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MECHANISM OF

CORROSION IN REINFORCED
CEMENT CONCRETE
CORROSION
2
Corrosion
3
Corrosion
4
4
Corrosion products-Volume ratio
5
CORROSION
6
Reinforcement Corrosion Process
Acidic Alkaline
2 0
0
4 6 8 10 12 14
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Corrosion
Rate
mm/yr
pH of Concrete
Relationship between pH
and corrosion rate
Corrosion Inhibitors
High quality concrete
High pH (Alkalinity)
concrete protects steel
surface from corrosion
Corrosion Promoters
Oxygen
Water
Stray electrical currents
Uneven chemical
environment around
reinforcement
Environments that lowert
the pH (alkalinity)
Chlorides
Corrosion-Induced Cracking and Spalling
C/d Ratio Cover
mm
Bar size Corrosion % to
cause cracking
7 89 #4 4%
3 38 #4 1%
Cracking and spalling of
concrete induced by steel
corrosion is a function of the
following variables :
1. Concrete tensile strength
2. Quality of concrete cover
over the reinforcing bar
3. Bond or condition of the
interface between the rebar
and surrounding concrete
4. Diameter of the reinforcing
bar
5. Percentage of corrosion by
weight of the reinforcing bar
9
Corrosion induced cracking and spalling in columns
10
Corroded rebar in a beam

Corroded rebar in a beam
Reduction in Structural Capacity
The structural capacity of a concrete member is affected by bar
corrosion and cracking of surrounding concrete. A research
conducted on flexural beams found that in steel with more than
1.5 percent corrosion, the ultimate load capacity began to fall,
and at 4.5 % corrosion, the ultimate load was reduced by 12%.
In compressive members, cracking and spalling of concrete
reduces the effective cross section of the concrete, thereby
reducing the ultimate compressive load capacity considerably.
Loss of section
Chloride Penetration
s
a
lt
Chlorides penetrate
into concrete with
the help of surface
moisture
Y
e
a
r
s
Moisture and
Oxygen
Chlorides penetrate
into concrete with
the help of surface
moisture
Y
e
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s
When chlorides penetrate to
reinforcing steel corrosion begins
Delamination spall
Further penetration of
chlorides results in
further corrosion,
delamination and
spalling
Y
e
a
r
s
s
a
lt
Chlorides can be introduced
into concrete by coming into
contact with environments
containing chlorides, such as
sea water or de-icing salts.
Penetration of the chlorides
starts at the surface, then
moves inward. Penetration
takes time, depending upon :
1. The amount of chlorides
coming into contact with
the concrete
2. The permeability of the
concrete
3. The amount of moisture
present
Cracks and Chlorides
Cracks and construction joints in concrete
permit corrosive chemicals such as de-icing
salts to enter the concrete and access
embedded reinforcing steel.
ACI 224R presents following tolerable
crack widths:
Exposure condition Tolerance
Crack Width
(mm)
Dry air, protective
membrane
0.41
Humidity, moist air, soil 0.30
De-icing chemicals 0.18
Seawater and seawater
spray; wetting and
drying
0.15
Water-retaining
structures
0.10
s
a
lt
Y
e
a
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s
Surface
Introduced
Chlorides
Y
e
a
r
s
Y
e
a
r
s
Crack or
Construction
Joint
s
a
lt
s
a
lt
Deep spalling
Cast-in Chlorides
Chlorides can be found in reinforced
concrete even before the structure is in
service. Chlorides may be introduced
deliberately as an accelerator, or in the form
of natural ingredients found in some
aggregates.
ACI 201.2R suggests following limits for
chlorides in concrete prior to placing
concrete:
Service condition % of Cl to
weight of
cement
Prestressed concrete 0.06
Conventionally reinforced
concrete in a moist environment
and exposed to chloride
0.10
Conventionally reinforced
concrete in a moist environment
not exposed to chloride
0.15
Above-ground building
construction where concrete will
stay dry
No limit
Y
e
a
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s
Note : shaded area
denotes level of
moisture penetration.
Y
e
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s
Chloride content is generally
the same throughout the
cross section
Concrete with Cast-in water
soluble chlorides
Delamination
Corrosion
Carbonation
Carbonation of concrete is a reaction between
acidic gases in the atmosphere and the products of
cement hydration. The level of carbon dioxide in
industrial atmospheres is, as a rule, higher.
Carbon dioxide penetrates into the pores of
concrete by diffusion and reacts with the calcium
hydroxide dissolved in the pore water. As a result
of this reaction, the alkalinity of concrete is
reduced to a pH value of about 10, and,
consequently, concrete protection of the
reinforcing steel is lost. The passivity of the
protective layer on steel is destroyed.
In good quality concrete, the carbonation process
is very slow. The process requires constant change
in moisture levels from dry to damp to dry.
Carbonation will not occur when concrete is
constantly under water.
Y
e
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pH is lowered by the reaction...
CO
2
+ H
2
O + Ca(OH)
2
--> CaCO
3
+ H
2
O
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e
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Corrosion takes place faster
when the pH is lowered
Carbonation
front
Delamination
Acidic gases CO
2
H
2
O
CO
2
H
2
O
Y
e
a
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s
Corrosion
Carbonation takes
place within crack
CO
2
CO
2
Crack
Structural Steel Member Corrosion
Corrosion of embedded metals
includes structural members such as
steel beams cast into concrete to form
a composite member, or to provide
fire protection. The top flange of a
beam is susceptible to corrosion when
a crack or construction joint intersects
the flange. Moisture and corrosive
salts are trapped on the flange,
providing an ideal environment for
corrosive activity. Corrosion on the
top flange exerts a jacking force on
the concrete above the flange. When
the force is sufficient, delamination
occurs. Evidence of slab separation
from the beam then becomes
apparent from the underside of the
slab.
Y
e
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Embedded Stuctural
Member
Embedded Stuctural
Member
s
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Crack or Construction
Joint over Embedded
Structural Steel
Aggressive
Environment
Y
e
a
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s
Lifting of slab
from top of
flange by
expanding
corrosion
products.
+
Dissimilar Metal Corrosion
Corrosion can take place in concrete
when two diffeent metals are cast into
a concrete structure, along with an
adequate electrolyte. A moist concrete
matrix provides for a good electrolyte.
This type of corrosion is known as
galvanic. Below is a list of metals in
order of increasing activity :
Zinc < Aluminium < Steel
< Iron < Nickel < Tin
< Lead < Brass < Copper
< Bronze < Stainless Steel
< Gold
Aluminium in
contact with fresh
concrete liberates
hydrogen gas,
thereby creating
localized porosity.
Aluminium Steel
Note : shaded area denotes level of
moisture penetration and active
electrolyte. If chlorides are present,
the process is accelerated.
Anode Cathode
Electrode flow
Ion OH Flow
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Corrosion occurs here. Aluminium
oxide causes expansion and
cracking of surrounding concrete
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Post-Tension Strand Corrosion
Corrosion of unbonded post-tension
strands has become a common
problem for structures exposed to
aggressive environments. Buildings
exposed to ocean salt spray and
parking structures exposed to de-icing
salts are typical locations for
unbonded strand corrosion.
Unbonded post-tension strands are
protected from corrosion by
protective grease and sheathing.
Unbounded Post-Tension Strand
s
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Aggressive
Environment
Y
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Strand corrodes and breaks
Broken protective
sheathing allows
exposure to
corrosive
environment.
Collapsing broken strand may
exit the structure at points of low
cover or at ends
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Unprotected strand without
protective sheathing
Leakage paths
into strand
system
7-wire strand
Anchorage
plug grout
Wedges
End anchor casting
Breakout bars
Push-thru
Heat
Sealed
Extruded
Protective Sheathing Types
Individual
wires
Grease
(typical)

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