Chapter One 1.1 Preamble
Chapter One 1.1 Preamble
Chapter One 1.1 Preamble
INTRODUCTION
1.1 Preamble
Cement concrete has clearly emerged as the material of choice for the construction of
a large number and variety of structures in the world today. This is attributed mainly
to low cost of materials and construction for concrete structures as well as low cost of
maintenance. Use of high water cement ratio (w/c) in a high early strength cement led
to serious problems with durability of structures, especially those subjected to severe
environmental exposures. (Kumar et al, 2013). Reinforced concrete structures can be
highly durable as long as a care and quality control are enforced at all stages of the
design,
production
and
construction
processes.
However,
experience
has
demonstrated that its potential long-term durability is not always achieved and early
failure of reinforced concrete structures may even occur. (Rodrigues et al, 2000).
According to Amusan and Olutoge (2014): The effect of sea water on concrete was
first discussed in 1840 by J. Smeaton and L. J. Vicat. Their two-year examination on
the research topic titled What is the trouble with concrete in sea water revealed that
a large number of concrete structures in sea water in the United States, Canada, Cuba
and Paramaare exposed to chemical deterioration.
It should be recognized that concrete is intrinsically a porous material. Despite the
improvements on its formulation and quality control to the best possible extent, it is
not possible to prevent completely the ingress of potentially harmful agents. Microcracks and macro-pores will always exist on the concrete surface, providing a path for
the transportation of aggressive ions into the interior of concrete. (Jose et al, 2008).
In every country tons of steel is used to strengthen the concrete structures in the form
of embedded ribs, hence life of those embedded ribs pose a constant challenge of
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corrosion to scientists and engineers. Already, much attention has been paid to the
research work in this field and to the development of process and products to meet the
challenge.
When steel embedded in concrete corrodes, the increase in volume from metallic steel
to corrosion product produces an expansive force, which can rupture the concrete.
After a crack has been formed in this way, the steel corrodes even more rapidly,
leading ultimately to complete failure of the structural member involved. Therefore
premature deterioration of reinforced concrete structures due to corrosion of the
reinforcing steel is a concern worldwide.
Corrosion, one of the main causes of deterioration in concrete structures, initiates due
to its exposure to harmful chemicals that may be found in nature such as in some
ground waters, industrial effluents and sea waters. The most aggressive chemicals that
affect the long term durability of concrete structures are chlorides, sulpates, CO 2 or
H2S. Concrete immersed in a wet or moist aggressive medium tend to suffer damages
and exhibits so in the form of micro-cracks.
The major cause of these problems is the chloride-induced corrosion of reinforcing
steel which, because of the substantial volume increase that accompanies the
transformation of iron to rust, can lead to cracking and spalling of the concrete cover.
Also, the corrosion of reinforcing steel bars can also cause a weakening of the bond
and anchorage between concrete and reinforcement, which can reduce the shear
capacity of reinforced concrete (RC) beams and affects the serviceability and ultimate
strength of concrete elements in RC structures. (Kamyab, Z. H., 2010).
Deterioration of concrete infrastructures has emerged as one of the most severe and
demanding challenges facing the construction industry. (Horrigmoe, G., 2000).
Corrosion of embedded steel represents the dominating type of deterioration due to
chloride reaction and it represents a major problem for the durability and long term
performance of concrete structures. Extensive research in the past few decades has
established the mechanisms of seawater attack on cement paste and concrete, and
shown that seawater certainty causes deterioration of cement paste as a result of
reactions with susceptible components of the paste, and formation of new reaction
products such as gypsum, ettringite, brucite, calcium chloroaluminate.
Due to the porosity of concrete, 0 2 can easily diffuse into concrete, becoming
dissolved in the pore solution and finally reaching the surface of steel. At the surface
(cathodic area, C), oxygen is reduced into hydroxide ion via an electrochemical
cathodic reaction:
concrete structures
To assess the effects of sulphates attack on the performance of reinforced
concrete structures
To evaluate the effects of chemical attacks on the mechanical properties of
reinforced concrete structures
1.6.3
also be used for the design of more sustainable civil infrastructures in aggressive
environments.
2.2 Factors affecting Corrosion of Reinforcement
Corrosion of reinforcement in concrete structure is an electro-chemical process and is
similar to the action which takes place in a flash battery. The anodic reaction which
is the oxidation process and is dependent on the PH of interstitial electrolyte, presence
of aggressive anions and the existence of an appropriate electrochemical potential at
the reinforcing bar surface, results in dissolution or loss of metal whilst the cathodic
reaction which is a reduction process and is dependent on the availability of O 2 and
the PH in the vicinity of rebar.
2.2.1 Effect of carbonation and entry of gaseous pollutants
The PH of the concrete is reduced by the carbonation and entry of acidic gaseous
pollutants such as SO2 and NO2. The fall in PH to certain levels may cause
commencement of reinforcement corrosion, loss of passivity of concrete against rebar
corrosion and catastrophic corrosion as indicated in the table below (Kumar et al,
2013)
Table 2.1: State of reinforcement corrosion at various PH
PH of concrete
Below 9.5
At 8.0
Below 7.0
concrete. The risk of reinforcement corrosion associated with the level of chloride
content in both uncarbonated and carbonated concrete is presented in the table below.
Table 2.2: Corrosion risk in concrete containing chlorides
Total chloride
(wt% of cement)
Less than 0.4%
0.4% - 1.0%
Condition
of
reinforcement
Carbonated
Uncarbonated,
concrete
made
adjacent
with
to Corrosion risk
High
cement Moderate
cement Low
High
cement High
cement Moderate
High
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steel to constraint corrosion expansion, which means that the possibility of concrete
surface cracking is at minimal diameter under the same condition is the same with the
cover depth of 50mm regardless of the concrete strength and steel diameter which implies
that when steel diameter is decreased. It is of benefits for structure safely under
consideration of concrete surface cracking.
In a related development, Matlob et al (2008) carried out an experiment on concrete
inhibitors, he uses materials such as OPC (Ordinary Portland Cement) which was
relatively tested in a cement test laboratory, a washed graded sand was also used with an
aggregate size of 20mm sieve according to specification IQS54:984 two type of anodic,
inorganic corrosion inhibitors were used such as Sodium benzoate (SB) (C 6H5COONa),
potassium dichromate (PD) (K2Cr2O7) to serve as an inhibitors. The Potassium
dichromate was added to water, mix and stirred until it diffuse completely, which was
later added to the concrete mix. Likewise a steel reinforcement of 0.5cm in diameter was
used which was cleaned with wetted grinding paper. A concrete mix in accordance with
American mix design (AC 1211) and a compressive strength of 25MPa (28days) in ratio
of 0.48 was prepared for the casting specimen. The specimen were immersed partially in
aggressive solution (3.5% NaCl soluble for 3 months, through this period of recording of
data) various test such as the compressive strength test, splitting tensile test, flexural
strength test, electrochemical test were carried out to analyze the result of the specimen.
The result of the compressive test shows that Sodium benzoate admixture in concrete
does not show any reduction in compressive strength in ages 18, 660 and 90 days which
gives a higher results than the reference mix (C25) by approximately 12%, 15% and 14%,
hence using sodium benzoate as corrosion inhibitors in concrete affect the compressive
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strength at early ages by 2% and 3% while potassium dichromate admixture affect the
compressive strength through reduction of 8% and 4% respectively. With the splitting
tensile result test results, sodium benzoate admixture reveal an increase in splitting tensile
strength of about 10%, 16.6% and 17%. However, the result of the experiment reveals
that if some kinds of anodic corrosion inhibitors like potassium dichromate are used in
low dosage, they will act as corrosion accelerators not as corrosion inhibitor (Matlob,
2008), the sodium benzoate admixture in dosage 2% and 3% by weight of cement has no
significant effects on concrete properties it only has an effects on concrete strength.
Kumar and Abhay (1999) also carried out a study on the effects of strength of concrete in
corrosion of reinforcement bar, 3 grades of steel bar, HYSD bars of grade Fe 415, and
CRS (corrosion resistant steel). The steel were tested in a laboratory accelerating a
corrosion test to determine the mass loss and assess the corrosion quality and the
thickness of concrete cover largely determines the effectiveness of general defensive
shield against corrosion. The mass loss of the steel are significantly influences by the
strength of the concrete. The rate of decrease of the mass loss for all type of steel is
maximum 35 to 40MPa concrete strength. The study also reveals that the higher carbon
content of the steel exhibit relatively large amount of corrosion, when compared to
HYSD steel and CRS bars. The performance index of CRS lies in the range of 1.3 to 1.5
and increases as the quality of concrete increases and decrease. All of the corrosion
process described above required oxygen in the absence of oxygen the corrosion rate is
appreciably reduced even with chloride concentration above the threshold level.
However, keeping oxygen from reinforcing steel in the field is extremely difficult, if not
possible when corrosion of reinforcing steel occurs, the corrosion products or rust can
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occupy several times, the volume then the original steel, causing tensile force to develop
in the concrete.
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CHAPTER THREE
BEHAVIOUR OF REINFORCED CONCRETE IN AGGRESSIVE CHEMICAL
ENVIRONMENTS
3.1 Aggressive Environment Impact on Reinforced Concrete Structures
Concrete is a very important construction material. It is highly resistant to compression
forces, but week under traction forces. To improve its properties, it is combined with steel
bars, highly resistant to traction. Concrete offers corrosion protection to carbon steel. It
acts like a physical barrier that partially isolates steel surface from the external
environment and establishes an alkaline PH that facilitates steel passivity. Durability of a
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estimated that Western Europe spends 5 billion Euros yearly for repair of corroding
concrete infrastructures. Repair-work on the public transportation infrastructure are
causing significant inconveniences and delays for both the industry and the general
public, and are now recognized as a substantial cost for the society. As a result of
corrosion reaction, rust forms and occupies a volume of up to 6-7 times that of the
original metal, hence generating bursting forces. These forces might exceed the tensile
strength of concrete, causing cracking and spalling of the concrete leading to further
corrosion and loss of bond between the concrete and the steel. Hazardous situations might
occur when pieces of spalled concrete fall and threaten the user or passer-by, or when the
structural member loses cross-sectional area and thereby experiences increased stress on
the remaining section, which potentially could lead to structural failure.
Examples of damages caused by corrosion are illustrated bellow:
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Figure 3.6: Sealers, which fill the pores at the surface and can partly be membranebuilding
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The means of addressing the corrosion problems have mainly followed one of five
distinct
strategies:
Developing very dense and strong types of concrete to protect the reinforcement
against ingress of corrosive substance, particularly chlorides, in combination with
sufficient concrete covers.
Inhibiting corrosion through passive protection (corrosion inhibitors) or through active
protection (cathodic protection/prevention)
Developing coatings to the concrete surface or to the carbon reinforcement
(particularly epoxy or zinc)
Develop non-metallic reinforcements (glass fibre, aramid fibre or carbon fibre)
Developing specially alloyed steel types with higher chloride threshold values for
corrosion initiation.
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CHAPTER FOUR
DISCUSSION OF RESULTS
4.1 Chemical analysis of seawater
The results below shows the chemical analysis of seawater:
Table 4.1: Chemical analysis of fresh water and sea water
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nitrate
attack
shows
the
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following:
CHAPTER FIVE
CONCLUSION
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iii.
iv.
v.
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