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1
Identification of rebar corrosion induced by carbonation in cracked
concrete
Rita Maria GHANTOUS1, Raoul FRANÇOIS2, Stéphane POYET1, Valérie L’HOSTIS1,
Nhu-Cuong Tran3
1Den-Service d’Etude du Comportement des Radionucléides (SECR), CEA, Université Paris-
Saclay, F-91191, Gif-sur-Yvette, France
E-mail: {ritamaria.ghantous, stephane.poyet, valerie.lhostis}@cea.fr
2Université de Toulouse, INSA, UPS, Laboratoire Matériaux et Durabilité des Constructions
F-31077 Toulouse, France
E-mail: [email protected]
3EDF, R&D, MMC
F-77818 Moret-sur-Loing cedex, France
e-mail: [email protected]
Abstract
Reinforced concrete is broadly used in the construction of buildings, historical monuments,
infrastructures as well as nuclear power plants. For different reasons, many concrete structures
are subjected to unavoidable cracks that accelerate the diffusion of atmospheric carbon dioxide
to the steel/concrete interface. Carbonation at the interface induces steel corrosion that could
cause the development of new cracks in the structure, which is a determining factor for its
durability.
The aim of this article is to study the effect of the existing cracks on the carbonation-induced-
corrosion development. The results indicate that after the initiation phase, the corrosion kinetics
decreases with time and that the crack opening does not have any influence on the corrosion
kinetics. The interpretation of the results allows the authors to conclude that a “corrosion plug”
is developed deep in the crack due to the high corrosion initiation kinetics. Therefore, this “rust
plug” acts as a barrier to oxygen, water diffusion and allow repassivation which drops down
the corrosion kinetics and makes it independent from the crack opening.
Keywords: reinforced concrete; cracks; carbonation-induced corrosion; environmental conditions.
2
1. Introduction
Corrosion of steel is the main pathology affecting reinforced concrete structures and therefore
it is a determining factor for their durability. These structures are subjected to unavoidable
cracks which create a pathway for atmospheric carbon dioxide, oxygen, water, chlorides to the
steel/concrete interface and subsequently reduce the time to corrosion initiation. Both
laboratory studies [1]–[6] and in situ observations [7]–[11] have noted an expedited corrosion
initiation in cracked concrete compared to un-cracked concrete. Load-induced cracking is
accompanied by interfacial slip and separation between concrete and steel. This phenomenon
is observed in several studies [12]–[15] that show that both chloride-induced corrosion and
carbonation-induced corrosion start and develop few millimeters around the rebar at the
interception with the preexisting crack [16], [17]. While general consensus on the deleterious
effects of cracks and steel/mortar interface quality on the initiation of reinforcement exists in
the scientific community, the effects of those phenomena on the propagation of reinforcement
corrosion are still up to debate. The study of Dang et al. [18] is among the most recent research
dealing with carbonation-induced corrosion propagation. In this study, ring-shaped mortar
specimens with mechanical preexisting cracks induced by internal pressure were carbonated in
accelerated conditions (50% CO2 - 65% RH). Thereafter, these mortar specimens were
subjected to humidification/drying cycles to accelerate the corrosion development. It was
observed that the carbon dioxide spread along the total length of the steel/mortar interface and
induces corrosion initiation on the entire circumference of the carbonated rebar. The
carbonation of the whole steel-concrete interface is quite contradictory with the previous results
of [12]–[15]. It is then questionable whether this result is due to the shape of the reinforced
concrete specimen and/or to the exposure conditions. This corrosion propagation all around the
steel reinforcement is very harmful for the structure. This is because corrosion products are
known to have a volume greater than the original iron volume that generates internal tensile
stress at the concrete surrounding rebar. Therefore, new cracks develop in the concrete cover
characterized by a low tensile strength resistance [19]. In a very aggressive corrosion
conditions, spalling of concrete cover may also be visible.
In the field of nuclear energy, reinforced concrete is used for structures that have an impact on
safety (containment building, cooling tower), it is therefore important to complete the study [4],
and understand the effect of cracking and steel/concrete interface damage, both in terms of
corrosion initiation and propagation in cracked specimens.
This study aims to give answers for the following questions:
Do crack openings have an impact on the kinetics of the carbonation-induced corrosion
in reinforcement?
Will carbonation-induced-corrosion deep in the crack induce the development of
corrosion cracks and threaten the durability of the structure or it will form a “corrosion
plug” in the crack and slow down the corrosion propagation?
In the forthcoming sections, the experimental protocols developed to provide answers for the
above questions are detailed and the obtained results are discussed afterwards.
2. Experimental program
2.1 Materials and specimens preparation
Specimens tested have a prismatic shape of 70×70×280 mm. For each specimen, a 6 mm
laminated rebar is used and is positioned in its middle as shown in Figure 1. All the specimens
3
are prepared with a mortar mix which uses three parts sand, two parts cement and one part
water. Ordinary Portland cement (CEM I 52.5) and siliceous sand (according to CEN EN 196-
1) are used. The yield strength of the steel used is 500 MPa. Mortar is poured in the prismatic
mold in two layers; each of them being vibrated in order to eliminate air bubbles. After 24
hours, the specimens are demolded and thereafter cured for 28 days immersed in water with
calcium hydroxide. The mechanical properties of the mortar mix measured following the
current standards and recommendations are shown in Table 1. The specimens tested in this
study are fabricated from 6 consecutive concrete batches.
Figure 1: Schematic of the reinforced mortar
specimen
Compressive strength fc (MPa) 55
Tensile strength fctk (MPa) 3.5
Young’s Modulus E (GPa) 33.3
Poisson’s ratio ν 0.21
Table 1: Mechanical characteristics of
the mortar mix
2.2 Cracking of the prismatic specimens
Immediately after curing, cracks of different openings are generated at mid-span of the
prismatic specimens using the three-point bending test. This cracking protocol consists in
applying the load in the mid span of the simply supported specimen using a hydraulic pump as
shown in Figure 2(a). The crack is usually obtained in the cross section subjected to the maximal
tensile stress. In order to quantify the crack opening, a Linear Variable Differential Transformer
(LVDT) is placed where the crack is expected to appear as shown in Figure 2(b). This LVDT
measures the horizontal displacement between two points located at 20 mm from either side of
the specimen center. Throughout the test, the applied load and the measured displacement by
the LVDT are registered continuously. Note that the displacement registered by the LVDT
before appearance of the crack is due to the flexural deformation of the beam and cannot be
considered as a crack opening. Therefore, to calculate the crack opening, these initial
displacements were set equal to zero.
At the beginning of the bending test, the load is increased slowly until a crack is
generated/detected. Then, by performing loading\unloading cycles and by increasing the
maximum applied load from one cycle to another cycle, the residual crack opening increases.
Therefore, the crack opening can be controlled and a range of crack opening be obtained (Figure
3). The load direction is perpendicular to the casting direction in order to apply the same
mechanical loading on the upper surface and the lower surface of the specimen with respect to
casting direction. The reason is that upper and lower steel/concrete interface are different due
to the effect of bleeding and settlement of fresh concrete ([20], [21]). It is important here to
limit the length of the zone in which the bond between steel and mortar is altered. It has been
proven in a previous study that the three point bending test does not lead to a total steel/mortar
interface damage [22]. For this study, three residual crack openings are performed on several
prismatic specimens which are 0.1 mm, 0.3 mm and 0.5 mm.
4
(a)
(b)
Figure 2: 3-points bending test on 70×70×280 mm specimens
Figure 3: Range of the residual crack opening obtained by the three point bending test
2.3 Corrosion
Corrosion is known to be slow in structures subjected to the atmosphere (carbonation induced
corrosion). In order to be able to study the corrosion propagation during this project, it was
inevitable to find a suitable protocol allowing the acceleration of corrosion process naturally in
the laboratory in a way to stay representative for the environmental conditions surrounding
cooling towers of nuclear power plants. Therefore, specimens are subjected to accelerated
carbonation at 3% CO2, 55% relative humidity and 25°C for one month. It was verified that this
duration is long enough to ensure carbonation of the alteration zone [22]. Carbonation induces
depassivation of the steel intercepting the crack and thus an active corrosion may start once the
LVDT (W)
LVDT
(deflection) Pump
F
LVDT Crack opening
280 mm
40 mm
210 mm
0
2
4
6
8
10
12
14
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4
Lo
ad
(kN
)
Crack opening W (mm)
Loading/unloading cycles (experimentally)
5
requested reagent (water and oxygen) are ensured. It is important to note that before
carbonation, the cracked specimens are pre-conditioned at (20 ± 1˚C – 60 ± 5% RH) for one
month. This step is important in order to reduce the water content of the cementitious materials
and thus ensure CO2 diffusion in these materials during the carbonation test.
After carbonation, specimens are subjected to corrosion conditions representative of those
surrounding cooling towers located in France. It is known that cycling between drying and
humidification of reinforced concrete is the most harmful process for corrosion. Therefore, it is
chosen here to accelerate corrosion by performing multiple raining/drying cycles. To perform
these cycles, a custom raining chamber is designed and manufactured.
In this device, the raining chamber is equipped with three rows, in order to settle the required
number of specimens. The rain is ensured using a micro drip system (Figure 5 (b)). On each
row, water is recuperated in a collector (yellow color in Figure 4) and is evacuated through a
common pipe for the three rows (grey pipe linked to the yellow collector in Figure 4). Tap water
is used to ensure rainfall. To avoid clogging of sprinklers due to hard water, water is filtered to
remove impurities (in green in Figure 4). The pH of the water is 7.5 and its chemical
composition is given in Table 1.
Raining/drying cycles are programmed by an automated control unit. In each row of each
raining chamber, a thermohygrometer is continuously measuring the temperature and the
relative humidity. Moreover, this experience is performed in an air-conditioned laboratory in
which the temperature is regulated at 20˚ C ± 1°C and relative humidity ranges around 60 ±5%.
A hygrometer is also continuously measuring the hygrometric conditions inside the laboratory
room. Dedicated software is registering hygrometric data each minute. A real view of the small
chamber in visible in the Figure 5 (a).
(a)
Figure 4 : Plans for custom raining chambers
6
(a)
(b)
Figure 5: Real atomized device for humidification/drying cycles
Table 1: Elements present in water
Element NH4-N
(mg/L)
NH4
(mg/L)
NO2
(mg/L)
HCO3
(mg/L)
Cl
(mg/L)
NO3
(mg/L)
SO4
(mg/L)
CO3
(mg/L)
Amount <0.039 <0.05 <0.01 200 12 17 45 <1
The rain phase duration is 30 minutes period at each cycle while the drying phase lasts 72 hours
following each rainfall period. During the rainfall period, the relative humidity value increases
to 95% ± 5%. After the raining period, the drying phase starts and in this phase relative humidity
value takes around 12 hours to drop down to approximately 60% ± 5% (Figure 6).
Figure 6: Relative humidity variation during raining/drying cycles in the reference protocol
2.4 Corrosion analyses
Three specimens are dedicated for destructive physical-chemical analyses at each measurement
date (15, 30, 60, 119 raining/drying cycles corresponding to 1.5, 3, 6, 12 months). Moreover,
Automatic
control unit
Limestone and
impurities
cartridge
Hygrometric
continuous recording
20
40
60
80
100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Re
lati
ve
hu
mid
ity (
%)
Days
Rain chamber (30 minutes raining) laboratory
72 h
12 h
Sprinkler
Pipe ND 13mm
7
the free corrosion potential of the rebars is monitored continuously during the experiment.
These two methods are detailed below.
2.4.1 Physical-chemical analysis: extraction of rebar and visual inspection of the
corrosion product distribution
The specimen is first split in two parts. Before extracting the reinforcement, visual inspection
of the corrosion products distribution along the steel rebar is performed. Corroded lengths
measured on its upper and lower part with respect to casting direction are noted. These corroded
lengths measurements are crucial for the calculation of the corrosion kinetics.
After steel extraction, phenolphthalein is pulverized on the splited surface to measure the
carbonated length along the steel mortar interface and compare it to the corroded length (Figure
7).
Figure 7: steel corrosion length with respect to the length of the carbonated steel/mortar
interface
2.4.2 Physical-chemical analysis: gravimetric measurements
The corrosion products attached to the extracted rebar are removed from the steel surface by
chemical attack (Sb2O3 + SnCl2 + HCl) following the standard ISO 8407 [23]. The difference
between the initial mass of the steel (before corrosion) and its final mass (after chemical
treatment) gives the steel mass loss induced by corrosion (∆𝑚𝑆).
In our study, to be accurate, gravimetric measurements are repeated on three rebars corroded in
the same conditions for each maturity date of analysis. And therefore, the average of these three
values are taken into account for the approximation of corrosion kinetics
2.4.3 Physical-chemical analysis: corrosion kinetics estimation
The carbonation-induced corrosion does not present a pitting morphology like the chloride-
induced corrosion. The corrosion products layer is known to be more homogenous in
carbonation-induced corrosion and this allow us to suppose that the thickness of the steel lost
during this corrosion process is uniform along the steel corroded length (Figure 8). Therefore,
the volume of the steel lost (VSL) during the corrosion process is calculated using equation 1.
SSL is the surface of the corroded twisted steel rebar. The determination of this surface is directly
dependent from the average of the corrosion length (LC) measured on the upper and the lower
4.7 cm
30mmCrack
Carbonated length
4.8 cm
Corroded length
Rebar footprint
8
part of the steel/mortar interface during the visual inspection. This surface is calculated by the
main of the polarization curve method where D is supposed to be equal to 6 mm. By replacing
the volume of the steel lost in equation 1 by equation 3 in which ρS is the density of steel equal
to 7860 kg/m3, the thickness of the steel lost during corrosion (TSL) can be calculated as shown
in equation 4. TSL is obtained at each maturity date of the corrosion analysis and thus the kinetics
of corrosion can be calculated using equation 5 and its unit is µm/year. This equation is adequate
to the one proposed in the study [24].
Figure 8: Assumption taken in the corrosion kinetics calculation
𝑉𝑆𝐿 = 𝑆𝑆𝐿 × 𝑇𝑆𝐿 1
𝑆𝑆𝐿 = 1.384 × 𝜋 × 𝐷 × 𝐿𝐶 2
𝑉𝑆𝐿 =
∆𝑚𝑆
𝜌𝑆
3
𝑇𝑆𝐿 =
∆𝑚𝑆
𝜌𝑆 × 𝑆𝑆𝐿
4
𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑘𝑖𝑛𝑒𝑡𝑖𝑐𝑠 =
𝑇𝑆𝐿
𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑑𝑢𝑟𝑎𝑡𝑖𝑜𝑛 (𝑚𝑜𝑛𝑡ℎ)× 12
5
2.4.4 Electrochemical analysis (Free corrosion potential measurements)
To monitor the steel corrosion state, an embedded Manganese Dioxide reference electrode
(ERE 20) for potential reading is cast into the mortar cover of some specimens and it is
positioned at 50 mm from the crack (Figure 9). In this configuration, the reference electrode
measures a coupled corrosion potential (between active and passive parts of steel bar) which is
continuously registered using a data acquisition switch unit.
Ste
elC
orr
ode
dL
eng
th (
LC)
Thickness of
the Steel Loss
(TSL)
Non corroded rebar Assumptions taken for the CPL
9
Figure 9: Electrochemical measurement
3. Results
3.1 Gravimetric measurements and length of corrosion products layer
Figure 10 presents the results of the gravimetric measurements, iron mass loss increases with
the number of cycles and with crack opening. Whatever the crack opening, the iron mass loss
tends to reach after 30-60 raining/drying cycles. One can notice a decrease in the iron mass loss
for specimens showing 0.5 mm residual crack opening between 60 and 119 cycles. It is
important to note that the iron mass lost cannot be recovered and this decrease is mainly due to
variability in materials properties and in the corrosion development process itself.
The evolution of the corrosion length with respect to the number of cycles is presented in Figure
11. Similarly to the iron mass loss, the corrosion length increases with the residual crack
openings and trend to stabilize after 30-60 raining/drying cycles.
Figure 10: Iron mass loss in specimens having different residual crack openings with respect
to raining/drying cycles (lines are only guides to the eye)
ERE 20 Referenceelectrode
Mortar
Steel
Varnish
Data Acquisition
Switch Unit
50 mm
0
20
40
60
80
100
120
0 20 40 60 80 100 120
Iro
n m
ass lo
ss (
mg
)
Number of raining/drying cycles
100 µm
300 µm
500 µm
1 month in the
1.5 month
3 months
Vertical crack (30min raining)6 months 12 months
10
Figure 11: Evolution of the corrosion length of steel in specimens having different residual
crack openings with respect to raining/drying cycles (lines are only guides to the eye)
3.2 Corrosion rate
The corrosion rate was estimated using equations (4) and (5) (Figure 12). It is plain to see that
the corrosion kinetics decreases with the number of cycles. It can also be noticed that nearly 60
cycles, the corrosion rate seems to be independent from the residual crack opening.
Figure 12: Evolution of the corrosion kinetics in specimens having different residual crack
openings with respect to raining/drying cycles
0
2
4
6
8
10
0 20 40 60 80 100 120
Ave
rag
e c
orr
osio
n le
ng
th (
cm
)
Number of raining/drying cycles
100 µm
300 µm
500 µm
1 month in the
1.5 month
3 months
6 months 12 months
Vertical crack (30 min raining)
0
10
20
30
40
50
60
0 20 40 60 80 100 120
Co
rro
sio
n k
ine
tics (
µm
/an
)
Number of raining/drying cycles
1.5 month
3 months
Vertical crack (30min raining)
6 months
12 months
11
3.3 Distribution of the corrosion Products layer
Figure 13(a) shows corrosion over carbonation length ratios measured on the upper part of
steel/mortar interface with respect to rain cycles while Figure 13(b) gives the same information
of Figure 13(a) regarding the lower part of steel/mortar interface. The upper part and the lower
part of the steel/mortar interface are defined according to the casting direction. It is visible that
the corrosion products fill the carbonated steel/mortar interface zone at the first thirty
raining/drying cycles and do not spread for a greater length. As a conclusion, the corrosion
products do not create corrosion cracks. Moreover, the digital scanning of specimens do not
show any additional crack other the initial one.
Figure 13: Corroded length with respect to carbonated length for different crack openings
(filled points correspond to the upper part of the steel/mortar interface while empty points
correspond to its lower part).
3.4 Free corrosion potential measurements
The evolution of the measured corrosion potentials is given in Figure 14. Two periods of
corrosion process can be observed. The first represents the corrosion initiation and the second
represents the corrosion propagation. A drop down in the corrosion potential from -70 mV/SCE
to -350 mV/SCE during the first month of exposure to raining/drying cycles indicates the
corrosion initiation. Thereafter, the corrosion potential starts to increase from -350 mV/SCE to
meet the corrosion potential of the uncracked specimen (around -70 mV/SCE). Furthermore,
the corrosion potential measured on specimens having 0.1 mm residual crack opening increases
earlier than in specimens having 0.3, 0.5 mm residual crack openings. This is in agreement
with the corrosion kinetics measurements showing at the beginning the lower value for
specimens having 0.1 mm residual crack opening.
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 20 40 60 80 100 120 140
(Co
rro
de
d /ca
rbo
nate
d)
len
gth
(cm
)
Number of raining/drying cycles
Upper and lower part of the steel/mortar interface (Vertical crack)
100 µm (1) 300 µm (1) 500 µm (1)100 µm (2) 300 µm (2) 500 µm (2)100 µm (3) 100 µm (3) 500 µm (3)
1 month in the
1.5 month
3 months
6 months
12 months
12
Figure 14: Corrosion potential (versus SCE) evolution in cracked specimens exposed to
raining cycles for 270 days.
4. Discussion
The results indicate a decrease in the corrosion kinetics with the number of raining/drying
cycles. The effect of the crack opening on the corrosion kinetics is masked after several
raining/drying cycles. Moreover, the corrosion products do not spread beyond the carbonated
zone limits. In addition, no corrosion cracks are visible on the outside surface of the specimens.
Furthermore, an increase in the free corrosion potential is noticed after several
humidification/drying cycles. All these results allow the authors to deduce that the corrosion
products form a plug in the crack. The latter acts as a barrier to oxygen and water that slows
down the corrosion propagation then leading to repassivation. This result is in agreement with
the one obtained by a numerical simulation in the study of Millard et al. [25].
5. Conclusion
In this research study, the effect of the crack opening on the propagation of carbonation-induced
corrosion is tested and analyzed. A suitable protocol is developed to ensure raining cycles
needed for the corrosion development in the laboratory. The authors deduce that a corrosion
plug develops deep in the crack and slows down the corrosion propagation according to the
results obtained from the corrosion kinetics and corrosion potential measurements and the
observed corrosion products distribution. The observed corrosion rates after 120 cycles of
raining/drying are very small (around 5 μm/year) and don’t influence the cooling tower safety
for the next decades of years. Moreover, this corrosion plug will cancel the effect of the crack
opening on the corrosion propagation. The results presented in this paper will be useful for EDF
in optimizing the maintenance program of French cooling tower fleet in the objective of
ensuring an operating lifetime beyond 60 years.
15 cycles
30 cycles
60 cycles
13
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