of the cement weight is made of calcium oxide (CaO, in a small part in solution,
the remaining being in the hydratation products) an approximately 0.5 to 1.5% Na2O e da K2O (mainly in
solution as NaOH e KOH). In blast furnace
In ground granulated blast furnace (GGBF) cement with 70% of slag, the CaO content is approximately 44%.
In cements with pozzolanic admixtures, the content of CaO is between these two values.
W/c Ratio and Curing
Concrete porosity has a strong influence on the carbonation penetration rate. The decrease of the w/c ratio
determines a reduction of the capillar porosity of the hydrated paste and allows to slow down the carbonation
penetration. However, the concrete should be cured adequately.
120
K = 15
100
Carbonation Depth [mm]
80
60 K = 7
40
K = 2.82
20
0
0 10 20 30 40 50
Time [years]
½
Fig. 4 - Depth of carbonation, calculated with the formula s = K· t , as function of time and K
Fig. 4 reports the plot of the thickness of the carbonated layer for different values of K as a function of time.
The thickness of the carbonated layer is lower than 20 mm after 50 years only if K is < 2.82, e.g. for very
compact concretes.
7.3.2.2 Propagation and Corrosion Rate
Once the carbonation has reached the rebars steel determining the depassivation of the surface, corrosion
can occur only in the presence of oxygen and water according to the reactions described in Section 7.2.
Apart from a condition of complete and permanent water saturation, oxygen is able to reach the rebars steel
surface in sufficient quantity to sustain the corrosion reaction.
But in reality, corrosion rate is determined mainly by the concrete resistivity. Water content in concrete is the
main parameter to determine the resistivity, being of secondary importance other factors such as the
characteristics of the concrete (cement type, w/c ratio, curing, etc.) which are crucial to determine the
carbonation penetration rate and thus the corrosion initiation time.
Since with good quality concretes the corrosion rate is negligible for relative humidity < 80%, it is common to
consider the wetting time (ω, e.g. the fraction of time when the relative humidity exceed 80%) as the
parameter to express the corrosion penetration (p) as a function of time. It is believed that corrosion occurs
only during the wetting time and it has been observed that corrosion rate tends to decrease with time. As a
matter of fact, corrosion products, although not able to passivate the rebars steel surface, interfere with the
corrosion reaction reducing the corrosion rate.
Following Fig. 5 reports the corrosion rates in carbonated concrete as a function of relative humidity. Only in
proximity of saturation conditions, it is possible to reach maximum corrosion rates of 100 to 200 μm/year
while maximum corrosion rates for the majority of natural environmental conditions existing in reality is
between 5 and 50 μm/year. Average values are approximately one order of magnitude lower.

14.01 TEC V AAA DIV 06856 0 18 of 41
Average Values
RH Corrosion rate
2 2
10 [%] [mA/m ] [μm/year]
Corrosion Rate [mA/m ]
2
Concrete < 50 0.1 0.12

1 quality
10
60 0.2 0.23
Max. 80 1 1.16

1
95 5 5.80
‐1 98 20 23.19

10
100 5 5.80
Min.
‐2
10
30 40 50 60 70 80 90 100 immersed
110 120
Relative Humidity [%]
Fig. 5 - Min., max. and ave. corrosion rate in carbonated concrete as a function of RH [15]
From the tabulated values, it is clear that corrosion rates in carbonated concrete could be deemed negligible
unless in high humidity conditions or in presence at the concrete surface of condensation cycles of such a
duration and frequency to change the water content at the steel rebars depth.
For example, in concrete structures exposed indoors or sheltered from the rain, the fact that the concrete at
the rebars depth is carbonated is rarely a problem because any momentary presence of condensation or
wetting of the concrete surface is not causing an increase in water content at the rebars depth.
If for any reason (such as water infiltration) water should penetrate in carbonated concrete, the corrosion rate
would no longer be negligible. Since in the conditions when the carbonation rate is at its highest (50 - 80%
RH), the corrosion rate is low and vice versa, the worst situations are represented by alternating conditions
of low and high humidity, as it happens in case of concrete structures exposed to rain.
7.3.2.3 Presence of Low Concentrations of Chlorides
The situation becomes more serious if chlorides are present in low concentration in the concrete, even at
concentration lower than required to initiate depassivation of rebar steel surfaces and thus corrosion. The
presence of low concentration of chlorides in the concrete can be due either to utilization of materials
containing such ions (water, aggregates and admixtures) or to penetration of such ions from external
environment (in particular in marine environments)
As a secondary effect, the carbonation reaction releases the chlorides making the pores solution more
aggressive.
7.3.3 CHLORIDE-INDUCED CORROSION OF STEEL IN CONCRETE
Chloride-induced corrosion is the most frequent cause of corrosion of steel rebars in concrete. Although the
present normative for the design and construction of reinforced concrete structures do not allow the use of
raw materials containing chlorides at significant concentrations, chlorides can penetrate from the external
environment.
The corrosion attack can occur only when the chlorides concentration at the rebars steel surface reaches a
critical value. The critical chlorides concentration needed to destroy the passive film on the rebars steel
surface depends form the potential of the rebars steel which is correlated to the quantity of oxygen available
at the rebars steel surface.
Corrosion attack can occur for a relatively low concentration of chlorides when the concrete is exposed to the
atmosphere where oxygen can easily reach the rebar steel. On the contrary it is necessary a much higher
concentration of chlorides when the concrete is immersed in seawater or when the availability of oxygen is
low and the rebars steel potential is low.

14.01 TEC V AAA DIV 06856 0 19 of 41
7.3.3.1 Chloride-induced Corrosion Mechanism
When the chlorides concentration at the rebars steel surface reaches a critical value, depassivation occurs
with a more dangerous mechanisms since the attack is localized (pitting corrosion). Although, the
depassivation and corrosion initiation mechanisms promoted by the chlorides ions are not yet fully
understood, many authors agree on the following mechanism.
The chlorides ions promote the formation of ferrous chloride (FeCl2) in the anodic region according to the
following reaction:
Fe2+ + 2Cl- → FeCl2 [2]
The ferrous chloride (FeCl2) is then hydrolyzed by water according to the following reaction [2] with local
release of acidity (H+ and Cl-):
FeCl2 + H2O → Fe(OH)2 + 2H+ + 2Cl- [2]
The phenomenon is characterized by the formation of local anodic regions of a surface much smaller than
surrounding cathodic areas. This area ratio generates very high local anodic current densities resulting is a
rapid and penetrating corrosion attack.
Pitting tends to develop where the passive film is weaker such as at grain boundaries or in correspondence
of surface defects or inclusions. This corrosion mechanism occurs when the concentration of chlorides is
sufficient to promote the local depassivation of the rebars steel (anodic areas) and in the presence of
sufficient oxygen needed to maintain the passive film of iron oxide on the remaining steel surface which
becomes the site of cathodic reactions.
The phenomenon proceeds as illustrated in Fig. 6 according to a self-propagating (or autocatalytic)
mechanism.
Fig. 6 - Schematic of processes occurring at an activated pit on iron [16]
7.3.3.2 Critical Content of Chloride
In concrete structures exposed to atmosphere the ingress of oxygen towards the rebars steel is not
prevented and the rebars steel potential is close to 0 V vs. SCE. In these conditions, corrosion initiation
occurs when chlorides concentration in the pores solution is sufficiently high to determine a critical value of
the [Cl-]/[OH-] ratio. Once concrete pH is known (and thus the concentration of the OH- ions), it is possible to
determine the critical content of chlorides. Critical chlorides content is usually expressed as percentage by
mass referred to the mass of cement in the concrete.
Only chlorides which are water soluble in the pores solutions are to be considered, not the chlorides which
are bonded to the cement paste constituents, such as chlorides absorbed by the C-S-H gel or chlorides
bonded to tricalcium aluminate (3CaO.Al2O3) to form chloroaluminates.
The capacity to bind chlorides depends mainly from the tricalcium aluminate content in the cement paste.
For instance sulphate resistant cements have a low tricalcium aluminate content so that the corrosion risk in

14.01 TEC V AAA DIV 06856 0 20 of 41
concrete made with sulphate resistant cements at the same total chlorides content is higher than common
concretes made with portland cements.
Several studies [17], [18], [19], [20] have been directed to define the critical chlorides content although the concept
of a critical chlorides content as an universal parameter is unrealistic. Rather, a critical chloride level should
be defined only in combination with a host of other parameters. The threshold chlorides level for corrosion
damage is influences by variables such as:
- the pore solution pH;
- moisture content of concrete;
- temperature;
- age and curing conditions of concrete;
- w/c ratio;
- pore structure and other embedded defects;
- oxygen availability (hence cover and density of concrete);
- presence of pre-stressing;
- cement and concrete composition.
Rather than identify a universal critical chloride level many authors prefer to speak in terms of probability or
risk of corrosion vs. the chlorides content. One example is reported in following Table 7.
Probability/risk of Critical chloride content
corrosion (% weight of cement)
Negligible < 0.4
Possible 0.4 ‐ 1.0
Probable 1.0 ‐ 2.0
Certain > 2.0
Notes:
3 3
assuming 350 kg cement/m and density 2350 kg/m
Table 7 - Probability/risk of corrosion vs. critical chloride content according to Browne [21]
From practical point of view, in non-carbonated concretes made with portland cements (e.g. with pH > 13),
corrosion risk is negligible for chlorides contents lower than 0.4% (percentage by mass referred to cement
content in concrete) and significant for chlorides contents higher than 1.0%. The critical content tends to be
even higher for low permeability concretes with addition of pozzolanic or blast furnace slag admixtures.
In case of water immersed structures or structures closed to water saturation (when rebars steel is
characterized by very negative potentials, e.g. between -400 and -600 mV vs. SCE), the critical chlorides
content can be considerably higher than aerial structures (even of an order of magnitude).
7.3.3.3 Modellization of Chloride Penetration
In the majority of the cases, chlorides are coming from the external environment. Corrosion can initiate only
when the chlorides content exceeds the critical content at the rebars steel surfaces. The time required to
initiate corrosion (initiation time) depends from the chloride content on the external surface of the concrete,
the characteristics of the cement paste, thickness of the rebars cover, and the critical chlorides content.
The penetration of chlorides the inside a concrete structure could be modelized according to three
mechanisms, as follows:
- diffusion;
- diffusion and combination;
- convection.

14.01 TEC V AAA DIV 06856 0 21 of 41
The different mechanisms generally operate in combination one with each other but in specific conditions
one particular penetration mechanism can prevail. For instance, in completely water saturated concrete, the
chlorides penetration occurs through a purely diffusion mechanism.
Buenfeld and collegues [22] have developed a model for chlorides penetration based on capillar suction by
dry concrete of water containing chlorides. According to this model, alternating wetting periods and water
evaporation cycles can then enrich in chlorides the concrete external layers.
Even in presence of other penetration mechanisms, experimental results showed that it is possible to model
with good approximation the chlorides concentration profiles vs. time using an equation formally identical to
the second Fick’s law equation which describes the non-stationary diffusion processes.
Generally speaking, it is possible to consider the total chloride content in concrete and use a effective (or
apparent) diffusion coefficient dawn experimentally. The following equation describes the relation:
∂C ∂ 2C
= - Dce 2 [2]
∂t ∂x
where C is total chloride content in concrete (mass percentage respect to cement) at the time t (s) at the
distance x (cm) from the concrete surface and Dce is the effective chlorides diffusion coefficient (cm2/s).
Assuming that the chlorides content at the concrete surface (Cs) is constant with time, Equation [2] is solved
as follows:
x
Cx = Cs (1 - erf ) [3]
2 Dce t
where erf is the error function tabulated in the mathematics books [29].
Equation [3] allows to calculate the chloride content Cx at the distance x at the time t. Following Fig. 7 shows
three different chlorides diffusion profiles in concrete calculated with Equation [3], after 10 years of exposure
to a surface concentration of 5% for values of effective chlorides diffusion coefficient of 10-11, 10-12 and 10-13
m2/s.
6
Cs = 5%
5 t = 10 years
Chlorides Content [%]
3
‐11 2
Dce = 10 m /s
2
1 ‐12 2
‐13 2
Dce = 10 m /s
Dce = 10 m /s
0
0 1 2 3 4 5 6 7 8 9 10
Penetration Distance [cm]
Fig. 7 - Chlorides diffusion profiles varying effective chlorides diffusion coefficient
Once Dce and Cs are know it is possible to evaluate the time evolution of chloride concentration profiles in the
steel rebars concrete cover and in particular estimate the moment when the critical chlorides content to
initiate corrosion is reached at the rebars steel surface depth. Equation [3] is based on three assumptions
which are not always verified in reality, e.g.:
- the chlorides content at the concrete surface, Cs, is constant for all the exposure time;
- the effective diffusion coefficient, Dce, does not change over the exposure time;
- the concrete is homogenous, thus the effective diffusion coefficient, Dce, does not change in function
of the depth.
Since the penetration rate depends from the chlorides content at the concrete surface, it is important to
determine this value accurately and monitor eventual changes with time. In case of structure exposed in
marine environments, it has been observed that Cs reaches a value after the first few months of exposure

14.01 TEC V AAA DIV 06856 0 22 of 41
that is then constant with time. This value depends from the position of the structure, the orientation of its
surfaces, the chlorides concentration in atmosphere and from the exposure conditions in respect to the
winds and the rains. The highest values of Cs are reached in the splash zone.
The values of the effective diffusion coefficient, Dce, vary from 10-13 to 10-10 m2/s depending on concrete
characteristics. In particular, Dce depends from the concrete permeability which is influenced by w/c ratio,
pouring, curing, and presence of cracks. Also the cement used plays an important role: passing from
concretes made only with portland cement to concretes made with blend cements, Dce is reduced drastically.
For concretes made with blend cements, Dce decreases with time even after decades.
Ground granulated blast furnace (GGBF) slag is particularly effective in reducing Dce when added in sufficient
quantity to highly cured concretes.
Following Fig. 8 shows the time required to reach the chloride content of 1% as a function of the distance
from the concrete surface calculated with Equation [3] (e.g. diffusion mechanism), assuming a chloride
content of 5% at the concrete surface.
100
‐13 2
90 Dce = 10 m /s
‐12 2
80 Dce = 10 m /s
70
Time [years]
60
50
40
30
20 ‐11 2
Dce = 10 m /s
10
0
0 1 2 3 4 5 6 7 8 9 10
Penetration Distance [cm]
Fig. 8 - Time required to reach a chlorides content of 1% vs. distance (with Cs = 5%)
7.3.3.4 Propagation
In case of concrete structures exposed to atmosphere, once the localized corrosion attached has initiated,
corrosion rate can increase from about 10 μm/year to 1 mm/year increasing the relative humidity from 70 to
95% and increasing the chloride content form 1 to 3% (in mass referred to the cement). Indeed, in concrete
contaminated with chlorides, corrosion attack, once initiated, could determine unacceptable reductions in
thickness of the steel rebars even in the most common conditions of atmospheric exposure.
The lower RH limit corresponding to negligible corrosion rate depends on concrete characteristics, chlorides
content at the surface and type of salt providing the chlorides. However, this limit is much lower that the limit
corresponding to negligible effects due to carbonation.
In the presence of high chlorides contents (especially if originated from highly hydroscopic salts such as
CaCl2 or MgCl2) even at external RH of 40 - 50%, average corrosion rate can be as high as 2 mA/m2 (2.32
μm/year).
In case of structures permanently and completely immersed water, even assuming that conditions for
corrosion initiation are reached, the limited oxygen availability at the rebars steel maintains corrosion rate on
low values so that the effects of corrosion attack can be negligible for many years.

14.01 TEC V AAA DIV 06856 0 23 of 41
8 CALCULATIONS
8.1 CALCULATION OF CHLORIDES PENETRATION PROFILES
8.1.1 INPUT DATA
8.1.1.1 Environmental Data
The only available environmental data are the temperature and the chloride concentration of Atlantic ocean
seawater, which are reported in following Table 8.
Environmental Data Symbol Value Notes

‐
Annual Average Temperature Tave. 17.5 °C
‐
August Average Temperature Tave. Aug. 23.1 °C
‐
January Average Temperature Tave. Jan. 12.5 °C
‐
Atlantic Ocean Seawater Salinity S 35‰
Table 8 - Available environmental data [2]
8.1.1.2 Concrete Data
Available concrete data needed for calculations are extracted from Table 1 and reported in following Table 9.
Concrete Data Symbol Value Notes

(1)
Water to cement ratio w/c 0.356
(2)
Silica fume addition CSF 0.052
(3)
Volume fraction of aggregates Vagg 0.74
Notes:
(1)
calculated as q.ty of water per cubic meter divided by q.ty of cement per cubic meter;
(2)
calculated as q.ty of silica fume per cubic meter divided total q.ty of cementitious paste
(cement + silica fume) per cubic meter;
(3)
calculated as sum of q.ty of aggregates (sand and gravel) per cubic meter divided by total
weight of concrete per cubic meter.
Table 9 - Calculated concrete input data
8.1.2 ASSUMPTIONS
The reinforced concrete caissons in contact with the embankment environment are exposed essentially to
soil which, considering the marine environment can be considered saturated with seawater. Besides, the
embankment side and the internal volume of the caissons have been filled with a mixture of soil and fine and
coarse sand which have been collected in proximity of the sea. Thus, it can be assumed that the soil of the
embankment and the soil filling the caissons is highly contaminated with chlorides and other seawater
constituents and saturated with seawater.
Actual chlorides content at the concrete surface at the embankment side is not known. However it can be
assumed, as a conservative approach, that the embankment soil has the same chloride content as the
seawater e.g. 35 ‰.
Physical and chemical analysis of soil is not available. In particular, it would be beneficial in order to asses
the corrosion risk to have knowledge of the water, chlorides, sulphates, oxygen, carbon dioxide content in
the soil and of soil resistivity.
The minimum concrete cover (e.g. minimum distance between the steel rebars and the concrete structure
external surface) of the steel rebars is assumed to be 40 mm.

14.01 TEC V AAA DIV 06856 0 24 of 41
Assumptions made are summarized in following Table 10.
Environmental Data Symbol Value Notes

‐
Soil chlorides content Cs 3.5%
‐
Min. concrete cover x 40 mm
Table 10 - Assumptions made
8.1.3 RESULTS OF CALCULATIONS
8.1.3.1 Calculation of Chlorides Diffusion Coefficient
Chlorides penetration profile can be calculated using Equation [3] to evaluate the time required to reach at
the rebars steel surface a critical chloride content of 0.4%, corresponding to possible risk of corrosion. The
only parameter of Equation [3] which is not known is the actual chloride diffusion coefficient (Dce) of the
caissons concrete.
In concretes made with portland cement, chloride diffusion coefficient (Dce) depends from w/c ratio, degree of
hydration, volume fraction of aggregates, coarse aggregate particle size distribution, fine aggregate particle
size distribution, interfacial transition zone thickness and air content. The main variables are w/c ratio,
degree of hydration and volume fraction of aggregates. Also the silica fume addition rate plays an important
role.
Following Equation [4] [23] can be used to predict the chloride diffusion coefficient (Dce) in concrete made with
Portland cement with addition of silica fume:
log10 (Dce) = -13.75 - 0.82(w/c) + 32.55(w/c)2 + 8.374CSF + 15.36(CSF)2 + 23.15 (w/c)CSF + 5.79α [4]
- 21.10(w/c)α - 43.15(CSF)α - 1.705Vagg
where:
w/c = water to cement ratio;
CSF = silica fume addition;
α = degree of hydration;
Vagg = volume fraction of aggregates.
The degree of hydration depends mainly from the water to cement ratio, curing time and cement particle size
distribution (PSD). However, the long term degree of hydration can be calculated with the following Equation
[5] [24]:
w
α = 1.0 - exp (- 3.15 ) [5]
c
Following Fig. 9 shows the values of degree of hydration vs. curing time for a values of w/c = 0.3. The solid
line is for 5 μm cement, the dash line is for 20 μm and the dotted line is for 30 μm.
[25]
Fig. 9 - Degree of hydration vs. curing time and cement PSD

14.01 TEC V AAA DIV 06856 0 25 of 41
Based on the following input data taken from Table 11 and applying Equations [4] and [5], chloride diffusion
coefficient (Dce) has been calculated as 0.1132 x 10-12 m2/s.
Variables Symbol Actual Values Ref.
Water to cement ratio w/c 0.356 Table 9
Silica fume addition CSF 0.052 Table 9
Volume fraction of aggregates Vagg 0.74 Table 9
Degree of hydration α 0.674 Calculated with Eq. [5]
Log10 of chloride diffusion coefficient log10 (Dce) ‐12.9462 Calculated with Eq. [4]

‐12 2
Chloride diffusion coefficient Dce 0.1132 x 10 m /s ‐
Table 11 - Calculation of chloride diffusion coefficient
8.1.3.2 Calculation of Chlorides Penetration Profiles
Chlorides penetration profile can be calculated using Equation [3] to evaluate the time required to reach at
the rebars steel surface a critical chloride content of 0.4%, corresponding to possible risk of corrosion. The
following parameters of Table 12 have been used.
Variables Symbol Actual Values Ref.
Chlorides content at surface Cs 3.5% Table 11
Critical chlorides content Cx 0.4% ‐

‐12 2
Chloride diffusion coefficient Dce 0.1132 x 10 m /s Table 10
Table 12 - Input data for calculation of chloride penetration profiles
Chlorides penetration profile calculated using Equation [3] and input data of Table 12 is plotted in following
Fig. 10. The plot shows the chloride penetration distance (e.g. distance where the critical chloride content of
0.4% is reached) vs. the exposure time. Exposure time (years) to reach the critical chloride content of 0.4%
at different depth (distance from the concrete surface) are also tabulated.
Distance Time
10.0 [mm] [year]

9.0
10.0 5.6
Penetration distance [cm]
8.0
7.0 20.0 22.3
6.0 30.0 50.1

5.0
40.0 89.1
4.0
3.0 50.0 139.3
2.0 60.0 200.6

1.0
70.0 273.0
0.0
0 20 40 60 80 100 120 140 160 180 200 80.0 356.6
Time [years] 90.0 451.3
100.0 557.1
Fig. 10 - Chloride penetration profile
The critical chloride content of 0.4% is reached at the rebars steel surface (at depth of 40 mm from the
concrete surface) after 89.1 years of exposure.

14.01 TEC V AAA DIV 06856 0 26 of 41
9 DISCUSSIONS
9.1 CORROSION DUE TO CARBONATION
The risk of concrete carbonation for the sections of the caissons exposed to the embankment environment
(e.g. in contact with the embankment soil) is considered negligible since those sections are not exposed to
the atmosphere. The carbon dioxide (CO2) content of the embankment soil is supposed to be very limited (no
data exists) but, if any, the carbon dioxide quantity will not be sufficient to promote the carbonation of layers
concrete of significant depth.
It is excluded that additional significant carbon dioxide can diffuse with time from the atmosphere to the
concrete via the embankment soil due to presence of layers covering the soil (mainly asphalt) and the low
gas permeability of compacted wet soil blended with fine sand particles.
9.2 CORROSION DUE TO CHLORIDES
9.2.1 CONCRETE QUALITY IN RESPECT TO DURABILITY
The concrete mix used for the manufacture the caissons meets the industry quality requirements of a high
strength concrete showing a high durability in severe environments (e.g. chlorides containing environments).
These requirements can be summarized as follows [26], [27]:
- the maximum water soluble chlorides ions content in the concrete mix should be less than 0.15% (%
by mass of cement) for reinforced concrete structure exposed to chlorides in service [28]. According to
Ref. [2], the chlorides content in the concrete mix is 0.023%.
- water-cement ration (w/c) or the water-cementitious materials ratio (where applicable) should not
exceed 0.25 to 0.35 by weight for severe conditions.
- cement content should be at least 335 kg/m3 of cementitious materials for concrete exposed to
severe environments.
- Chemical admixtures such as water reducers and superplasticizers should be used to reduce the
water-cement ratio, resulting in reduced permeability and less absorption of corrosive substances
into concrete.
- Supplementary cementitious materials, such as fly ash and silica fume, should be used reduce
permeability and to by-produce additional cementitious compounds that increase strength. Dosages
for these materials by weight of cementitious material range from 15 to 40% for fly ash and 5 to 15%
for silica fume.
9.2.2 CONCRETE CHLORIDE DIFFUSION COEFFICIENT: TIME TO CORROSION INITIATION
A calculation of chlorides ions penetration vs. time has been performed for the aerial section of the
reinforced concrete caissons forming the main port breakwaters (caissons 3 to 39) (see Ref. [2]). The input
parameters used are slightly different than those used in this report as shown in following Table 13.
Values used in
Variables Symbol Values of Ref. [2] Notes
This Report
Water to cement ratio w/c 0.356 0.35 ‐
Silica fume addition CSF 0.052 0.5 ‐
Volume fraction of aggregates Vagg 0.74 Not stated ‐
Degree of hydration α 0.674 Not stated ‐
Table 13 - Input parameters for calculation of chloride diffusion coefficient in Ref. [2]
Applying Equation [4] with input data and results from Report in Ref. [2] (see Table 14), chloride diffusion
coefficient used (Dce) can be calculated as 0.1965 x 10-12 m2/s.

14.01 TEC V AAA DIV 06856 0 27 of 41
Variables Symbol Values of Ref. [2]
Chlorides content at surface (ave.) Cs 1.64%
Critical chlorides content Cx 0.4%
Time to reach Cx at 40 mm depth x 95.8 yeas
2 ‐12 2
Chloride diffusion coefficient [m /s] Dce 0.1965 x 10 m /s
Table 14 - Results for calculation of chloride diffusion coefficient in Ref. [2]
The values of chloride diffusion coefficient calculated in this Report and in Report in Ref. [2] are slightly
different, the main reason being the different input data. However, applying Equation [4] with the input data
used in Report of Ref. [2], it is possible to calculate the chloride diffusion coefficient simply assuming a lower
degree of hydration as shown in following Table 15.
Variables Symbol Values of Ref. [2] Ref.
Water to cement ratio w/c 0.35 Ref. [2]
Silica fume addition CSF 0.05 Ref. [2]
Volume fraction of aggregates Vagg 0.74 Assumed as this Report
Degree of hydration α 0.60 Assumed
‐12
Chloride diffusion coefficient Dce 0.1992 x 10 ‐
Table 15 - Results for calculation of chloride diffusion coefficient using input data from Ref. [2] and Eq. [4]
The considerations above show that Equation [4] is sufficiently accurate the estimate the chloride diffusion
coefficient and that the value of chloride diffusion coefficient is mostly depend from the degree of hydration.
In this study, the degree of hydration is the only parameter which cannot be directly extracted from the
concrete composition. In this study, the degree of hydration has been calculated with Equation [5] while in
Report [3], a value of 0.6 has probably been assumed. For the purpose of discussion the influence of the
chloride diffusion coefficient, four values have been studied as shown in following Table 16.
Variables Symbol Case 1 Case 2 (Ref. [2]) Case 3 ‐ Base Case 4
Water to cement ratio w/c 0.356 0.35 0.356 0.356
Silica fume addition CSF 0.052 0.05 0.052 0.052
Volume fraction of aggregates Vagg 0.74 Not stated 0.74 0.74
Degree of hydration α 0.674 Not stated 0.60 0.55

2 ‐12 ‐12 ‐12 ‐12
Chloride diffusion coefficient [m /s] Dce 0.1132 x 10 0.1965 x 10 0.2228 x 10 0.3517 x 10
Table 16 - Results for calculation of chloride diffusion coefficient varying the degree of hydration, α
Chlorides penetration profiles calculated using Equation [3] (with chlorides content at surface assumed as
3.5%) are plotted in following Fig. 11. The plot shows the chloride penetration distance (e.g. distance where
the critical chloride content of 0.4% is reached) vs. the exposure time, varying the concrete degree of
hydration.
Exposure times (years) to reach the critical chloride content of 0.4% at 40 mm depth are also tabulated.

14.01 TEC V AAA DIV 06856 0 28 of 41
‐12
Case Dce x 10
2
10.0 Colour # [m /s]
9.0
---------- 1 0.1132
Penetration distance [cm]
8.0
7.0 ---------- 2 0.1965
6.0 ---------- 3 0.2228

5.0
---------- 4 0.3517
4.0
Distance Time
3.0
Case
2.0 [mm] [year]
1.0
1 40.0 89.1
0.0
0 20 40 60 80 100 120 140 160 180 200 2 40.0 51.4
Time [years] 3 40.0 45.3
4 40.0 28.6
Fig. 11 - Chloride penetration profiles varying the of chloride diffusion coefficient
In all the 4 cases studied, the critical chlorides content of 0.4% is reached at the rebars steel surface before
100 years which is the design life of the concrete caissons. These calculations are purely theoretical since
do not take into account possible microcracks or damages that can be created with time in an aging
structure.
To validate the values of the chloride diffusion coefficients studied in this Report, it is suggested that the
actual chloride diffusion coefficient is measured on the concrete sample blocks of the caissons structure.
Chloride diffusion coefficient can be measured according to ASTM C1556.
In addition the above calculations are also conservative for the following two reasons:
- it has been assumed that the embankment soil has the same chloride content of the ocean seawater
(e.g. 3.5%). In order to validate the calculations, it is suggested that the actual chloride content of the
embankment soil is measured from a soil sample.
- Equation [3] assumes that the chlorides content at the concrete surface, Cs, is constant for all the
exposure time. This is probably not verified since chlorides diffused into the concrete will not be
easily replaced by other chlorides which need to diffuse from the ocean seawater through a
compacted wet soil blended with fine sand particles.
9.2.3 CORROSION PROPAGATION
Once the critical chlorides content of 0.4% is reached at the rebars steel surface determining the local
depassivation of the steel surface, corrosion can occur only in the presence of oxygen and water according
to the reactions described in Section 7.2.
The oxygen content of the embankment soil is supposed to be very limited (no data exists) but, if any, the
oxygen will be readily consumed in the cathodic reactions on the depassivated steel surface. Once all the
oxygen available has been consumed, corrosion will stop.
It is excluded that additional significant oxygen can diffuse with time from the atmosphere to the concrete via
the embankment soil due to presence of layers covering the soil (mainly asphalt) and the low gas
permeability of compacted wet soil blended with fine sand particles.
Oxygen diffusion from the ocean seawater through a compacted wet soil blended with fine sand particles will
also be prevented.

14.01 TEC V AAA DIV 06856 0 29 of 41
10 CONCLUSIONS AND RECOMMENDATIONS
10.1 CONCLUSIONS
This report has studied the risk of concrete caissons damage due to rebars steel corrosion caused by long
term exposure of the concrete caissons to the embankment environment which is essentially made of wet
soil and sand highly contaminated with chlorides and other seawater constituents. Other degradation
mechanisms such as chemical attack by acids or sulphates, alkali-aggregate reactions, physical and/or
mechanical degradation mechanisms have not been consider to the aim of this study. Also risk of rebars
steel corrosion due to seawater for the caissons sides exposed to seawater and due to marine environment
for the caissons section exposed to marine atmosphere has not been considered.
The possible corrosion mechanisms involved in the corrosion of steel rebars of reinforced concrete have
been assessed. The corrosion mechanism requires that the passive oxide layer naturally formed on the
rebars steel surface due to the highly alkaline concrete environment (pH from 12.5 to 13.5) is destroyed to
initiate corrosion. Once initiated, corrosion proceeds in the presence of water and oxygen.
Depassivation can occur for three reasons:
- starting from the exterior layers, the alkalinity of the concrete can be neutralized by reaction with the
carbon dioxide (CO2) coming from the external environment (atmosphere) so that the pores solution
passes from pH > 13 to pH < 9 destroying the oxide film and with that the passivity conditions. This
phenomen is called carbonation.
- In contact with environments containing chlorides, chlorides ions can penetrate the concrete and
reach the rebar steel. If at the rebar steel surface, a critical content of chlorides is reached the
passive film can be locally destroyed.
- Finally, in case of structure subject to electrical fields and thus where possible stray currents can
interfere with the reinforcement bars (e.g. in some regions the current is passing from the concrete to
the steel rebars and in other regions from the steel rebars to the concrete), the passive film can be
destroyed where the current is exiting the steel rebars.
Corrosion due to concrete carbonation is a general corrosion spread all over the rebar steel surfaces.
Corrosion caused by chlorides is a localized form of corrosion with penetrating damage taking the form of
pits surrounded by uncorroded areas (so called pitting corrosion). Only in case of very high chlorides
concentrations (specially with decreasing pH), the passive film can be destroyed over large areas, resulting
in a more general form of corrosion. Corrosion caused by stray currents appears as a localized corrosion
damage where currents leave the rebars steel to enter into the concrete.
In the corrosion mechanism, it is possible to distinguish two different phases in respect to degradation due to
rebar steel corrosion:
- initiation of the corrosion, e.g. when the different phenomena responsible for loss of the passivity
conditions take place, resulting in a local or general destruction of the passive film;
- propagation of the corrosion, at different corrosion rates, starting from the moment when the passive
film is destroyed.
Mathematical models existing to predict the initiation times have been reviewed. Carbonation penetration
rate takes the form of a parabolic law while for chlorides induced corrosion a critical chloride content is
required at the rebars steel surface to promote depassivation. For mild carbon steel rebars, a content of
chlorides ≥ 0.4% (mass percentage respect to cement) has been associated with possible risk of corrosion.
Chloride ions are coming from the external environment and can penetrate inside the porous structure of the
concrete. Possible penetration mechanism includes:
- diffusion;
- diffusion and combination;
- convection.
with diffusion being the most important mechanism. The chloride diffusion inside the concrete can be
modellised with the second Fick’s law once the chloride diffusion coefficient and the chloride content at the
external surface of the concrete are known.

14.01 TEC V AAA DIV 06856 0 30 of 41
Evaluation of chloride diffusion coefficient has been performed based on literature models and on available
concrete mix data (such as constituents and quantities). Four values of chloride diffusion coefficient have
been calculated based on different degrees of concrete hydration. For each of the calculated chloride
diffusion coefficient, chloride penetration profiles have been calculated based on the diffusion law equation
and plotted. Following results and conclusions can be drawn from this study:
- for all the calculated chloride diffusion coefficients, the critical chloride content corresponding to
possible risk of corrosion will be reached at the rebars steel surface before the design life of the
concrete caissons (100 years). In the base case, the critical chloride content of 0.4% will be reached
at the rebars steel surface (e.g. at a depth of 40 mm from the external surface) after 89.1 years
considering the embankment soil saturated with the same chloride content of seawater (3.5%).
- It is predicted that conditions for local depassivation of the steel rebars due to chlorides attack will be
reached. However, the oxygen content of the embankment soil will only be sufficient to sustain
corrosion at a negligible corrosion rate.
- It is anticipated that the risk of corrosion due to concrete carbonation for the sections of the caissons
exposed to the embankment environment (e.g. in contact with the embankment soil) will be
negligible since those sections are not exposed to the atmosphere. The carbon dioxide (CO2)
content of the embankment soil is supposed to be very limited but, if any, the carbon dioxide quantity
will not be sufficient to promote the carbonation of concrete layers of significant depth.
10.2 RECOMMENDATIONS
Following recommendations are suggested in order to validate the calculations performed in this Study:
- measure the actual chloride diffusion coefficient on a concrete sample block of the caissons
structure. Chloride diffusion coefficient can be measured according to ASTM C1556.
- measure the actual chloride content, O2 and CO2 gas permeability of the embankment soil from a
soil sample.

14.01 TEC V AAA DIV 06856 0 31 of 41
ANNEX A - CEMENT TECHNICAL DATA SHEET

14.01 TEC V AAA DIV 06856 0 33 of 41
ANNEX B - SILICA FUME TECHNICAL DATA SHEET

Notice technique
Edition 12.2008
®
CONDENSIL S95 DM

CONDENSIL S95 DM
Fumée de silice densifiée, addition pour bétons haute durabilité et hautes,
très hautes et ultra hautes performances
Conforme à la Norme NF EN 13263-1, Marquage CE
En cours d’enregistrement REACH
Code CAS 69012-64-2
Code EINECS 273-761-1
CARACTERISTIQUES GENERALES
Présentation CONDENSIL® S95 DM est une fumée de silice ultrafine obtenue lors de la
fabrication du silicium.
La fumée de silice CONDENSIL® S95 DM permet de fabriquer des :
Bétons à haute durabilité résistants en milieux agressifs :


- domaines agricoles : ensilage, stockage d’engrais, aires de
stabulation…
- milieu industriel : industries chimiques et agro-alimentaires,
sucreries, conserveries, laiteries, bacs de retention…
Domaines d’application - stations-service : béton en contact d’huiles et de carburants
- milieu marin : digue, aménagement portuaire …
- zone de montagne : présence d’eau pure, d’eau séléniteuse
+ gel dégel ou de sels de déverglaçage
- stations d’épuration, égouts, caniveaux…
 Bétons à hautes résistances (BHP, BTHP et BUHP)
 Bétons pompables
 Bétons projetés
CONDENSIL® S95 DM confère aux bétons les propriétés suivantes :

 améliore les performances mécaniques à long terme : résistances en
compression, flexion et traction
 augmente le module d’élasticité
 réduit le fluage
Caractères généraux  améliore la résistance à l’abrasion et à l’érosion
 améliore la durabilité en milieux agressifs
 diminue les risques d’expansion dus aux phénomènes d’alcali-réaction et
de la réaction sulfatique interne (RSI)
 diminue la perméabilité aux gaz et aux liquides
 facilite le pompage de tous les bétons même peu dosés en ciment
 réduit le risque de ségrégation du béton
CARACTERISTIQUES TECHNIQUES
Coloris Gris
3
■ Vrac (toutes quantités jusqu’à 25 tonnes = ≈ 55 m )
Conditionnement ■ Big bag ( ≈ 900 kg)
■ Vrac : silo étanche d’un volume suffisant et spécialement équipé
Stockage (nous contacter).
■ Big bag dans un local à l’abri de l’humidité.
Conservation En silo ou dans son emballage d’origine intact, le produit se conserve 3 ans.
DONNEES TECHNIQUES
Densité apparente 0.45 ± 0.1

Densité réelle 2.24
Surface spécifique BET (m /g) Entre 15 et 35
2
Teneur en SiO2 ≥ 85 %
Teneur en Si élémentaire ≤ 0.4 %
Teneur en Na2O équivalent  1.0 %
Teneur en SO3 ≤ 2.0 %
Teneur en Cl
_
 0.1%
Indice d’activité à 28 j ≥ 100
Perte au feu ≤ 4.0 %
Teneur CaO ≤ 1.0%
CONDITIONS D’UTILISATION
Le dosage peut être compris entre 5 à 10 % du poids du ciment. Le

Consommation / Dosage dosage le plus courant est de 8 % du poids du ciment.
■ CONDENSIL® S95 DM doit être pesé dans la bascule à ciment avec

iment pour l le ciment pour le vrac ou introduit avec le ciment.
■ Afin d’obtenir toutes les performances de CONDENSIL® S95 DM, il est
Mise en œuvre indispensable de défloculer complètement les micro-particules de silice.
Pour cela, CONDENSIL® S95 DM doit être systématiquement associé
avec un superplastifiant, haut réducteur d’eau.
Précautions d’emploi ■ L’emploi d’un masque est obligatoire lors de son utilisation
■ Fiche de données de sécurité fournie sur demande.
Produit réservé à un usage strictement professionnel.
Nos produits bénéficient d’une assurance de responsabilité
civile.
«Les informations sur la présente notice et, en particulier, les recommandations
relatives à l'utilisation finale des produits sont fournies en toute bonne foi et se
fondent sur la connaissance et l'expérience que la Société CONDENSIL a acquises
à ce jour de ses produits lorsqu'ils ont été convenablement stockés, manipulés et
utilisés dans des conditions normales. En pratique, les différences entre matériaux
et conditions spécifiques sur site sont telles que ces informations ou toute
Mentions légales recommandation écrite ou conseil donné n'impliquent aucune garantie de qualité
marchande autre que la garantie légale contre les vices cachés. Nous sommes à
votre disposition pour toute précision complémentaire. Notre responsabilité ne
saurait d'aucune manière être engagée dans l'hypothèse d'une utilisation non
conforme à nos renseignements. Toutes les commandes sont acceptées sous
réserve de nos Conditions de Vente et de Livraison en vigueur. Les utilisateurs
doivent impérativement consulter la version la plus récente de la fiche technique
correspondant au produit concerné, qui leur sera remise sur demande».
CONDENSIL
265 RUE DES EPINETTES Tél. 00 33 4 79 62 74 03
ZONE DES LANDIERS NORD Fax 00 33 4 79 96 35 94
73000 CHAMBERY E-mail condensil@vicat.fr
14.01 TEC V AAA DIV 06856 0 36 of 41
ANNEX C - SUPERPLASTICIZER TECHNICAL DATA SHEET

CHRYSO®Fluid Optima 175
Superplasticizer – High Range Water Reducer
Description Characteristics
Nature: liquid
CHRYSO®Fluid Optima 175 is a new generation Colour: white / yellow
superplasticizer based on polycarboxylate and
Bulk density: 1.055 ± 0.010
phosphonate modified.
pH: 6 ± 1
It is developed to reduce water contents considerably and
/ or increase the workability of the concrete, yet maintain Na2O equiv. ≤ 1 %
the workability of fresh concrete without compromising the Cl- ion content: nil to BS 5075
setting time. Dry extract (EN 480-8): 30.5 ± 1.5
Dry extract (24h, 105°C): 30.0 ± 1.5
CHRYSO®Fluid Optima 175 is especially adapted to Packaging

readymix and fluid concretes which require high short and Bulk
long term strengths. Barrels: 215 litres
Drums: 60 litres
Conformity
CHRYSO®Fluid Optima 175 is a superplasticizer – high

range water reducer which conforms to CE marking. The
appropriate declaration can be found on our internet site.
CHRYSO®Fluid Optima 175 also conforms to NF085
certification, whose technical specifications are those
applied in the non harmonized part of the NF EN 934-2.
Adresse AFNOR – 11 avenue F. de Pressensé – 93571 Saint Denis La Plaine
Cedex
Applications
Precautions
Fields of application
All types of cement Store away from frost.
Extended workability concretes
Readymix Should the product freeze, its properties can be
White or pale concretes recovered after thawing and agitating thoroughly.
High performance and very high performance
concretes Do not store the product at high temperatures for
Plastic, super-plastic and fluid concretes long periods.
Highly reinforced concretes
Slabs and industrial flooring Shelf life: 9 months.
Directions for use

Dosage: between 0.3 kilos and 3 kilos per 100 kilos
of cement.
The normal dose is 1 % of the weight of the cement.
It is preferable to add CHRYSO®Fluid Optima 175 to

the water before mixing the concrete.
In all cases the mixture must be sufficiently mixed
to obtain a homogenous concrete.
CHRYSO®Fluid Optima 175
Superplasticizer – High Range Water Reducer
Applications
Tests
These results were obtained following the methods defined by the ISO 4012 norm (strength tests, chart A) and the EN
12358 norm (consistency tests, chart B).
Chart A
Control Chart B Control
At equal consistency
With water/cement ratio constant
Concrete made with CEM I 42,5 cement
50 Concrete made with CEM I 42,5 cement
40
Dispersion (mm) 800
Strength (MPa)
30 600
Control + Control +
20
CHRYSO®Fluid 400 CHRYSO®Fluid
10 Optima 175 Optima 175
dosed at 1.3 % of 200 dosd at 1.6 % of
0
cement weight cement weight
24 hrs 28 days 0
SAFETY
CHRYSO®Fluid Optima 175 is a product classified « harmless». It is recommended to wear the normal
protective equipment.
For further information, please refer to the safety data sheet on our internet site www.chryso-online.com.
The information contained in this document is given to the best of our knowledge and is the result of objective testing. However, it
cannot under any circumstances be considered as a warranty involving our liability in the case of misuse. Tests should be carried out
before any use of the product to ensure that the methods and conditions of use of the product are satisfactory. Our specialists remain at
the disposal of the users to help with any problem they may have.
“ Please enquire for the latest update ” Last update : 01/05

14.01 TEC V AAA DIV 06856 0 39 of 41
ANNEX D - RETARDANT TECHNICAL DATA SHEET

CHRYSO®Tard CHR
Set retarder
Description Characteristics
®
CHRYSO Tard CHR slows down the hydration of cement  Nature: liquid
by momentarily blocking the surface of the cement  Colour: brown
particles. At the end of setting, the concrete hardens  Density (20° C): 1.06 0.01
rapidly and high compressive strength is obtained after  pH: 10.5 1.0
28 days.  Freezing point: –1° C
®
 Cl- ions content: ≤0.10%
CHRYSO Tard CHR has no surface tension effects. Its  Na2O equivalent: 0.5%
use in concrete modifies in no way the consistency of  Dry extract (24h, 105° C): 14.7% 1.0%
concrete.  Dry extract (EN 480-8): 15.0% 1.0%
®
CHRYSO Tard CHR can be used simultaneously with Packaging
high range water reducing superplasticizers.
 Bulk
 Drums of 60 L
 Barrels of 215 L
Conformity
CHRYSO® Tard CHR is a set retarder which conforms to
CE marking. The appropriate declaration can be found
on our internet site.
®
CHRYSO Tard CHR is a set retarder which conforms to
NF EN 934-2.
®
CHRYSO Tard CHR also conforms to ASTM C 494-B.
AFNOR – 11 avenue F. de Pressensé – 93571 Saint Denis La Plaine cedex - France
Application Precautions
 Should the product freeze, it will recover its
Domains of application properties after thawing and agitating.
 All types of cement  Shelf life: 18 months.
 Mass concrete and tiling mortar
 Piles, diaphragm walls
 Pouring of concrete at high temperature
 Transport of concrete over long distances
 Cold joints prevention
Method of use
Dosage: 0.2 to 1 kg per 100 kg of cement. For different
dosages, please contact our specialists.
®
CHRYSO Tard CHR is completely miscible in water. It
must be added to the mixing water.
®
The retarding effect of CHRYSO Tard CHR is
proportional to the dosage used.
®
The optimum dosage of CHRYSO Tard CHR can only
be established after trial tests, taking into account local
conditions affecting the workability of the mix and the
mechanical properties required from the concrete.
CHRYSO®Tard CHR
Set retarder
Application
Tests
Example of results obtained according to the methods defined in the NF-EN 480-1 European certification.
Type of concrete 1 using Cement grade 52.5 N (SSB : 3200 - 4000 cm²/g and C 3A : 7-11%).
Workability Strength (MPa)

7 days 28 days Initial set Final set Set extension
Control Slump 6 cm 29,1 35,1 Control 4 h 08 7 h 00 2 h 52
Control + 0,27% Control + 0,27%
Slump 6 cm 30 36,5 5 h 58 10 h 13 4 h 15
CHRYSO®Tard CHR CHRYSO®Tard CHR
References
 Cairo Metro
 Channel Tunnel
Safety
CHRYSO® Tard CHR is a product classified as « harmless». It is recommended to wear the normal protective
equipment.
For further information, please refer to the safety data sheet on our internet site www.chryso.com.
The information contained in this document is given to the best of our knowledge and the results from extensive testing. However, it
cannot, in any case be considered as a warranty involving our liability in case of misuse. Tests should be carried out before any use of
the product to ensure that the methods and conditions of use of the product are satisfactory. Our specialists are at the disposal of the
users in order to help them with any problem encountered.
“Please enquire for the latest update” Last update: 10/06

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ROYAUME DU MAROC

AGENCE SPECIALE DE TANGER MEDITERRANEE Ministère de l’Equipement et du transport

Halcrow Group Limited

SOCIETE DE REALISATION DU PORT DE TANGER MEDITERRANEE

1 avenue Eugène Freyssinet 1/7 avenue San Fernando Bd de la Corniche – El Hank –

NOUVEAU PORT DE TANGER MEDITERRANEE

0 2 First Issue FCA 01/03/10 ABO 01/03/10

TECHNICAL NOTE - REBAR STEEL CORROSION RISK ASSESSMENT

Revision Description of the Revision

New Mediterranean Port of Tangier

REVISION REVISION REVISION

New Mediterranean Port of Tangier

New Mediterranean Port of Tangier

9.1 CORROSION DUE TO CARBONATION ....................................................................................................... 26

New Mediterranean Port of Tangier

2 SCOPE OF THE DOCUMENT

3 DEFINITION AND ABBREVIATIONS

The following definitions are applicable throughout this document:

The following abbreviations are applicable throughout this document:

4.1 CONTRACTOR DOCUMENTS

New Mediterranean Port of Tangier

4.2 NORMATIVE REFERENCES

4.2.1 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

4.2.2 EUROPEAN NORM (EN)

4.2.3 FRENCH STANDARDS (NF)

4.2.4 MOROCCAN STANDARDS (NM)

4.3 LITERATURE REFERENCES

New Mediterranean Port of Tangier

New Mediterranean Port of Tangier

5 DESCRIPTION OF THE PORT

New Mediterranean Port of Tangier

6.1 DESIGN LIFE

6.2 MATERIALS OF CONSTRUCTION: REINFORCED CONCRETE

Component Denomination SUPPLIER/Origin Nominal Composition

Cement CPJ 45 (V) PM LAFARGE/Tanger 455 Kg

Silica fume S95 DM CONDENSIL 25 Kg

Fine sand ‐ Quarry Haft Lebnate 450 Kg

Coarse sand ‐ Quarry Haft Lebnate 220 Kg

Gravel GI 3.5 ‐ 12 mm Quarry Haft Lebnate 520 Kg

Coarse gravel GII 10 ‐ 20 mm Quarry Haft Lebnate 650 Kg

Superplasticizer Optima 175 CHRYSO/Sermaises 6.2 Kg

Retardant ChrysoTard CHR CHRYSO/Sermaises 0.0 Kg

6.2.2 SILICA FUME

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the permeability of concrete to chloride ions [11].

Table 2 - CONDENSIL DM S95 silica fume main properties

The technical data sheet of the silica fume is reported in Annex B.

Table 3 - CHRYSO®Fluid Optima 175 superplasticizer main properties

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The technical data sheet of the superplasticizer is reported in Annex C.

Table 4 - CHRYSO®Tard CHR retardant main properties

The technical data sheet of the retardant is reported in Annex D.

6.2.5 REINFORCING BARS (REBARS)

FeE500 0.22 0.050 0.050 ‐ 0.012 0.50

Table 5 - Chemical composition of grade FeE500 according to NF A35-016

NF A35‐016 FeE500 500 ‐ ≥ 1.03 ≥ 2.5

Table 6 - Mechanical properties of grade FeE500 according to NF A35-016

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7.1 MECHANISMS OF REINFORCED CONCRETE DEGRADATION

7.1.1 REINFORCED CONCRETE DEGRADATION DUE TO CORROSION OF REINFORCING STEEL

7.2 STEEL PASSIVITY IN CONCRETE

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