DURABILITY OF CONCRETE STRUCTURES

CHAPTER - 5

Design & Detailing For Durability

5.1 Design Engineers consider design of concrete structures to mean assessing: i) The size and strength of structural components and concrete strength grade to meet safety and serviceability limits. ii) The amount, size and distribution of reinforcements for strength and control cracks to an acceptable size. It is anticipated that with good site control and good workmanship, the structure and its components shall last indefinitely. They have forgotten to take into account the environmental loads while designing the structures (Structures are designed adequately for DL & LL, and some times for erection loads). Environmental factors affect durability of structures. Hundreds of bridges and structures are collapsing or showing signs of deterioration with corroding reinforcement all within 25 years of construction. It is, therefore, necessary for the designer to develop a feel for the problem and design the structures to satisfy safety, serviceability and durability requirements (structural and non-structural loads caused by environment). 5.2 Environmental factors : Critical environmental factors which affect concrete are carbon dioxide, chlorides, water and temperature as shown in fig 5.1 5.3 Design for carbonation: 5.3.1 The rate of carbonation depends upon the integrates of concrete of the cover zone. The penetration rate of carbonation in a good concrete structure remote from the seacoast and not subjected to de-icing salt is given by: D = k t0.5 k = 1 for M-35 & above (w/c= 0.40) k = 2 for M-25 (w/c = 0.45) k = 5 for M-15 D = Depth of carbonation in mm k = Carbonation coefficient in mm/year depending upon quality of concrete t = time of exposure in years. It is seen that by doubling the cover, quadruples the design life. Similarly with good quality concrete ( M-35 concrete with w/c ratio 0.4 ) five times design life can be achieved as compared to poor quality concrete ( M-15 concrete ).

DURABILITY OF CONCRETE STRUCTURES

DURABILITY OF CONCRETE STRUCTURES

5.3.2 The graph shown in fig. 5.2 can be used to select the cover and grade to meet the required design life. Example : For 100 years life, if the mix is M-35 or above the minimum cover requirement is 20 mm. i.e. if the mix is M-15 the cover requirement shall be between 40 and 60 (say 50 mm). 5.3.3 From the graph in fig. 5.2 it may be concluded that it is always better to go for richer mixes from durability angle even if it is not required from strength criteria. In the interior of the buildings the rate of carbonation can be high and must be considered while designing. Carbonation effect can be taken care by ensuring adequate cover of good quality concrete. This is necessary for all the sites in India. It also presupposes that the integrity of cover concrete (Concrete in cover portion) i.e. both quality and extent, is assured. Thick cover is of no avail if the concrete is highly penetrable. 5.4 Design for chlorides induced corrosion: For the marine structures, including buildings within 1 km of coast line, and for bridges exposed to deicing salt, the penetration of chloride is calculated from the following equation: i) K.C Clears Life Model: Life of corrosion on set (in years) 129 x ( cover-1.22 ) = -----------------------w/c x Cl-0.42

Where cover is in inches and w/c ratio and Cl are in % ii) The Chloride penetration curves in fig. 5.3 give a very simple method for design.

Example : For 100 yrs. design life and 60 mm cover, the minimum conc mix shall be M-50 or richer. 5.5 Design for sulphate exposure : This is dealt in detail under suitability of various types of cement in para 6.6 (iv) of chapter 6. 5.6 Design for durability : As durability depends upon permeability. It is important to control parameters affecting permeability. Therefore, it is necessary to lay down permissible limits for parameters like minimum cementitious material content, maximum water cement ratio, maximum crack width and extent of cover to reinforcement etc. depending upon the exposure condition. Following values for these parameter are recommended.

DURABILITY OF CONCRETE STRUCTURES

DURABILITY OF CONCRETE STRUCTURES

i) Minimum cementitious material content and maximum water cement ratio: Recommended values are given in table-5.1 Table 5.1 Minimum cementitious material content and maximum w/c ratio
Exposure Min. grade of mix PCC Min. cementitious* material content Kg/m Mild Mod Severe Very severe Extreme M-20 M-25 M-25 M-30 M-30 300 350 380 400 400
3

Max w/c ratio

RCC Min. grade of mix

Min. cementitious* material content Kg/m

3

Max w/c ratio

PSC Min. grade of mix

Min. Cementitious* material content Kg/m

3

Max w/c ratio

0.55 0.50 0.45 0.45 0.40

M-25 M-30 M-35 M-40 M-45

380 400 400 430 430

0.45 0.40 0.40 0.38 0.35

M-35** M-35** M-45 M-50 M-50

400 400 430 440 440

0.40 0.40 0.40 0.35 0.35

The areas covered under different exposure conditions shall be as under:

Mild: Concrete surfaces protected against weather or aggressive conditions. Moderate: Concrete surfaces sheltered from severe rain or freezing while wet, concrete continuously under water. Severe: Concrete surface exposed to severe rain , alternate wetting and drying or occasional freezing or severe condensation. Concrete exposed to aggressive sub soil / ground water or coastal environment. Very severe: Concrete surface exposed to sea water spray, corrosive fumes, severe freezing. Extreme: Concrete surface exposed to abrasive action. Surface of members in tidal zone. * Min. cementitious material content is for 20mm Max. size aggregate (MSA) Add extra cementitious material for 10 mm MSA = + 20 Kg/m3 for 40 mm MSA = - 10 Kg/m3 ** Minimum grade of concrete mix should be M-40 for pretensioned PSC bridges. Note: The maximum content of cementitious material should be 500 Kg/m3

DURABILITY OF CONCRETE STRUCTURES

ii) Minimum clear cover : Recommended values are given in table-5.2. The clear cover shall mean cover from the outer most metal /steel, binding wire or its end. Table 5.2 Minimum clear cover* Sr. No. Structures RCC/PSC Extreme environment Very severe Severe environment environment 50 50 75 75 50 75 25 40 50 75 50 75 Mild and Moderate environment 25 35 50 50 50 50

1 2 3 4 5 6

Slabs Beams Columns Wells, piles and footings PSC girders PSC girder for HTS cables

50 60 75 75 50 75

* While designing, it should be ensured that cover does not exceed 2.5 times dia of reinforcing bar. If cover is more, chicken mesh may be provided in cover concrete to keep the concrete in position. iii) Flexural Crack Width : It is necessary to control the crack width to protect steel rebar against corrosion. The crack width is controlled by reducing shrinkage, and distributing the reinforcement over the zone of maximum concrete tension, uniformly, and using smaller dia bars. Cement with low heat of hydration and not too fine should be used. Recommended value of maximum crack width to be considered during design are given in table-5.3. Design of crack width may be calculated as described in Appendix- I to this chapter. Table 5.3 Maximum crack width to be considered during design Type of structure Aggressive environment (Severe, Very severe and Extreme) Exposed 0.10mm 0.20mm Unexposed 0.20mm 0.20mm Non- aggressive environment (Mild and Moderate)

Bridges RCC beams, slabs

0.20mm 0.30mm

DURABILITY OF CONCRETE STRUCTURES

5.7 Admixtures : Chloride free water-reducing super plastisizers may be used for RCC & PSC works. However creep effect of plastisizers need to be considered in design. Air entraining agents may be used in upper Himalayan regions. 5.8 Temperature: The concreting shall be done only when the temp is between 5 0C & 32 0C. Preferably temperature variation of concrete during concreting should be within 5 0C. The special precautions to be taken shall be laid down by the designer. 5.9 Curing : All properties of concrete improve with extended wet curing. This is particularly so for permeability, which strongly affects durability and service life. A minimum wet curing for 7 days by ponding water/continuous spraying, followed by 3 weeks curing by curing compounds is recommended. 5.10 The form work : The form work is removed too early after obtaining cube test results to economise the cost of form work. It is not good from durability point of view. The time recommended is as follows: Columns Beams Slabs 3 days 10 days 14 days

5.11 Detailing : Normally the aspect of congestion of reinforcement at the junction of beams & column is neglected by design engineer. The drawings should be prepared by showing the full size of bars, laps, bends, distribution bars, spacers, cover blocks etc. It should be possible to place & compact concrete by a 50 mm. dia .needle vibrator. The corners & sharp edges should be chamfered. Circular sections are preferred. The design detailing should be such as to ensure effective drainage of water and to avoiding standing pool or rundown of water towards the critical components. The criteria of constructibility is of paramount importance. The layout and disposition of prestressing tendons should be designed for easy placement and vibration of concrete in the space between tendon ducts. When two or more rows of ducts are used, the horizontal space between the ducts should be vertically in line to facilitate proper flow of concrete as shown in Fig. 5.4. 5.12 Design of form work and false work : There is no practice of approval of design and drawings for form work and false work. With the result, the contractors use, whatever they like, risking the safety of workers and quality of concrete. Thus, it is necessary that the design and drawing for these items are also made, approved in advance and checked at site. For important works forms of plywood / other similar product which can absorb water are preferable as compared to steel forms. It is advisable to pay this item separately.

DURABILITY OF CONCRETE STRUCTURES

5.13 Recommendation: i Life of a structure may be different under different environmental region. Hence structure have to be designed for a particular design life. The structures may be designed for the service life as given in table 5.4. Table 5.4 Sr. No. 1 2 3 4 5 6 Type of structure Bridges in sea Bridges within 1 km of coast line Bridges in rest of India Buildings in coastal areas Buildings in rest of India F.O.B.Slabs Design life in years. 50 80 100 80 100 50

ii Each structure should be designed for durability and the design life should be printed on each drawing, design sheet & method statements. iii The soil where piles, footings etc. rest, and water in case of marine structures, should be tested and used in design and selection of type of cementitious material. iv The form and false work should be designed in advance, drawings prepared and paid for separately as an item. v The use of nominal mixes should be banned.

vi In place of cement, cementitious material has been used, to bring to focus that blended cements are superior to pure cements and should be used in all structures. vii The specifications of cementitious material should be decided for each work. Low heat blended cements are preferred for hot weather climate.

DURABILITY OF CONCRETE STRUCTURES

Appendix-I (Chapter-5 Clause 5.6D) Design Crack Width Calculation (Extract of Clause 6.21.A.6 of IRS Concrete Bridge Code 1982) The design crack width may be calculated by the following formula: Design surface crack width = 3a cr m a cmin 1 + 2 cr h x

Where Cmin - is the minmum cover to the tension steel, h - is the overall depth of the member x - is the depth of the neutral axis found from analysis to determine m (see below) acr - is the distance from the point considered to surface of the nearest longitudinal bar. m - is the average strain at the level where cracking is being considered, calculated allowing for the stiffening effect of the concrete in the tension zone, and is obtained from equation given below: 12 . bt h a ' x m = 1 10 3 where f y is in N / mm2 A (h x ) f y s and 12 . bt h a ' x m = 1 10 2 where f y is in kg / cm2 A (h x ) f y s Where a' x f s = 1 dx E s d fs Es 1 bt a As fY effective depth of tension reinforcement actual stress in steel modulus of elasticity of steel is the strain at the level considered, calculated ignoring the stiffening effect of the concrete in the tension zone. is the width of the section of the centroid of tension steel. is the distance from the compression face to the point at which crack width is being calculated, and is the area of tension reinforcement is the yield strength of steel in N/mm2 (kg/cm2)

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DURABILITY OF CONCRETE STRUCTURES