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8/13/2019 Influence of Corrosion on Bond Degradation
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INFLUENCE of CORROSION on BOND DEGRADATION in REINFORCED CONCRETE
Ghandehari M.1, Zulli M.2, Shah S.P.3
1Assistant Professor, Polytechnic University, Brooklyn, NY.
2PhD Student, University of Roma La Sapienza, Rome, Italy.3Professor, Northwestern University, Evanston, Ill.
ABSTRACT
Accelerated constant current corrosion tests are performed on reinforced concrete
cylinders. The influence of dimensional parameters (rebar diameter and concrete cover)
on corrosion penetration and the splitting of concrete is investigated. A fracture
mechanic splitting model indicates correlation between the measured extent of
corrosion and the splitting strength of concrete cylinders. The effect of cracking on
specimen impedance, and corrosion rate are explored.
INTRODUCTION
Corrosion of steel is accompanied by its volumetric expansion. The corrosion
induced pressure caused by this expansion at the rebar-concrete interface causes
splitting of the concrete cover. When assessing structural integrity, reduction in bond
strength by splitting can be a bigger factor than the loss of rebar tensile load capacity by
cross section reduction. Corrosion induced splitting of concrete is the focus of this
study.
Due to carbonation and in the presence of chlorides, corrosion is initiated by the
breakdown of a passive layer. The composition, pore structure and size of the bulk
concrete cover play a big role in corrosion initiation period as well as rate of corrosion.
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The rate of corrosion is often modeled using Faradays law. The pH driven corrosion
reaction rate is current density dependent. The resulting mass loss to oxidation for a
constant current time interval according to Faradays law is:
W =tA/ZF (1)
Where : W = weight loss (grams)
= corrosion current (amp)
t = time (sec)
A = atomic weight of iron (56g)
Z = valency of the metal (2)
F = Faraday constant (96500 Amp-sec)
By inserting the specific values of A, Z, and F into eq. (1), the rebar mass conversion as
a function of time and corrosion current is:
W =25t (1a)
Taking into account the steel density (approx 0.0078 g/mm3), the rebar length and
diameter, the extent of corrosion penetration is:
x =3197it (see figure 5.) (2)
Where: i = /dL= current density (A/mm2) [Table 1]
t = time (days)
The effects of the concrete pore solution (electrolyte conductivity) and the conductivity
of other phases, such as corrosion product and interfacial transition zone (ITZ), is
reflected in changes in the corrosion current density.
Corrosion products are multi-layered and depending on their composition they will
have different transport and mechanical properties. Contrary to the passive oxide layer,
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which is mainly crystalline, corrosion products are amorphous and their mechanical
response, which is moisture dependent, has been difficult to assess. 1An expansion
parameter of 2 to 3 is typically found in the literature.
The splitting of concrete and the associated loss of bond strength is not only a
function of the degree of corrosion, but it is also a function of the material parameter
(e.g. toughness) and of the size and geometry of the member cross section. The effect
of concrete cover and corrosion level on splitting and bond strength of corroded rebar
has also been examined in other research.2,3,4,5 It has been shown that in the presence
of transverse reinforcement the effect of corrosion on bond strength may be negligible.
However in the absence of transverse reinforcement or other confining mechanisms
that effect can be substantial.
In the study presented here, constant current accelerated corrosion tests are
performed on rebars embedded in concrete cylinders. The influence of rebar size and
cylinder size, on the extent of corrosion and on the mechanical fracture of the specimen
is explored. The effect of the above parameters on the rate of corrosion is observed and
compared to that described by Faradays law. Subsequently, the influence of corrosion
and cracking on the specimen resistance is investigated.
EXPERIMENTS
Specimens
Figure 1. shows the specimen geometry. The concrete batch was mixed in
proportions of 0.5, 1, 2, 2 parts by weight of water, cement, sand and gravel
(dmax=8mm), achieving a 28 day compressive strength of 40 Mpa. The rebars were
placed in plastic molds, the concrete was cast and cured for 28 days at a temperature of
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23C and 95% relative humidity. A total of 4 different specimen geometry were cast. Two
cylinder diameters (100mm and 150mm), and two rebar diameters (9.5mm and 20mm)
were used as shown in Figure 1. and Table 1. The specimens are labeled
CsRs,CsRl,ClRs, and ClRl, where C and R stand for cylinder and rebar, and the
subscripts s and l stand for small and large respectively. Epoxy resin was applied to the
exposed rebar for corrosion protection during curing. After curing, silicon adhesive was
applied to the top and bottom of the concrete cylinders, providing an axi-symetric
corrosion condition, and effectively capturing the influence of the cylinder diameter.
Corrosion cell and test procedure
Four specimens of each geometry type were cast corresponding to four target levels
of corrosion. The current required to achieve the target corrosion levels (2.5%, 5%, 7.5&
, and 10% by weight) was determined by Faraday's law assuming 100% current
efficiency (Eq.1). The corresponding calculated current is shown in Table 1. The
corrosion cell consists of a power supply, a copper plate (cathode), and the specimen
(anode) submerged in a 5% by weight NaCl solution. In order to compare the measured
weight loss with that predicted by the Faraday law, a constant current driving circuit was
devised. The fluctuations in the electric current caused by changes in the specimen
resistance were monitored by measuring the voltage across a fixed resistor placed in
series with the specimen. An tunable resister was used to adjust and maintain the
constant current. This procedure was repeated at 6 hour intervals for 4 weeks.
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Specimen Evaluation
In addition to continuous observation of the specimens for surface cracking, the
specimens were cut in 50mm slices at the end of each corrosion level (week 1,2,3 and
4). The rebar in each slice was tested in pullout to obtain the effect of corrosion on bond
strength. Weight loss measurements were performed using the ASTM procedure C.3.1,
where the rebar was wire brush cleaned with a solution of HCl, Sb2O3, and SnCl2. The
procedure was repeated several times removing as much rust as possible.
RESULTS
Impedance Measurement
Figure 3 shows the influence of rebar corrosion and concrete cracking and how it is
reflected by changes in the specimen's resistance (Rs). The initial increase in the
resistance is attributed to initial oxidation of the rebar surface. Rs reaches a maximum
level and maintains that level until the specimen begins cracking. All specimens reach
the point of maximum resistance at approximately 5 days. The elapsed time up to first
cracking is also noted in the Figure. It indicates the time that a single visible crack
emerged on the specimen surface. The following pattern is observed in the figure:
-The small specimen with large rebar (CsRl) cracked first at 6 days. At that time the
specimen resistance dropped by about 50% in a period of about two days.
- The large specimen with the same rebar size (ClRl) cracked next, at 13 days
followed by approximately the same ratio of resistance drop, reaching a steady state in
about a week.
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- The small specimen with small rebar (CsRs) cracked at 19 days, followed by a
resistance drop twice in magnitude, but with the same ratio (50%) of the pre-crack
resistance. The resistance of this specimen also reached steady state in about a week.
- The large specimen with small rebar (ClRs) never cracked and maintained
constant resistance after the end of week 1.
The slower resistance drop after cracking for the specimen with larger cover (ClRl
vs. CsRl) suggests that increasing the concrete cover is beneficial with regards to the
rate of ionic penetration. This effect is meaningful when the time scale of the
accelerated corrosion is transformed to the actual life cycle time scale. Therefore
increasing the concrete cover plays a role in strength and in durability.
On the other hand, comparison of the large specimen with different rebar sizes
(ClRs vs ClRl) indicates that decreasing rebar size increases the corrosion/splitting
resistance. This is not only due to the influence of size of the rebar as a flaw in
bond/splitting fracture7, but it is also due to the effect of smaller expansive forces
generated by the smaller rebar as predicted by the Faradays law. The effect of
corrosion on bond strength is isolated and will be discussed later in Figure 6.
Results of the microscopic measurement of total crack opening due to corrosion
(w) in each slice near the rebar is shown in Figure 8. Based on these measurements it
was verified that the specimen ClRl had not cracked by the end of week 1. The next
crack opening measurement of this specimen at the end of week 2 revealed internal
cracking in addition to the externally observed crack. The gradual drop in the specimen
resistance between these two measurements suggests that small internal radial cracks
had formed near the rebar between week 1 and 2 influencing the specimen resistance.
The slices from specimen CsRs revealed no cracks at the end of week 1 and end of
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week 2. Finally, observation of the specimen ClRs confirmed that cracks had not formed
throughout the 4-week test.
Weight Loss Measurement
The procedure for the evaluation of the extent of corrosion by weight loss
measurement was outlined earlier. Given the measured weight loss (Wm), the
corrosion penetration (xm) can be deduced:
xm (Wm/W)d/4 (3)
Where: d= rebar diameter
W= original rebar weight
A comparison of the measured corrosion penetration (xm), and the predicted corrosion
penetration (x) is shown in Figure 5. The predicted penetration is based on Faradays
law, assuming corrosion was initiated immediately at the start of the test (Eq. 2). The
rate of corrosion indicated by the slope of the dashed lines in Figure 9 is simply a
function of the corrosion current density (Table 1). (The current density shown in the
table is selected to achieve the same percent weight loss for all specimens.
modeling
A strong motivation for this study was to determine the time-to-cracking for different
specimen geometry. Based on time-to-cracking (Figure 3), it was shown that corrosion
resistance increases with increasing cover dimension and decreasing rebar diameter. In
order to explain these trends, the specimens are modeled as a hollow cylinder subject
to internal pressure. This type of analysis was carried out in previous research 7, in
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order to evaluate the bond/splitting resistance of ribbed rebars tested in pullout. An
iterative non-linear fracture mechanics analysis was carried out prevously, for the
evaluation of internal pressure caused by the rebar pullout. It is similarly carried out
here for the evaluation of corrosion pressure. The procedure outlined below is
performed using the Finite Element program FRANC2D 8as follows.
1. Start with some small initial guess for crack length (two symmetric cracks).
2. Guess an initial crack tip opening displacement (CTOD).
3. Assume linear crack profile.
4. Apply crack flank traction based on an exponential material constitutive model.
The constitutive model developed by Gopalaratnam9 describes the relation
between the crack opening displacement (COD) and the crack flank traction (T).
5. Apply the splitting force until the crack tip stress intensity factor KI= KIc. (KIcfrom
Jenq and Shah 10).
6. Check the corresponding numerical crack profile (COD).
If the output crack profile (COD) and the input T satisfy the material model within a
stipulated accuracy, then consistency is achieved.
Grow the crack to a new length and repeat steps 1 through 6.
Else guess a new CTOD and repeat steps 3 to 6 using the new crack profile as
given by the current iteration.
That this iterative algorithm leads to consistent results was established by adopting
the same scheme for wedge pullout specimens whereexperimental data for the splitting
force were available for comparison.
Table 2 shows a correlation between the trends observed in the time-to-splitting
caused by corrosion, and the predicted pressure required for splitting a hollow core
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concrete cylinder. Based on this comparison it would be possible to isolate the sources
of damage whether by corrosion or by mechanical action.
Bond Strength
The effect of the corrosion of rebar on bond strength is shown in Figure 6. The bond
strength of the corroded rebar is shown normalized with respect to the bond strength of
the non-corroded rebar, and therefore reduction in the indicated strength reflects only
the influence of corrosion. Bond strength is evaluated based on the pullout of rebars
from 50mm long concrete sample slices.
The influence of increasing the cover dimension is evident in the Figure. Keeping the
rebar size constant, moderate exposure to corrosive currents (here less than 1 week)
does not influence the pullout strength of a large specimen nearly as much as a small
specimen. This effect is not only due to the anticipated larger splitting capacity of the
larger cylinder (Table 2), but may also be due to the effectiveness of the large concrete
cover in the inhibition of corrosion progress. Furthermore, it is shown that for the small
cylinder with different rebar sizes the effect of corrosion of the large bar (CsRl) on bond
strength is more pronounced than corrosion of the small rebar (CsRs).
CONCLUSIONS
Constant current accelerated corrosion tests on reinforced concrete cylinders were
performed:
- A comparison of the measured rate of corrosion penetration with that predicted by
Faradays law indicates an overall agreement. The assessment of a proper initiation
time would substantially improve those predictions.
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- The rate of decrease in the specimen impedance after cracking depends on the
cover dimension.
- Corrosion resistance increases with increasing cover dimension and decreasing
rebar diameter.
ACKNOWLEDGEMENTS
Generous support from the National Science Foundation Center for Advanced
Cement Based Materials, and the Department of Civil Engineering at Polytechnic
University is gratefully acknowledged. The support of the scholarship from Ferdinando
Filauro Foundation and University of LAquila, Italy is also greatly appreciated.
REFERENCES
1. Wang, K., Monteriro P.J., Corrosion Products of Reinforcing Steel and their Effects
on the Concrete Deterioration, Third CANMET/ACI International Conference on
Performance of Concrete in Marine Environment, pp. 83-97.
2. Cabrera J. G., Deterioration of Concrete due to Reinforcement Steel Corrosion,
Cement and Concrete Composites, 18 (1996) 47-59.
3. Andrade, C., Alonso F., Molina F.J., Cover Cracking as a Function of Bar Corrosion
Part I-Experimental Test, Materials and Structures 1993, V.26, pp. 453-464
4. Al-Sulaimani, G. J., Kaleemullah, M., Basunbul, A., Rasheeduzzafar, Influence of
Corrosion and Cracking on Bond Behavior and Strength of Reinforced Concrete
Members, ACI Structural Journal, March-April 1990, pp. 220-230.
5. Amleh L., Mirza S., Corrosion Influence on Bond Between Steel and Concrete, ACI
Structural Journal, May-June,1999
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6. Ghandehari, M. Krishnaswamy S., Shah S.P., A Technique for Evaluating
Kinematics Between Rebar and Concrete, Journal of Engineering Mechanics, Feb
1999 V.125, no.2, pp. 234-241
7. Ghandehari M., Krishnaswamy S., Shah S.P., Effect of Specimen Dimensions on
Bond Failure in Reinforced Concrete Journal of Applied Mechanics, accepted for
publication.
8. FRANC2D, 1995, A Two Dimensional Crack Propagation Simulator, vol.2.7,
Cornell University.
9. Gopalaratnam, V.S., and Shah, S.P., 1985, Softening Response of Plain Concrete
in Direct Tension, ACI Journal, vol.82, no.3, pp310-323.
10. Jenq, Y.S., and Shah, S.P., 1985,. A Two-parameter Fracture Model for Concrete,
J. Eng. Mech. ASCE, vol.111, no4, pp1227-1241.
LIST OF FIGURES
Figure 1 - Specimen geometry
Figure 2 - Corrosion cell
Figure 3 - Relation of corrosion level with specimen resistivity and cracking
Figure 4 - Dilation and cracking at the rebar
Figure 5 - Corrosion penetration obtained from measured weight loss
Figure 6 - Influence of corrosion on bond strength
LIST OF TABLES
Table 1 - Specimen dimensions and corrosion current levels
Table 2 - Splitting strength vs. corrosion level
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5% NaCl Solution
Copper Plate
Specimen
Power Supply
e
Resistor
(Cathode)
(Anode)
+-
by weight of Water
Current
Constant current
circuit
CsRs CsRl
ClRlClRs
D
d
L
Figure 1 Specimen geometry
Figure 2 Corrosion cell
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TABLE 1 SPECIMEN DIMENSIONS AND CORROSION CURRENT LEVELS
dimensions current design corrosion level
specimen Cylinderdiameter
(D)
Rebardiameter
(d)
CylinderLength
(L)
I i 1week
2week
3week
4week
mm mm mm mA A/m2 % % % %
CsRl 102 19 203 75 6.16
ClRl 152 19 304 115 6.16
CsRs 102 9.5 203 20 3.29
ClRs 152 9.5 304 30 3.29
2..5 5 7.5 10
Corrosion level (weight loss) according to Faradays law
0
50
100
150
200
250
300
0 1 2 3 4 5Time (week)
Resistance
(Ohm)
CsRl
ClRl
CsRs
ClRs
Crack CsRs
Crack CsRl
Crack ClRl
Figure 3 Relation of corrosion level with specimen impedance and crack
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Figure 5 Corrosion penetration obtained from measured weight loss
Corrosion product
Original rebar
Penetration (x)
w
Figure 4 Dilation and cracking at the rebar
0
100
200
300
400
500
600
700
800
0 1 2 3 4 5
Time (week)
Penetration (x)
(micron)
CsRl
CsRs
ClRl
ClRs
Faraday, large rebar
Farafay, small rebar
CsRlcrack
ClRlcrack
CsRs
crack
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Table 2 - Splitting strength vs. corrosion levelSPECIMEN Splitting strength Penetration at cracking (x) Time to splitting
Mpa micron Week
CsRl 14 70 0.8
ClRl 17 90 1.9CsRs 35 160 2.8
ClRs 48 150 @ 4 weeks) not split
Splitting strength from cohesive crack model [Ghandehari (1999)]
Figure 6 - Influence of corrosion on bond strength
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
0 1 2 3 4 5
Time (week)
NormalizedBond
Strength
CsRl
ClRl
CsRs
ClRs
cracked
cracked
cracked
no
crack