Shayan Far 2016
Shayan Far 2016
structure
Abstract
Compressive strength reduction of concretes due to corrosion of reinforcement is one of the main reasons of failure in reinforced
concrete structure which has not been taken into account by researchers yet. Therefore, in this article, for the sake of examination of
concrete’s compressive strength reduction due to rebar corrosion, reinforced concrete cubic specimens are constructed, and then,
accelerated corrosion is applied to them. With fixing all effective parameters in compressive strength except water-to-cement ratio,
specimens with different water-to-cement ratios (0.4, 0.45, and 0.5) are constructed with various reinforcements. Finally, compressive
strength tests are performed for corroded and non-corroded specimens and reduction in compressive strength is measured under dif-
ferent degrees of corrosions.
Keywords
accelerated corrosion test, compressive strength reduction, corrosion of longitudinal reinforcement, degree of corrosion, reinforced
concrete structure
Shayanfar et al. (2015), and Saassouh and retrofitting of damaged structures, due to corro-
Lounis (2012) are regarded as probabilistic sion (Lee et al., 2003), are the other research
studies and uncertainty consideration. The works about corrosion of RC structures.
study of chloride penetration into RC beams
and corrosion initiation as in Enright and Although different and relatively comprehensive
Frangopol (1998) and Duprat (2007) and the researches have been done on the corrosion and its effects
studies about concrete carbonation by Yoon on the load-bearing capacity of RC members, there are
et al. (2007) and Stewart et al. (2011) are parts not sufficient researches about the effects of developed
of this class. Estimated time calculations of cracks due to corrosion on the reduction in concrete com-
crack occurrence due to corrosion (Liu and pressive strength. Vecchio and Collins (1986) presented a
Weyers, 1998; Saad and Fu, 2013) can be con- theoretical model for calculation of compressive strength
sidered in this category. reduction based on crack model in a two-dimensional
Experimental studies about corrosion effects on space for two-dimensional elements with shear and in-
the bond behavior between reinforcement and plane normal loadings. This model is being used in stud-
concrete such as by Amleh and Mirza (1999), ies of some researchers such as Zandi Hanjari et al.
Shayanfar et al. (2007), Coronelli and (2011) in case of corrosion of reinforcement.
Gambarova (2004), and Coronelli (2002) and According to theories of elasticity (Timoshenko and
analytical and numerical analysis such as by Goodier, 1951) and classical mechanics of materials
Shayanfar and Safiey (2008) and Berto et al. (Beer et al., 2002), when an element is subjected to a
(2008b) have studied other important parts of biaxial or triaxial stresses, the compressive stress along
corrosion effects on RC structures. the main direction may increase or decrease depending
Damage assessment of concrete with calculation on normal stresses perpendicular to the main direction
of crack occurrence and development due to stresses. Considering that the under-corrosion elements
rebars’ corrosion and spall in tensile region of are internally subjected to stress due to the increase in
cross section is studied by some researchers such steel volume, these stresses generate micro- and macro
as Santiago Guzmán et al. (2011) and Shodja cracks in the concrete, and they reduce the compres-
et al. (2010). sive strength of concrete.
The research for determination of reinforcement The effects of corrosion cracks on concrete com-
area decrease and its effect on reduction in struc- pressive strength and hence structure loading capacity
tures’ capacity by Val and Melchers (1997) and are considerable and clear in cases such as concrete
Enright and Frangopol (1998) and area reduction walls (especially in under-pressure parts), foundation
and steel yield stress (Du et al., 2005) are other and beams with top penetration of salt and chloride
important researches in corrosion study of RC ions, reinforced columns, and all reinforced structures.
structures. Most part of these and similar researches Therefore, due to the lack of experimental and analyti-
are about bending capacity of reinforcements. cal models regarding these effects, reduction in maxi-
Of important and limited research about corro- mum compressive strength in terms of degree of
sion effect on capacity of RC columns is the cal- corrosion is investigated by construction of various
culation of interaction curve of moment–axial experimental specimens and application of accelerated
force of concrete columns (Tapan and corrosion to them.
Aboutaha, 2011; Wang and Liang, 2008).
The effect of corrosion on load–displacement
Steel corrosion process
curve of beams is studied by experimental speci-
mens and finite element analysis (Al-Saidy et al., Rusting refers to iron oxidation. Iron oxidation usually
2010; Dekoster et al., 2003; Maaddawy et al., happens through reaction with iron. Rusting of iron in
2005). So some researchers such as Xue and concrete is an example of electrochemical corrosion.
Seki (2010) study the influence of longitudinal Electrochemical process includes an anode (i.e. a piece
bar corrosion on the shear behavior of RC. of metal which loses electrons easily), an electrolyte
Corrosion effects on the behavior of large-scale (i.e. a liquid which helps electrons’ motion and is con-
structures and nonlinear behavior of structures crete here), and a cathode (i.e. the part which accepts
have been studied by Berto et al. (2008a, 2008c) electrons) (Bertolini et al., 2004). According to Shi
and Saetta et al. (2008). et al. (2011), the pH amount of concrete with Portland
The analysis of different additives’ effects on cement is close to 13 which will be slightly more than
compressive strength and concrete corrosion 12 by adding additive materials. This degree of alkali-
characteristics (Cao and Sirivivatnanon, 1991; nity protects the rebar inside the concrete against cor-
Shi et al., 2011) and some studies about rosion by making a passive layer. Over time and by
Shayanfar et al. 3
penetration of damaging elements such as chloride or amount of increased volume of corrosion products
carbonation (CO2 penetration), the passive layer according to Nielsen (1985) and Al-Ostaz (2004) can
around the steel ruins and each iron atom loses two be seen in Table 1.
electrons. The region where the passive layer is ruined
is called anode region. With penetration of water and
air (they are present inside the concrete) and reach of Experimental work
released electrons from the metal, which moves from In order to do compression strength tests, several sets
the reinforcement to the cathode region, these materi- of square cubic specimens are made by putting reinfor-
als react according to the following equation cements inside the concrete and are compared with
control specimens. In order to do the tests and study
1
O2 + H2 O + 2e ! 2OH ð1Þ corrosion effects on compressive strength decrease in
2 normal concrete, the specimens are made with differ-
The process continues and the produced hydroxyl ent ratios of water to cement (w/c = 0.4, 0.45, and
ion moves toward the anode region and reacts with 0.5). Details of the utilized mixing plan are presented
Fe2 + ion and produces iron hydroxide Fe(OH)2. The in Table 2.
corrosion process is demonstrated in Figure 1. The utilized cement in all the plans is Portland type
Some other products are produced during corrosion II, coarse aggregate (gravel) of fractured stone with max-
occurrence. Fe(OH)2 or iron hydroxide, which is known imum nominal size of 19 mm and density of 2600 kg/
as usual rust, reacts with dissolved oxygen and produces m3. Fine aggregates (sand) are used under cement grain
hydrated ferric oxide (Fe2O3H2O) which is also called with fineness modulus of 2.65 and density of 2550 kg/
red-brown rust, black magnetite (Fe3O4), and then green m3. Water absorption of sand and cement is 0.02 and
hydrated magnetite (Fe3O4H2O) (Liu, 1996). 0.039, respectively. Based on the measured aggregate
Since the volume of rusted products is so higher moisture in every construction, necessary modifications
than iron (about 2–6.5 times), the formation of corro- of the consumed amounts have been done. Volume
sion products during time and after filling the empty ratios of sand and cement are chosen equal.
space between concrete and steel makes internal pres- A total of 10 cm 3 10 cm control cubic specimens
sure from the rebar inside the concrete and creates of normal concrete are constructed in common plastic
cracks and spalls the concrete cover (Liu, 1996). The molds which are usually used in workshops and
laboratories for compressive strength tests with pre-
sented mix plans of Table 2. After casting concrete in
the molds and vibrating the specimens, they are kept
in the molds for 24 h, and after that they are kept in
the water tank with constant temperature of about
22°C (62). Vibration is used instead of knocking in
order to avoid impact or displacement of reinforce-
ments. Table 3 shows records of compressive strength
of different constructed cubic specimens. Similar con-
trol specimens are built with rebar at the center of
Figure 1. Process of steel corrosion occurrence in concrete. mold. Also, normal cubic specimens are built with
Table 2. Details of used material in construction of every mixing plan in volume unit (kg/m3).
Table 3. Average strength of normal cubic specimen with non-corroded reinforcement (MPa).
It must be paid attention that during the tests, the end insulator performance is estimated during test by
end part of the rebar and generally the concrete bot- checking current variations and necessary modifica-
tom must be covered with adhesive to prevent short tions and insulator replacement are done if required.
circuit. Then, its top must be covered with melted can- To calculate accurately the degree of corrosion and
dle. In this case, current flow will be through the con- mass decrease in reinforcements, the bars can be taken
crete and the passing current will be dependent on the out of the concrete easily by applying pressure to the
concrete strength against chloride ions’ penetration. In cubic specimens in the direction normal to the bar’s
this system, the chloride ions will pass according to the length; it is done after compressive strength test of cor-
described mechanism in Figure 1 through concrete and roded specimens. According to the standard ASTM
reach the bar and create corrosion. G1-03 (2003), the reinforcements are brushed and HCl
is used to clean their surface chemically before weight-
ing them. Finally, the available rebar weight is com-
Calculation of degree of corrosion pared to the initial one and the exact degree of
Theoretical mass reduction of bars during accelerated corrosion is determined based on equation (3)
corrosion is calculated proportional to corrosion flow
and based on Faraday law, equation (2). Time estima- Cw (real mass loss) =
tion calculations corresponding to the considered cor- mbase (weight before test) mremain (weight after test)
3 100
rosion based on this equation are used for initial mbase (weight before test)
planning and tests’ timing ð3Þ
mt (mass loss) = Figure 3 shows the summary of all tests performed
t(s) 3 I(A) 3 M(g=mol for iron = 55:847) ð2Þ in this research in order to calculate the reduction in
compressive strength versus degree of corrosion.
z(for iron = 2) 3 F(coulomb=mol = 96, 487)
where mt is the mass loss, I is the current, M is the
Test results
molar mass of element, z is the valency of the element,
t is the time, and F is Faraday’s constant. Time is the In this section, first the important factors affecting the
only unknown parameter for calculation of pre- compressive strength of concrete are considered.
determined corrosion amount when keeping I constant Except w/c ratio which is the most important para-
and known in equation (2) and can be obtained easily. meter, all other parameters and conditions are held
Passing current from each specimen during short inter- same and constant for all specimens.
vals is measured and recorded based on the acquired The temperature of the specimen is conversely pro-
amount from the direct current source to change vol- portional to the compressive strength of concrete, dur-
tage for keeping current constant if needed. Also, the ing curing or the test was held at about 20°C constant
temperature. The curing conditions of non-corroded aforementioned, the amount of corrosion degree is
and corroded specimens are also considered the same. determined using mass reduction of bar in specimens.
In addition, non-corroded and corroded specimens are In every construction, plus every specimen for
also tested at the same time and same age, and based applying corrosion, the base specimen is constructed
on this, by comparing the strength reduction of the for comparison and determination of the percentage of
corroded specimen with the non-corroded one (with compressive reduction in different degrees of corrosion
non-dimensioning of corrosion), the influence of based on weighting method. The values obtained and
strength increasing with age enhancement is neutra- their details are reported for every construction test in
lized in calculations. The dimensions of cubic speci- Tables 4 to 6. Although the calculation of theoretical
mens are considered as 100 mm 3 100 mm. The mass reduction based on equation (2) is done for tests’
loading rate which is directly proportional to the com- timing and is not the aim of this study, for the base
pressive strength for all specimens is kept the same. mix concrete with w/c = 0.45, real degree of corrosion
Moreover, the amount, dimension, shape, and gener- and theoretical degree of corrosion are recorded based
ally grading of the used aggregates (despite of being on equation (3). According to Table 4, equation (2)
uniform and almost large) and also the amount and with respect to equation (3) usually is overestimated
type of the used cement are also held constant in all for calculating the amount of mass loss.
specimens. Air of concrete which is conversely propor- According to Table 4, for the specimen with w/
tional to compressive strength is fixed at about 0.02 in c = 0.45, the following equation illustrating the effect
all specimens. of reinforcement corrosion on compressive strength
After construction of specimens with w/c = 0.4, reduction is obtained using least square regression
0.45, and 0.5 and applying corrosion to them, the com- method
pressive strength reduction is determined relative to
the base specimens. Compressive strength test is car- l = 2:288Cw 1:733 ð4Þ
ried out for both corroded and non-corroded speci- where l is the percentage of compressive strength
mens based on the standard BS 1881:PART116 (1983) reduction and Cw is the corrosion level. The correla-
as shown in Figure 4. Then, according to what tion coefficient (by eliminating rows 6, 7, and 10 that
Table 4. Relationship between compressive strength of concrete with strength of 38 MPa in various corrosion levels (w/c = 0.45).
No. Specimen Specimen bar Base Weight of rebar Cw % Cw % (real) Day of Mean of f 9c for f 9c from Percentage of
size weight (g) after corrosion (faraday) test base specimen test reduction in f 9c (l)
Shayanfar et al.
Table 5. Compressive strength of cubic specimens with strength of 45 MPa in various corrosion levels (w/c = 0.4).
No. Specimen Specimen As_basic Base Weight of rebar Cw % Day of Mean of f 9c for base f 9c from test Percentage of
bar size weight (g) after corrosion test specimen reduction in f 9c (l)
reduction in f 9c (l)
have high dispersion) equals 0.89 (R2 = 0.89). In the
case that all data are considered, we have R2 = 0.05,
Percentage of
which is unacceptable.
After computing l, the reduced compressive
14.37
21.70
26.29
13.14
1.90
6.67
9.09
4.92
6.30
strengths can be calculated as follows
0
0
30.9
29.4
31.0
29.2
26.7
30.9
25.8
30.4
34.2
29
31.5
31.5
34.1
34.1
34.1
32.5
36.5
29
35
35
1.66
2.79
3.89
3.60
8.84
2.69
2.83
6.45
3.52
cement corrosion
Weight of rebar
Base specimen
No corrosion
63.11
63.89
86.17
85.47
87.62
63.4
62.7
No bar
[ 10
[ 10
[ 10
[ 10
[ 10
[ 10
[ 16
F 12
F 12
F 12
10-[ 16
10-F 12
10-F 12
10-F 12
10-base
10
11
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