study on corrosion resistance in concrete by …the effect of mineral admixtures like nano-silica,...

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International Journal of Civil Engineering and Technology (IJCIET)

Volume 8, Issue 10, October 2017, pp. 988–1000, Article ID: IJCIET_08_10_103

Available online at http://http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=8&IType=10

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

STUDY ON CORROSION RESISTANCE IN

CONCRETE BY MINERAL ADMIXTURE

ADDITION AND FRP WRAPPING OF

REINFORCEMENT BARS

Varun Kumar K and Mini K.M

Department of Civil Engineering, Amrita University,

Coimbatore, Tamilnadu, India

ABSTRACT

Corrosion is a major concern in structural applications due to its detrimental

effect which reduces the lifespan of the structures, particularly in coastal areas. The

main sources of corrosion in concrete are chloride intrusion and carbonation. Due to

corrosion, the spalling and delamination of the concrete due to the expansion of steel

is unavoidable. Hence, the steel reinforcement bars are to be protected from corrosion

so that the structure remains safe. In the present paper, modifications are done for

steel using Fiber Reinforced Polymer (FRP) wrapping and the concrete is modified by

doping with Zeolite and Micro Silica. The corrosion resistance offered by the

specimens is monitored by Half-cell potential method, Open circuit potentials (OCP),

Linear Polarization Resistance (LPR) and Tafel Polarization techniques. As there are

modifications in steel and concrete, water absorption , compressive strength and bond

strength of the specimens are checked and are compared with control specimens.

Key words: Corrosion, Zeolite, Micro-silica, Open circuit potential (OCP), half-cell

potential, LPR, Tafel Polarization, FRP Wrapping.

Cite this Article: Varun Kumar K and Mini K.M, Study on Corrosion Resistance in

Concrete by Mineral Admixture Addition and FRP Wrapping of Reinforcement Bars.

International Journal of Civil Engineering and Technology, 8(10), 2017, pp. 988–

1000.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=8&IType=10

1. INTRODUCTION

Concrete is a versatile composite material which has been used over century in the

construction area due to its economical, ecological and technical advantages. But, the

corrosion of steel reinforcement bars in the concrete is a longstanding global problem being

faced by many technical engineers which causes damage to the concrete structures [1]. In case

of adverse environments, numerous structures have experienced unacceptable loss in safety or

serviceability far earlier than expected due to corrosion of reinforcing steel bars and therefore

there is a need for replacement. Corrosion is mainly caused by the chloride intrusion (passage

of aggressive chloride ions from marine environments, deicing salts, and use of chloride



contaminated aggregates) and carbonation. When chloride ions react with steel, corrosion

products such as rust is formed which involves a substantial increase in volume which results

in expansion of the concrete and thus spalling and delamination of concrete takes place. In

general, these are repaired using Fiber reinforced Polymer (FRP) patches and in case of harsh

environments associated with marine and coastal regions, partial or full delamination of these

patch repairs due to continued corrosion is unavoidable. These repairs won't last for a longer

duration and thus concrete starts to crack and spall. So, it is necessary to stop the corrosion at

the initial stage itself, so that the life of the structure is improved which indirectly reduces the

maintenance cost.

Several studies were carried out by mixing mineral admixtures like nano-silica, micro-

silica and micro-zeolite for improving the compressive strength and reducing the water

absorption of concrete [2-4]. But the addition of mineral admixtures for resisting corrosion is

still under investigation. The effect of mineral admixtures like nano-silica, nano calcium

carbonate, micro-silica and micro zeolite on water absorption are studied out in controlling

the corrosion [5]. The effect of silica fume on CNT based cement composite was carried out

by K.M.Mini et.al [6] which also shows reduced water absorption and thus can reduce

corrosion. Different corrosion inhibitors are added to the concrete to reduce the corrosion of

steel bar. The effect of different inhibitors like fly ash, zeolite, diatomite, leaf-extract of

morindalucida, imidazoline based inhibitors, high volume fly ash, nano-calcium carbonate etc

is studied and concluded that all the inhibitors are good at resisting corrosion when compared

to the normal traditional concrete without any admixtures [7-12].

Several studies were carried out using FRP wrappings for concrete [13] which are mainly

focused on improving the compressive strength, fatigue and flexural behavior of concrete

[14,15], retrofitting large scale corrosion damaged RC beams[16-20]. Nimrat Pal Kaur [21]

conducted a study on CFRP as active protection of corroded steel rebar embedded in FRP

wrapped concrete by using nondestructive monitoring techniques. Less and Adeli [22]

investigated the structural behavior and corrosion resistance of hybrid FRP wrapped steel

reinforcement bars in concrete and life cycle cost analysis as performed to assess the

economic advantages and disadvantages of hybrid bars.

Several studies were carried out on corrosion of rebar using different type of coatings like

basaltic pumice, colemanite, barite and ground granulated blast furnace slag (GGBS), out of

which colemanite offers a best corrosion resistant [23]. Several other coatings like inorganic

zinc, epoxy, polyurethane, molybdenum disulfide and other anti-corrosion resistant alloy

coatings were developed in the past few years [24-28] and are still under investigation.

The effect of corrosion on the bond strength between reinforcement steel bars and

concrete, stress distribution and bond-slip behavior is studied by varying the level of

corrosion, with and without the confinement of steel. Pull-out tests were conducted on

different specimens and the study concluded that bond strength was very sensitive to the bars

without confinement when compared to the bars with confinement [29-31].

There are different methods for measuring the rate of corrosion. Weight loss is one of the

best ways to represent the corrosion exactly but it takes a long time and hence it is represented

by the electrochemical methods and their importance is studied by many researchers [32, 33].

In the present paper, two modifications are carried out, one for steel and one for concrete.

Micro-silica and zeolite are the mineral admixtures which are added to the concrete by

replacing the cement, due to which small pores are replaced by the admixtures thus reducing

the water absorption of the concrete which indirectly reduces the corrosion. The water

Study on Corrosion Resistance in Concrete by Mineral Admixture Addition and FRP Wrapping of

Reinforcement Bars


absorption of the concrete is checked as per ASTM C642-06 [34]. As the concrete is modified

by adding the mineral admixtures, the compressive strength of the concrete is studied by

using compression testing machine as per IS 516-1959 [35]. The steel rebars are wrapped with

CFRP and GFRP sheets using epoxy and hardener in different layers with different

combinations. These sheets act as a secondary barrier and reduce the passage of water, which

indirectly results in reduction of corrosion. The bond strength between the steel and the

concrete is checked by using the pull-out test as specified in the IS 2770(Part 1)-1967 [36].

The rate of corrosion is measured by using different methods like half cell potential method,

open circuit potentials (OCP), Linear Polarization Resistance (LPR) and Tafel Polarization

methods to have a proper check on corrosion monitoring.

2. METHODOLOGY

2.1. Cement, Steel and Aggregates

All the experimental specimens are cast using OPC (Ordinary Portland Cement) of Grade 53

with a specific gravity of 3.15.

All the steel reinforcements used are of TMT (Thermo Mechanically Treated) bars of Fe

415 grade. The density of the steel is 7850 kg/m3, elastic modulus is 200GPa and Poisson's

ratio is 0.28.

The coarse aggregate used in the preparation of the specimens has a specific gravity of

2.75 and the specific gravity of fine aggregates is 2.62.The water absorption of the coarse

aggregate and fine aggregates are 2% and 1.6% respectively.

2.2. Micro Silica & Zeolite

Micro-silica and zeolite are the pozzolonic materials that are added to the concrete by

replacement of cement. The properties of Micro-silica and Zeolite are listed in Table 1.The

cement is replaced with different percentages of micro-silica and zeolite namely 0%, 10%,

20%, and 30%.

A study is conducted on the water absorption of the concrete as per ASTM C642-06 [34]

by replacement of cement with different compositions of Micro-silica and Zeolite. Cubes of

size 100mm × 100mm ×100 mm are considered for the study and the specimens are cast as

per the percentages mentioned above and cured for 28 days. Then the water absorption of the

concrete is determined and the study concluded that 10% replacement of cement with Micro-

silica and Zeolite resulted in less water absorption and is shown in Fig. 1.

2.3. Fiber-Reinforced Polymer (FRP)

Fiber-reinforced polymer (FRP) (also fiber-reinforced plastic) is a composite material made of

a polymer matrix reinforced with fibers. The fibers are usually glass, carbon, aramid and

basalt. FRP has seen an increased use in structural engineering applications in recent years

due to a number of advantageous qualities, including a high ultimate strength, light weight,

corrosion resistance, and formability. In this paper, bidirectional CFRP and multidirectional

GFRP are used for wrapping the reinforcement bars and the properties of FRP’s are listed in

the Table 2.

2.4. Specimen Preparation

For studying the corrosion of steel in the concrete, a cylindrical specimen of 100mm diameter

and 200mm height is considered and a 10mm diameter TMT steel bar is embedded inside the



concrete up to a depth of 150mm from the top so that uniform cover is maintained from all the

sides. By taking the characteristic compressive strength (fck) of concrete as 25MPa, the

quantity of materials used in the preparation of control specimens are calculated using IS

10262:2009 [37] and are listed in Table 3.

Table 1 Properties of Micro-silica and Zeolite

Figure 1 Water absorption for micro-silica and zeolite

Table 2 Properties of FRP

Property CFRP GFRP

Ultimate tensile strength (MPa) 600 440

Modulus of Elasticity (GPa) 70 25

Poisson’s Ratio 0.1 0.2

Shear Modulus(GPa) 5 4

Nominal thickness 0.23 0.21

Thermal coefficient 2.1 11.6

4

4.5

5

5.5

6

6.5

7

0 10 20 30 40

Wate

r ab

sorp

tion

% Replacement of cement

Microsilica Zeolite

Physical Zeolite Microsilica

Bulk density 0.8-1.1gm/cc 0.76gm/cc

Specific gravity 2.63 2.63

Loss on ignition 14% Max 0.015%

Ph 4.5 to 6.5 6.9

Moisture 1% max 0.058%

Melting point 1735oC 1600

oC

Chemical Zeolite Microsilica

Silica 45.17 99.886

Ferric oxide 0.5 (Max) 0.04

Alumina 37.59 0.043

Titanium dioxide 0.5 0.001

Calcium oxide 0.22 0.001

Magnesium oxide 0.12 0.0

Sodium oxide 0.31 0.003

Potash 0.07 0.001


Reinforcement Bars


As per the study conducted on micro-silica and zeolite (Fig.1), the cement is replaced with

10% of micro-silica and zeolite and are noted as MS,Z respectively and the conventional

concrete without any modifications for steel and concrete is noted as CS. The reinforcement

bars are wrapped with CFRP and GFRP sheets using epoxy and hardener. At first the epoxy

and hardener are mixed well in the ratio of 1kg: 150ml respectively and applied on the FRP

sheet. The steel bar is wrapped with the FRP and kept in oven at a temperature of 45oC for

approximately 14 hours to get it hardened. In case of FRP wrappings the modifications and

their notations are given as follows:

CS-Control Specimen

MS-Micro-silica

Z-Zeolite

2C- CFRP wrapped in two layers

3C-CFRP wrapped in three layers

2G-GFRP wrapped in two layers

3G-GFRP wrapped in three layers

2G+2C-GFRP wrapped in two layers over which CFRP is wrapped in two layers

For each type of combination a total of six specimens are casted (3 specimens for pull-out

test and 3 specimens for corrosion test) and cured for 28 days and are subjected to accelerated

corrosion by immersing them in 0.5M NaCl + 0.5M H2SO4 for 120 days.

Table 3 Materials used in preparation of concrete For one cum concrete, w/c ratio=0.48

Material Quantity

Cement 370 kg

Sand 691 kg

Coarse aggregate 1179 kg

Water 212 L

2.5. Experimental Setup

2.5.1. Compressive Strength

The cement in the concrete is replaced with 10% micro-silica and zeolite to reduce its water

absorption property. As there is a change in the composition of materials used in the concrete,

compressive strength is determined for the specimens with 10% replacement of micro-silica,

zeolite with cement and no replacement of cement (control specimens).The specimens are

checked for compressive strength using the compressive testing machine as per IS 516-1959

[35].

2.5.2. Pull-out Test

As the cement and steel in the concrete are modified by adding different admixtures and

wrappings respectively, the bond strength between the steel rebar and concrete is checked by

conducting pull-out test as specified in IS: 2770 (Part 1) -1967 [36].

2.5.3. Corrosion Testing

The rate of corrosion can be expressed in many ways. Among all the different ways, Loss of

weight is the best way to measure the rate of corrosion accurately which takes a long time. As

the corrosion involves the electro-chemical reactions, the rate of corrosion can be obtained

easily by using Half-cell Potential method, Linear Polarization resistance (LPR) method,



Open circuit potentials (OCP) and Tafel Polarization method. In the present study, these four

methods are used for corrosion monitoring to have a proper check on the corrosion resistance

offered due to modifications in steel and concrete. The rate of corrosion is measured for 0th

day (after curing for 28days), 40th

day, 80th

day and 120th

day respectively and the readings

are noted down.

2.5.4. Polarization Techniques

The corrosion measurement using electrochemical techniques are currently experiencing

increasing popularity among corrosion engineers, primarily due to the rapidity with which

these measurements can be made. Long term corrosion studies, such as weight loss

determinations may require some weeks to complete while an electrochemical experiment

will requires only several hours. The speed of electrochemical measurements is especially

useful for those metals or alloys that are highly corrosion resistant. In this study, all the

readings were taken using the CHI604E electrochemical analyser. Here, the working electrode

is steel bar, the counter electrode is platinum wire and the reference electrode is silver-silver

chloride electrode.

3. RESULTS AND DISCUSSION

3.1. Compressive Strength

The compressive strength is checked for the specimen as mentioned in the code IS 516-1959

[35] and the results of the compressive strength are tabulated in Table 4.

Table 4 Compressive strength for different specimens

Notation Characteristic Compressive strength (MPa)

Control specimens (CS) 31

Micro-silica(MS) 39

Zeolite(Z) 34

From the above results, it is clear that both micro-silica and zeolite induced specimens

have increased compressive strength when compared to the control specimens.

3.2. Pull-out Test

In this test, the concrete specimen is fixed to the lower end of the testing machine and the

steel rebar is being pulled out and the corresponding deflections are noted down. The testing

of a specimen is shown in Fig. 2. The bond strength for different types of combinations is

shown in Fig. 3. The load deflection curves for the specimens are shown in Fig. 4. The bond

strength for different specimens is tabulated in Table 5.

Table 5 Bond strength values

Notation Bond-strength (MPa)

CS 0.87004

MS 0.89126

Z 1.46422

2C 1.16714

3C 1.72948

2G 1.93108

3G 2.66319

2G+2C 1.78254


Reinforcement Bars


Figure 2 Testing of a specimen for pull-out load

1-CS, 2-MS, 3-Z, 4-2C, 5-3C, 6-2G, 7-3G, 8-2G+2C

Figure 3 Bond strength of the specimens

Figure 4 Bond Strength -deflection graph

0

0.5

1

1.5

2

2.5

3

1 2 3 4 5 6 7 8

Bond Strength

Bond Strength

0

2

4

6

8

10

12

0 1 2 3 4 5 6

Bo

nd

Str

eng

th (

MP

a)

Deflection (mm)

CS MS Z 2C 3C 2G 3G 2G+2C



From the above results, it is clear that all the specimens have sufficient bond strength

when compared to the control specimens and highest bond strength is accounted for 3G

specimen.

3.3. Half-Cell Electrical Potential Method

In this method, the negative charge is obtained by measuring the concrete surface electric

potentials relative to that of the standard electrode. Copper-copper sulfate electrode is used as

the reference electrode in this method. At half-cell, electrons transform Cu+2

ions in the

copper sulfate solution to Cu atoms and deposit on the rod in the half-cell, thus voltmeter

indicates a negative value. The higher the negative value, higher is the corrosion. According

to ASTM C876-91 [38], the criteria for the probability of corrosion are given in Table 6.

Table 6 Criteria for corrosion of rebar in concrete for different half-cells[38]

Cu/CuSO4 electrode Ag/AgCl electrode Likely corrosion condition

> -200 mV > -106 mV Low(10% risk of corrosion)

-200 to -350 mV -106to -256 mV Intermediate corrosion risk

<-350 mV < -256 mV High(>90% risk of corrosion)

<-500 mV <-426 mV Severe corrosion

The half-cell potential values (in mV) for different days are given in Fig. 5

Figure 5 Half-cell potentials

From the above figure, it is understood that till 80 days both zeolite and micro-silica have

offered very good resistance as their potential lies in the range of low and intermediate

corrosion risk, and at the range of 120 days both zeolite and micro-silica have severe

corrosion. But, at 40 days itself, all the remaining specimens are lying under high risk of

corrosion and at 120 days all these specimens are having severe corrosion, whereas the

control specimen lies in the severe corrosion at all the time.

3.4. Open Circuit Potential Method

In this method, Ecorr will be obtained directly from the electrochemical analyzer which gives

qualitative information about the risk or degree of corrosion. The more negative potential

indicates more active corrosion, and the open circuit values (mV) of different samples on

different days are given in Fig. 6. The criteria for the probability of corrosion are illustrated in

Table 5.

-900

-800

-700

-600

-500

-400

-300

-200

-100

0

0 40 80 120

Po

ten

tia

l (m

V)

Time (days)



Reinforcement Bars


Figure 6 Open circuit Potentials

So, from the above figure, it is clear that in the initial days, all the specimens are lying

under low corrosion risk, but as the days passed it is clear that zeolite offers higher resistance

than all the specimens.

3.5. Linear Polarization Resistance Method

In this method the potential is changed about 10-20mV from Ecorr and the corresponding

current is measured. When a plot is drawn for current vs potential, the slope of the plot gives

the Polarization Resistance.

The corrosion current (icorr) can be calculated from the equation icorr = B / Rp

Where Rp is polarization resistance obtained from the slope, B is considered as 26mV for

concrete [19]

The corrosion rate in terms of corrosion density (Icorr) is given by Icorr= icorr/A, where A is

the polarized area.

The corrosion density for all the days is plotted and shown in Fig. 7.

Figure 7 Corrosion rate calculated from LSV method

-600

-500

-400

-300

-200

-100

0

100

0 20 40 60 80 100 120 140P

ote

nti

al

(mV

)

Time (days)


-5E-10

0

5E-10

1E-09

1.5E-09

2E-09

2.5E-09

3E-09

3.5E-09

0 20 40 60 80 100 120 140

Co

rro

sio

n d

en

sity

(μ

A/c

m2)

Hu

nd

red

s

Time (days)




In the initial days, the corrosion rate is almost same for all the specimens, but as the days

passed the trend is changed and zeolite has very low corrosion density and thus it offers very

high corrosion resistance when compared to remaining specimens.

3.6. Tafel Polarization Method

A Tafel plot is performed on a metal specimen by polarizing the specimen about 300 mV

anodically (positive-going potential) and cathodically (negative going potential). The

corrosion current, Icorr, is obtained from a Tafel plot by extrapolating the linear portion of the

curve. After extrapolation the corrosion current and potential are obtained directly and will be

shown by electrochemical analyzer. The corrosion density obtained for different specimens

are plotted and shown in Fig. 8.

Figure 8 Corrosion rate calculated from Tafel Polarization method

From the above plot, it is clear that in the initial days all the specimens except 3C are

having low corrosion density, but as the days passed zeolite offered best corrosion resistance

at all the time.

In the present paper, the corrosion resistance offered by the modifications in steel and

concrete is studied. As per the study conducted on water absorption of the micro silica and

zeolite, it is revealed that 10% replacement of cement with micro silica and zeolite resulted in

less water absorption. This is because all the small voids are filled up by the micro-silica and

zeolite admixtures which make the concrete impermeable. From the compressive test results,

it is clear that both micro-silica and zeolite induced specimens have higher compressive

strength than the control specimens and the highest compressive strength is accounted for

micro-silica.

As per the study conducted on the pull-out strength of different specimens, it is concluded

that all the specimens have higher bond strength when compared with the control specimen.

The highest bond strength is accounted for 3G specimen. So, by the addition of admixtures

and wrapping the steel, there is no adverse effect on the bond strength.

Based on the different methods that are used to measure corrosion rate for different

samples, it is clear that from half-cell electrical potential method and open circuit potential

method; zeolite offers higher corrosion resistance as it has very low negative potential when

compared to remaining specimens. From Linear Polarization Resistance (LPR) and Tafel

Polarization methods, it is understood that in the initial stages, all the specimens are having

-2E-09

0

2E-09

4E-09

6E-09

8E-09

1E-08

0 40 80 120

Co

rro

sio

n d

ensi

ty

(μA

/cm

2)

Hu

nd

red

s

Time (days)



Reinforcement Bars


less corrosion current but as the days passes the trend is changed and lowest corrosion current

is offered by zeolite when compared with remaining specimens.

4. CONCLUSIONS

The present paper reports a study on the modifications in concrete and steel to reduce the rate

of corrosion of steel reinforcement bars. The concrete is modified by replacing cement with

micro-silica and zeolite admixtures which fills all the small pores present in the cement and

makes concrete impermeable. In case of steel modification, CFRP and GFRP sheets are

wrapped around the steel bar which acts as a secondary reinforcement (barrier) for the

passage of water.

From the experiments conducted on water absorption, the lowest water absorption is

obtained for specimens with 10% replacement of cement with micro-silica and zeolite.

Based on the test results on compressive strength, it is clear that micro-silica induced

specimens have higher compressive strength when compared to control specimens and zeolite

induced specimens.

From the pull-out test conducted on all the different type of specimens, specimens

wrapped with 3 layers of glass fiber showed highest bond strength when compared to

remaining specimens.

From all the electrochemical methods conducted for measuring the rate of corrosion, it

can be concluded that zeolite offers better corrosion resistance when compared to remaining

specimens.

So, from all the above results it is clear that addition of 10% zeolite gives less water

absorption, good compressive strength, appreciable bond strength, better corrosion resistance

when compared with different specimens.

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study on corrosion resistance in concrete by …the effect of mineral admixtures like nano-silica,...

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