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The paper presents the results of an experimental study on section due to corrosion results in failure of serviceability.11
111 under-reinforced concrete beams to determine their resid- Service life predictions based on the loss of safety margin in
ual flexural capacity after undergoing different degrees of rein- concrete members due to section loss have also been attempt-
forcement corrosion. Corrosion was induced in the laboratory ed.12 Some researchers have defined levels of deterioration
by an accelerated corrosion technique using two sources of based on visual indications, such as rust stains.13 Color modifi-
external power supply. The beams were precured for different cations, however, are not always present and cannot be consid-
periods of up to 1 year before accelerated corrosion was ered as a prerequisite for damage classification. Some
induced in the reinforcement. Different degrees of reinforcing researchers have considered the presence of longitudinal crack-
bar corrosion were induced in increments, ranging from 1.25 to ing in concrete as a sign of ultimate limit state,14 but flexural
10 percent at corrosion rates of 1, 2, 3, and 4 mA/cm2. The testing of members in this condition has shown small loss in the
beams were reinforced with two longitudinal bars. Shear rein- ultimate flexural strength. The significant loss of reinforcement
forcement was provided by external means using steel collars. bond with concrete due to steel corrosion15 is likely to be the
The results show marked reductions in flexural strength due primary cause of reduction in flexural strength.
to reinforcement corrosion, which is caused primarily by the
Development and validation of some predictive models for
breakdown of bond at the steel/concrete interface.
the service life assessment of reinforced concrete have been at-
tempted.16-18 Their accuracy relies on the correct modeling of
Keywords: flexural strength; load-deflection curve; reinforced concrete;
deterioration processes. Also, the relationship between degree
reinforcement corrosion; repairs.
of reinforcement corrosion and the residual strength and stiff-
ness of flexural members is a key requirement for any model for
INTRODUCTION
predicting the service life of structures. This paper derives such
The large-scale construction of infrastructure in Europe and
the United States after World War II relied heavily on the use of a relationship based on experimental data.
reinforced concrete. It was based on the secure assumption that
protection awarded to steel reinforcement by concrete was per- RESEARCH SIGNIFICANCE
manent. Recent experiences, unfortunately, have proved other- Optimal decision making about repair and maintenance of re-
wise and have highlighted the importance of developing service inforced concrete structures requires the capability of predicting
life prediction models of deteriorating structures so that optimal the residual structural capacity of members that are undergoing
strategies for their maintenance and repair can be developed. reinforcement corrosion. The complex interactions that occur
One of the major deterioration processes in reinforced con- between different bars (i.e., shear and tensile reinforcement)
crete is reinforcement corrosion made possible by carbonation during corrosion need to be simulated in the laboratory in a con-
of concrete or by chloride penetration to steel level. A concep- trolled manner so that their individual and cumulative effects on
tual model1 to estimate the service life of corroding reinforced structural capacity can be quantified. The parameters of rein-
concrete is based on corrosion initiation and corrosion propaga- forcement corrosion which are routinely monitored in the field,
tion time periods. Steel is depassivated at the end of the corro- i.e., time of corrosion initiation, and rates of reinforcement cor-
sion initiation period either because of the presence of threshold rosion need to be related to the residual structural capacity of re-
levels of chloride concentration on its surface or because of loss inforced members so that decisions on optimal repair/
of alkalinity of the cover concrete due to carbonation. Research maintenance strategies can be made. The experimental investi-
on the corrosion initiation period has reported different thresh- gation presented in this paper makes a significant contribution
old levels of chloride concentration which depassivate steel.2-4 to satisfy this need by developing analytical expressions (and
Models for predicting long-term chloride concentration from nomograms) which can be used to determine the long-term
routine inspection data of concrete construction have also been structural capacity of reinforced concrete beams undergoing dif-
derived.5,6 Field methods for determining the corrosion propaga- ferent degrees of reinforcement corrosion. The degree of corro-
tion rates in reinforced concrete have been developed,7-10 which sion is a function of rate of corrosion, duration of corrosion
assist with service life predictions. period (since initiation), and reinforcing bar diameter.
The next link required in the service life prediction of corrod-
ing structures is a knowledge of the residual strength of rein-
forced concrete elements as affected by the degree of ACI Structural Journal, V. 96, No. 1, January-February 1999.
Received September 29, 1997, and reviewed under Institute publication policies.
reinforcement corrosion. A number of researchers have attempt- Copyright 1999, American Concrete Institute. All rights reserved, including the
making of copies unless permission is obtained from the copyright proprietors. Perti-
ed to define the service life of corroding reinforced concrete. It nent discussion will be published in the November-December 1999 ACI Structural
has been suggested that 10 to 25 percent reduction in steel bar Journal if received by July 1, 1999.
EXPERIMENTAL
Fig. 1—Beam specimens with stirrup reinforcement (Groups 1
Test program and 4).
Details of the test program are given in Table 1. Nine groups
of beam specimens were manufactured for the experimental
study. A total of 111 under-reinforced beams were subjected to
accelerated corrosion damage by two external power supply
sources and then tested under flexure. The degree of corrosion
(as a percentage reduction in reinforcing bar diameter) is de-
fined by the expression 2RT/D percent, where R is the rate of
corrosion in mm/year, D is the reinforcing bar diameter in mm,
and T is the time elapsed in years after corrosion initiation. In
Table 1, the corrosion rate is defined as the intensity of the in-
duction current provided from the external power supply. Cor-
rosion duration is defined as the time taken to complete the Fig. 2—Beam specimens of Groups 2, 5, 6, 8, and 9 (without
induction of corrosion in reinforcement to the desired degree. stirrup reinforcement).
The precorrosion period is defined as the duration of curing the
beams in water (after demolding) prior to inducing corrosion in cement content was 425 kg/m3 (715 lb/yd3 ). One percent (by
the reinforcement and, therefore, simulates the period after weight of cement) sodium chloride salt was added to the mix to
which corrosion is initiated in the reinforcement. improve concrete conductivity so that accelerated galvanic cor-
The under-reinforced concrete beam specimens were 910-mm rosion could be induced as described in Section 2.3 by means of
(36-in.) long and had a rectangular cross section of 150-mm (6- external current supply. The average compressive strength of
in.) depth, 100-mm (4-in.) width. Each beam specimen was sin- the concrete cubes after 28 days was 40 N/mm 2 (5.8 ksi), with a
gly reinforced with two deformed steel bars of 10-mm (0.4-in.) standard deviation of 1 N/mm 2. The concrete mix was cast hor-
diameter (8 mm in Groups 3 and 7 in Table 1) as shown in Fig. izontally in the beam molds and compacted by means of an elec-
1 and 2. The bars were 1100-mm (43-in.) long, including the an- tric poker vibrator. After casting, the molds were covered with
chorage length in the form of U-shaped hooks at the ends. The polythene sheets for 24 hr and then demolded. After demolding,
reinforcing bars were positioned symmetrically in the cross sec- the beam specimens were cured by complete immersion in wa-
tion at a spacing of 50 mm (2 in.), and the cover to the centroid ter for periods ranging between 10 days and one year, as shown
of tensile reinforcement was 25 mm. Double-leg stirrups made in Table 1. Although corrosion is active, even under water, in
with mild steel bars of 6-mm (0.24-in.) diameter were provided highly chloride contaminated concrete due to O2 diffusion into
at a spacing of 70 mm (2.75 in.) in specimens of Groups 1 and saturated concrete, the rate is very slow and is negligible relative
4 in Table 1. Two 6-mm (0.24-in.) diameter longitudinal bars to corrosion induced by external current supply (Section 2.3).
were also provided at the top of the beam to hold the reinforce- The control beams tested after the pre-curing period of 10 days
ment cage together (Fig. 1). The presence of stirrups interfered and 1 year showed no reinforcement corrosion. After precuring,
with the corrosion-inducing phase in the reinforcement and specimens were transferred to the accelerated corrosion induc-
made it impossible to maintain an accurate and uniform control ing apparatus for periods between 12 and 384 hr to induce dif-
on the degree of reinforcing bar corrosion. Consequently, no stir- ferent rates of corrosion in the reinforcement as described in the
rups and no top steel were provided in the beam specimens of next section. After inducing a predetermined degree of corro-
Groups 2, 3, 5, 6, 7, 8, and 9. Instead, shear reinforcement was sion in the reinforcement (Table 1), the beams were again cured
provided by means of external collars as described in Section under immersion in water until they were ready for flexural test-
2.4. ing after a total age of 28 days after casting (except for Group 9
tests where the beams were tested at 1 year after casting).
Materials and mixes
Ordinary portland cement was used throughout. The fine ag- Accelerated corrosion in reinforcement
gregate was a washed concrete sand conforming to the medium After a minimum period of 11 days after casting, each beam
zone of BS 882:1965 (FM 2.15 to 3.45). The coarse aggregate specimen of Groups 4, 5, 6, 7, 8, and 9 (Table 1) was subjected
was 10 mm maximum size crushed grey granite. The reinforcing to an accelerated galvanic corrosion process in an electrolytic
bars used in the experiments were standard 10 and 8-mm diame- cell by means of two identical integrated systems. Each system
ter high-yield bars. The yield strength of the reinforcement bars incorporated a direct current power supply with a built-in am-
was 520 N/mm2 (75.4 ksi) and modulus of elasticity was 206 meter to monitor the cell current. Fig. 3 shows the layout of the
kN/mm 2 (29,877 ksi). corrosion setup. The corrosion process of reinforcing bars took
The concrete mix used for the beams had proportions (by place in a plastic tank where 3.5 percent NaCl solution was used
weight) of 1:2.24:3.22 with a water-cement ratio of 0.53. The as the electrolyte. The solution level in the tank was adjusted to
slightly exceed the concrete cover plus reinforcing bar diameter diameter (excluding the bent-up portion) within a short times-
to ensure adequate submersion of the longitudinal reinforcement, cale. The relationship between corrosion current density and the
excluding the vertical portion of the bent up bars at the ends of the weight of metal lost due to corrosion was determined by applying
beam. The current intensity of the power supply and the corrosion Faraday’s law19 as follows
period were selected for each beam in order to achieve the desired
AIt
degree of corrosion of the submerged level of reinforcement bar, as ∆ ω = -------- (1)
shown in Table 1. Each degree of corrosion was selected to pro- ZF
vide a predefined percentage reduction in the longitudinal bar
T
= 2312i ---- (7)
D
Fig. 11—Effect of corrosion rate on flexural strength of beams. Fig. 13—Relation between degree of corrosion (2RT/D per-
cent) and flexural strength of beams. (Corrosion rate: 1 mA/
exist at lower degrees of reinforcement corrosion. This indicates corroded beams
that the interfacial bond strength reduction at the steel/concrete Fig. 13 shows the relationship between the degree of corrosion
interface is the primary factor responsible for the deterioration (2RT/D percent) and the flexural load capacity B (as a percentage
of flexural capacity of the corroded beams of this investigation of the control beam) of the beams of Group 8 tests (Table 1) which
rather than the reduction in reinforcing bar cross section. were corroded at a rate of 1mA/cm2 (6.45 mA/in 2). The individual
Fig. 11 illustrates the effect of corrosion rate on the flexural results of the three beam specimens tested at each of the different
load capacity of beams damaged by different degrees of corro- degrees of corrosion (2RT/D percent) of 1.25 to 10 percent are
sion induced in the reinforcement at four different corrosion shown separately. Nominal scatter between the results of individ-
rates: 1, 2, 3, and 4 mA/cm2. Up to a corrosion degree of 3.75 per- ual beams is evident (coefficient of correlation 95 percent). A
cent (2RT/D = 3.75 percent), the results in Fig. 11 show a small nonlinear regression analysis of the experimental data gives the
effect of corrosion rate on flexural load capacity. However, at a following relation between B percent and 2 RT/D percent.
corrosion degree of 5 percent and beyond, the flexural load ca-
pacity decreases significantly with increasing corrosion rate.
B percent = 1 – sin 7 ----------percent 1 0 0
Fig. 12 presents results of the flexural capacity of beams of Group 2 2R T
(8)
9 which were damaged by 5 percent degree of reinforcement corro- D
sion at a rate of 3 mA/cm2. The beams were pre-cured for dif-
ferent periods (15 days, 28 days, 6 months, 1 year) before
corrosion was induced. The results show that the residual flexural Similar relationships of the form
strength of the corroded beams for each of the pre-curing periods
is about 70 percent of the control beams. The implication of this
B percent = 1 – sin ψ 2----------percent
2 RT 1 0 0 (9)
result is that the age of a concrete structure when corrosion initi- D
ation occurs may not have any significant effect on the residual
strength of the corroded elements when corrosion in the rein-
forcement has propagated to a significant degree. are obtained for beams in which corrosion was induced at rates of
2, 3, and 4 mA/cm 2 (Groups 6 and 8, Table 1). A typical example
Development of residual strength equation of of such a relationship shown by the experimental data is given in
Fig. 14. In Eq. (9), ψ is a constant which varies with the corrosion
rate adopted.
As previously explained, the corrosion rate R due to a current
density i of 1 mA/cm 2 works out to be 1.156 cm/year (0.46 in./
year). Therefore, a general expression can be obtained by sub-
stituting for R in terms of current density i in Eq. (9). This gen- Fig. 16—Predicted flexural strength with time [Eq. (11)] of
eral expression relates the flexural load capacity (B percent) of reinforced concrete beams corroding at different rates. (Corro-
the beam to the corrosion current density i, the time elapsed in sion currents 10 to 60 µA/cm2 .)
years since the initiation of corrosion (T), and the diameter of re-
inforcement ( D) as follows Eq. (11) has been used to produce nomograms for determin-
ing the residual strength of corroding beams reinforced with re-
inforcing bars of different diameters. A typical example is given
T
B percent = 1 – sin 2.312 ψ ----i 1 0 0
2
(10) in Fig. 16. The range of corrosion current densities covered are
D
10 µ A/cm2 (64.5 mA/in. 2) to 60 µ A/cm2 (387 mA/in. 2) which
represent the likely range of values encountered in field struc-
Table 2 presents the values of the corrosion current density (i tures undergoing high to very high rates of reinforcement corro-
µA/cm2 ) and the corresponding values of the coefficient ψ de- sion. Current information available in literature, based on outdoor
termined from the nonlinear regression analysis of the experi- exposure and field studies, shows that high rates of corrosion oc-
mental results. These values of ψ are approximately the natural cur at Icorr values exceeding 1 µ A/cm2 (6.45 µ A/in.2 )20 and 2.7 to
logarithm of the corresponding values of current density (ψ = 27 µA/cm2 .16,21 Very high rates of corrosion are expected at Icorr
lni). Therefore, Eq. (10) can be rewritten as values exceeding 10 µ A/cm2 (64.5 µA/in.2) 20 and exceeding 27
µA/cm2 .16,21 Field data on some highway bridges in the UK also
showed high corrosion currents in the range 10 to 60 µA/cm2 .
1 0 0
B percent = 1 – sin 2.312----ilni
T
2
Nomograms at lower corrosion currents, however, can also be
(11)
D easily derived from Eq. (11). The countervailing influences of in-
ternal stirrup reinforcement improving flexural resistance while
Considering the relationship described by Eq. (11), a graph is also increasing the rates of corrosion in the longitudinal rein-
plotted in Fig. 15 representing the equation and the correspond- forcement (which reduces flexural strength) are not covered by
ing experimental data obtained in this investigation. Fig. 15 the nomograms since, in the tests reported, shear reinforcement
shows that up to a corrosion degree 2R T/D of 3.75 percent, val- was externally provided by collars.
ues of the flexural load capacity calculated from Eq. (11) are in
good agreement with the experimental results. At higher de- Further discussion
grees of corrosion, the predicted flexural capacity from Eq. (11) The predictive model for residual strength of corroded rein-
becomes more conservative. forced concrete beams presented in Eq. (11) provides a conser-