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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
1378 (2019) 022095
IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
Reinforcement bar Corrosion - Causes and Management
M. Oki1*, S.A. Akintola2, A.A. Adediran1, P.P. Ikubanni1 and B. T.
Ogunsemi1
1
Mechanical Engineering Department, Landmark University, Omu-Aran, Kwara State, Nigeria.
Department of Petroleum Engineering, University of Ibadan, Oyo State, Nigeria
Corresponding Author;
[email protected],
[email protected]
2
AbstractConcretes are composite materials which decay as a result of steel corrosion in concrete
structures is mostly accelerated in environments laden with chlorides and industrial
effluent gases as well as harsh chemicals employed in and those generated from wastes
in agricultural industries. This review summarises the effects of various environmental
pollutants which promote deterioration of concretes with resultant corrosion of
reinforcing bar (rebar). An overview of traditional and current methods for significant
reduction of this mode of material deterioration is described. Discussions on
management tools for rebar corrosion in agricultural and marine environments have
been highlighted. Repair methods include the traditional application of patch repair
mortar which has been modified with polymeric materials to improve adhesion and
reduce porosity. The use of cathodic protection system to reduce rebar corrosion to its
barest minimum has gained currency. Attention should be directed at corrosion
reduction practices at the design and planning stages as well as modification concrete
mixes with modified agricultural wastes/products and polymers.
Key words: Rebar, concrete, steel, green corrosion inhibitors, agricultural
industries.
1.
Introduction
Agricultural, marine and other facilities are often built of reinforced concretes in order to
withstand various inclement environments as well as heavy traffics of various animals and
moving equipment. In the past, corrosion of reinforcement bar (rebar) in concrete mainly
focused on bare steel. However it has been established that in the high alkaline concrete
environment which is free of aggressive ions, such as Cl-, SO42-, CO32- including uric acids,
manures and fertilizer chemicals etc, a layer of tenacious oxide passive film forms on the surface
of bare rebar which can protect the steel from corrosion [1].This passive film is only a few
nanometres in thickness and it may be compromised at flaws in the film, where the substrate is
exposed to aggressive ions when present or gained access into the concrete in one manner or
the other. The concentration of these aggressive ions must attain a threshold limit to cause
corrosion of the rebar. Studies have shown that corrosion of steel in concrete containing chloride
will gradually change from pitting corrosion to uniform corrosion, and the initial accelerated
corrosion rate, later decreases as a result of re-passivation of the steel during favourable
environmental conditions.
Later, a second generation of rebar materials made of scaled steels, which are supposed to
simplify descaling procedures and save costs, were employed. It was established that the
passivity of the scaled rebar can be maintained in the alkaline environment in the concrete as
well as showing better resistance to chlorides, sulphates and agricultural chemicals attack
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
1378 (2019) 022095
IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
depending on post treatment of the rolled steel [2]. While the water cooled steel carries a loosely
held oxide scale, with attendant appreciable number of flaws through which any chloride or
aggressive anions in the steel environment will cause a high degree of corrosion damage, the
air cooled counterpart has a more adherent and compact oxide layer. Hence, the air cooled steel
gives a better performance.
This review describes the occurrence; methods of protection and monitoring rebar corrosion
throughout the service life of reinforced structures with background information on the problem
of reinforced corrosion. Further various additives into concrete mixes to improve the physical
properties of concretes such as strength and porosity which will translate into better protection
for the reinforcing steel bar against corrosion are well documented [3-7].
2. Reinforcement bar corrosion
The occurrence of corrosion implies the ingress of an electrolyte such as water contaminated
with ions must be present on the metallic surface. The contaminated water which may be a thin
layer of moisture must wet the rebar in the concrete. Once corrosion commences, its rate of
progression is determined by revelation of anodic and cathodic sites as well as physical and
chemical properties of the water in addition to the integrity of the concrete. This further
determines the oxygen content in the concrete as well as its extent of carbonation. It has been
established that, unprotected steel in the atmosphere quickly develops brown oxide which will
continue to grow unless some means are provided to prevent its growth. According to Pourbaix
[8], with reference to the E/pH diagram, Fig.1, the provision of an alkaline
Fig.1.Pourbaix diagram of Fe-H2O system [8]
environment having a pH value in the range of 9.5 to 13 will provide such a deterrent to the
occurrence of corrosion. An environment of this nature is provided by wet concretes in the
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
1378 (2019) 022095
IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
absence of aggressive anions. In the pH regime in concretes which may be between 12 and 13,
passive films form on steel. This, in the absence of aggressive ions will reduce the rate of
corrosion drastically. However, due to some extraneous environmental factors, corrosion of
reinforcement bar still occurs. Rust has a larger volume than the parent steel which translates to
stress being generated within the concrete and the result can lead to cracking, rust-staining and
later spalling of the concrete cover to expose the steel bar, Fig.2, for further accelerated
Fig. 2. Spalled reinforced concrete wall showing exposed reinforcement bar
corrosion. The rate of this will depend on the constituents in its immediate environment and
oxygen. The occurrences of such phenomena mostly arise from loss of alkalinity in concrete in
the environment adjacent to the rebar which is further dependent on the integrity of the concrete.
In addition, the presence of high concentration of aggressive ions such as chlorides has been
implicated as corrosion accelerators.
2.1 Loss of Alkalinity
Loss of concrete alkalinity is a major cause of rebar corrosion. This may arise as results of
reactions with acid-forming gases (such as CO2 and SO2) in the atmosphere and subsequent
leaching away of Ca(OH)2, a product of the hydration reactions of cement in the form of calcium
bi-carbonate which is very soluble. Such carbonation reactions have been described in the
literature [9] and may involve some step reactions culminating in the formation of
Ca(HCO3)2which is very soluble. With the leaching phenomenon, a rapid and dangerous fall in
the pH from about 12 to 8 will occur. However, if the concrete is of good integrity, the
carbonation reactions take place only on the surface.
SO2 in the atmosphere can react with Ca(OH)2 in concrete directly in a similar manner to carbon
dioxide culminating in the formation of hydrated calcium sulphate, CaSO4.2H2O, which can
then react with tri-calcium aluminate in the concrete to form calcium sulpho–aluminate hydrate.
This complex has a volume which is about twice that of its precursor, calcium aluminate. The
bulky nature of this product induces stress within the component parts of the concrete leading
to cracks formation and consequent spalling and erosion of the concrete.
Other contaminants like chlorides and organic acids do cause deterioration of concretes based
on similar reactions as exemplified by CO2 and SO2. However, the extents to which these occur
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
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IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
are functions of the integrity of the concrete and on the conditions of exposure. For long term
exposure as in the cases of bridges, provisions are often made for an acceptable degree of
carbonation in the concrete bearing in mind factors such as porosity, permeability and degree
of exposure. However, to provide the steel with an effectively permanent protective alkaline
environment, the designer must ensure that the thickness of the concrete cover to the reinforcing
steel closest to the surface is sufficiently greater than the depth of atmospheric penetration.
Usually, if not all cases, reinforced concrete structures are built to guidelines given in Standard
Codes of Practice in which cases, very long maintenance-free lives are accommodated.
However, it has been observed severally that concretes at times may not give the desired, almost
indefinite, protection to the steel reinforcement. Such occurrences have been observed when:
(a) Errors of construction/supervision suggest that adequate concrete cover was not achieved
for the reinforcement.
(b) The concrete may contain high concentrations of extraneous ions, such as chloride, either
present in high quantity in the materials from which the concrete is made or rapid setting of the
concrete was accelerated by addition of extra chloride.
(c) The concrete may be exposed to sea water as in the cases of bridges, thus additional
precautions should be taken.
In these situations, it is desirable to know the extent of the impact of corrosion on the steel
reinforcement.
However, chemical admixtures are often added to modern structural concretes such as blast
furnace slags, fly ash or silica which may be derived from waste agricultural products such as
rice husks, corn cobs etc. The most commonly employed admixtures are plasticizers which
improve workability of concretes [10] with subsequent reduction in porosity within the finer
structure induced by this additive. In general a concrete with higher strength and improved
durability will be achieved.
2.2 Chloride ingress in concretes
Chlorides can enter concretes by various mechanisms which include capillary absorption, wick
action, diffusion and permeation depending on exposure conditions. Conventionally, durability
of concretes can usually be addressed by the selection, at design stages, a combination of
thickness and depth of concrete cover, which is adequate to eliminate high chloride
concentration over and above the threshold limit at the depth of the reinforcement within the
design life of the structure. Chlorides have been established to be injurious to steels and other
metals of construction at a level of about 0.35% to 1% by weight of cement especially in moist
conditions which can allow the flow of corrosion currents. Such corrosion damages arise as a
result of the disruptive actions of chlorides on the passive oxide layers of steel which are
converted from the stable, gamma variety to soluble, iron chloride. Thus, from thermodynamics
point of view, the region of passivity of iron on the E/pH diagram [8] will be reduced while
expanding the active zone. Hence kinetically, all forms of corrosion, ranging from pitting to
general will occur on the steel’s surface depending on the resistivity of the environment and the
integrity of the concrete. However, as indicated earlier, the addition of extra cementitious
materials, such as slags, ashes derived from waste agricultural materials which contain
substantial quantities of silica often induce improved durability as a result of pore refinement in
concretes. In addition, adequate incorporation of these secondary materials often achieves high
degrees of resistance to chloride ingress and sulphate attacks.
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International Conference on Engineering for Sustainable World
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doi:10.1088/1742-6596/1378/2/022095
2.3 Agricultural Wastes and Chemicals in Concretes
Various agricultural chemicals are aggressive towards concretes. These range from uric acid
which are wastes encountered in urine. Such acids neutralise the alkaline environment provided
by cement thereby causing sharp decline in the alkalinity and further convert the components
of the concrete to their soluble salts. Consequently, erosion of the concrete will expose the rebar
to inclement outside environment with its attendant accelerated corrosion and further erosion of
the structure. Thus, in agricultural environments, reinforcements require additional attention in
terms of managing corrosion right from the design stages.
3. Management, protection and monitoring of rebar corrosion
It has been considered adequate that, epoxy coated reinforcing bars as corrosion resistant
alternatives to bare carbon steel bars are adequate for on-shore reinforced structures as well as
marine sub-structures. Several case studies [9] on the durability and deterioration of both bare
and epoxy coated C-steel bars within 30 years period found the applicability and corrosion
resistance superiority of the epoxy coated counterpart. In addition, the methods for predicting
the end functional service life for structures reinforced with bare and coated bars have shown
that the epoxy coated bars can give three times years of maintenance free service life over and
above those of bare C-steel bars. Epoxy coating, a relatively modern development, provides
barrier for reinforcing steels which will be exposed to significant moisture and chlorides on
bridge decks as well as marine sub-structures. The coating provides an additional barrier that is
resistant to corrosive anions and significantly increases the service life of the reinforced
structure. However, minor setbacks to the use of this procedure have been encountered in
extremely harsh environments where corrosion of coated rebar occurred at cracked regions in
concretes and at some coating defects due to damages during construction. These
notwithstanding, epoxy coated rebar still proved to be a cost effective alternative to C-steel
rebar in reducing maintenance costs over a long service period. In addition to the
aforementioned improvements, epoxy coatings also act as insulators to electronic movements
which contribute to electrochemical corrosion.
Another highly favoured management tool is the use of stainless steel rebar with proven
resistance to chloride ions. Although stainless steels are far more expensive than mild steels,
however, they do not corrode over the design life of structures which has been taken to be 125
years in the case of highway bridges. From this consideration, downtime for maintenance and
costs implications are drastically reduced which make the use of stainless steel very attractive
despite the initial costs of implementation of this option. There are several types of stainless
steel; however, types 315 and 316 are favoured over others as a result of their resistances to
corrosion on experimental exposure to stagnant and flowing sea water over a period of 12.5
years. On the other hand, carbon steel exhibited corrosion and loss of strength.
Other management tools include the use of prediction models which can be safely divided into
damage prediction and corrosion rate prediction models. The former is predicated on some and
combinations of the following methods in determining the conditions of reinforced concretes
(i) visual inspections of surface and under carriage of concrete structures; (ii) delamination
survey with the use of steel hammer or rod in sounding the structure. In this case, the resultant
sound can be interpreted as the presence or absence of delamination; (iii) depth of cover
measurement with the use of pachometer which measures concrete thickness variation by means
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
1378 (2019) 022095
IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
of magnetic flux. Although a destructive analogue of holes drilling to make direct measurements
have been employed as well, however, the former is preferred for obvious reasons; (iv)
determination of chloride content with the aid of ion specific probes. Such probes convert
voltage measurements from a solution of 3 grams of concrete powder taken at a specific depth,
into percent chloride by weight of concrete; (v) Others include potential mapping as per ASTM
C876 standard; petrographic analysis; determination of rebar cross section loss; rebound tests
using a spring driven hammer and penetration test which involves driving a small rod into the
concrete while the distance of penetration indicates the compressive strength of the concrete.
Thus, models developed along these routes do not take into consideration the time and other
environmental-dependant corrosion damages to the rebar which influence the integrity of the
concrete in service. The corrosion rate dependent models have been developed by various
researchers, however, the most popular is that developed by Weyers et al.[11] called “diffusion
spalling model”. This model used Fick’s law to calculate the length of rebar corrosion initiation
period. To this period, it was stipulated that 4-5 years are added for the corrosion products of
the steel to build up to an extent that will cause extensive damage to the concrete in order to
warrant damage control management.
Prior to discussion on damage control management, it is pertinent to mention methods for
corrosion monitoring techniques for rebar corrosion in order to forestall end of service life
maintenance. These include detection by electrode potential measurements with reference to
copper/copper sulphate standard electrode which provides information on passivity if the
potential is 0.2V, whereas, it indicates corrosive activities if the potential is 0.35V and above;
detection by constant anodic current polarization method; monitoring by electrical resistance
probe which can continuously, on daily bases, give corrosion figures that can be converted to
corrosion rates. Others are monitoring by polarization resistance probe method and monitoring
by alternating current (AC) impedance which may still in its infancy for use on steel in
concretes. It has the advantage of being independent of the resistivity of the concrete. However,
using some of this electrochemical corrosion inspection/monitoring techniques, a recent study
[12] on a reinforced concrete bridge in Sweden showed that it was in good condition. This was
confirmed to be true during visual inspection which revealed little or no corrosion of the steel
after the reinforced bridge was loaded to failure.
Other corrosion and environment-induced concrete damage monitoring methods, such as
imaging techniques have been advocated by various researchers [13,14], however, evaluation
of relevant and promising processing technologies are still ongoing.
3.1 Damage Control Management- Repair and Rehabilitation Strategies
It may be understandable that epoxy coated reinforcements (ECR) and stainless steel
reinforcements (SSR) may not require rehabilitation within the current knowledge of their
service lives, some of the drawbacks witnessed in the use of ECR have been mentioned in which
epoxy coating defects and disbondment have been sources of concern to the integrity of
reinforced concrete. It is common knowledge that, C-steel reinforcements require rehabilitation
and maintenance within 12-20 years of construction. While there are yet to be established
guidelines for repair/rehab for ECR and Stainless steel reinforcements (SSR), a general
approach can be described as follows:
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
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IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
(1) For cracking which is not induced by corrosion, rehabilitation can be effected by
injection of epoxy coatings into the cracks and flooding same with corrosion inhibitors.
(2) For corrosion induced cracking and spalling, recoat the steel with epoxy coating after
thorough cleaning and application of anti-rust [15]. Apply corrosion inhibitors on all
surfaces and in case of delamination, add corrosion inhibitors to repair mortar.
There are various types of inhibitors [16], some synthetic [17] while others are naturally
occurring and can be extracted from several plants such as pawpaw leaves [18] and the dried
skin of onions which has no food nor commercial value but its extracts performed well as
corrosion inhibitors [17] cannabis extract [20], argan extract [21], onion extracts [22],
coriandrum sativum leaves extract [23], veronica amygdalina [24,25], Jatropha curcas [26],
curcuma longa [27], rice husk [28, 29], treculiaafricana [30], atropa belladonna [31] and many
more. These are eco-friendly and sustainable. They are referred to as “Green corrosion
inhibitors” and are currently being investigated by several researchers in order to gain further
insights into their potency. However as mentioned by Oki [32] elsewhere, the biodegradability
of green inhibitors puts them at a disadvantage because microbes will feed on them and their
dosages will be continuously replenished in order to maintain a reasonable level of corrosion
control which may imply higher costs. In addition microbial induced corrosion may become
very important in such an environment after a protracted period of time. However for the
biodegradable inhibitors to be viable they must be mixed with other eco-friendly inorganic
inhibitors/organic chemicals.
Another important rehabilitation strategy is the use of cathodic protection. Although this can be
incorporated at the design stage, it is also useful in arresting the advancement of rebar corrosion
in on-going reinforced structures. When applied at later stages of commencement of chloride
induced corrosion, the alternate anodic reaction will be the oxidation of chloride leading to
formation and elimination of chlorine as gas from the environment of the concrete with limited
moisture content [33].
There is a web based tool described by Broomfield [34] in which the technique selects repair
options and analyze life cycle costing of corrosion damaged rebar concrete structures. From
such considerations, it was concluded that from quantitative analyses of good quality survey
data, the costs and advantages of different repair options can be obtained objectively.
Conclusions
For reinforced agricultural facilities, it is best to incorporate, at the design stage, corrosion
prevention gadgets such as means of monitoring corrosion of rebar and cathodic protection, use
of inhibitors in concrete, as well as planned maintenance schedule. Prediction models are
veritable tools in the management of rebar corrosion. However, management of reinforcement
bar corrosion and its attendant damage to concretes should commence at design stages wherein
all relevant and necessary corrosion prevention methods and monitoring techniques are
incorporated.
Acknowledgements
The authors wish to acknowledge Landmark University Centre for Research, Innovation and
Development (LUCRID) for the support towards this work.
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International Conference on Engineering for Sustainable World
Journal of Physics: Conference Series
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IOP Publishing
doi:10.1088/1742-6596/1378/2/022095
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