Carbon steel

Reinforced concrete (RC) is the building block of modern architecture and industry. The failure of which is costly and dangerous. Typically made with carbon steel rebars, corrosion resistant alloys provide an alternative method of delaying failure. Stainless steels, while more expensive than carbon steels, provide excellent corrosion resistance, but less is known about the long term monitoring of corrosion activity for stainless steel than for carbon steel. This study looks at samples prepared between 2005 and 2009 using 304SS, 316SS, and 2304SS rebars, as well as SMI and Stelax stainless steel clad carbon steel reinforcements embedded in three different concrete mixes. These selected samples are split into two exposure environments, inside humidity chambers within the laboratory and outdoor exposure. Measurements reported here were made monthly over the course of 250 plus days using the Galvanostatic Pulse method, Electrochemical Impedance Spectroscopy, and a Gecor 8 device. These methods were used to determine corrosion current, isolated corrosion current density, and solution resistance.
Corrosion current density values calculated from measurements by the Galvanostatic Pulse and Electrochemical Impedance Spectroscopy method are too small to indicate corrosion, based on value ranges provided by Andrade. However, Gecor 8 corrosion current density values indicate low levels or moderate levels of corrosion for all samples compared to the Andrade’s value ranges. The area used by the Gecor is unknown, so it’s possible this is driving up the measured values.

A significant amount of reinforced concrete structures in the USA are reaching the design life span of 50 years. Degradation of these infrastructure due to corrosion presents an economical, safety and quality of life challenge for our society. Being able to study and determine the conditions of our infrastructure, perform maintenance before failure and predict failure before occurrence has become critical for our society and our way of life. This study was performed to add to existing research in the understanding of the relationships between the corrosion current of the embedded carbon steel rebars in reinforced concrete, rebar mass loss due to corrosion and the degradation of the mechanical properties of the carbon steel embedded in high performance concrete structures. The study also aimed to study the influence of different independent variables such as the chloride solution reservoir size and the concrete composition of the prepared specimens for the study.
Specimens for the study were prepared by embedding three carbon steel size #4 rebars in blocks of high performing concrete with different admixture to enhance their performance against corrosion. To initiate corrosion specimens were exposed to accelerated chloride transport method (electromigration). To accelerate corrosion some samples were selected for anodic polarization and additional electromigration.
After corrosion initiation, the rebars Open Circuit Potential (OCP) and corrosion current (Icorr) were periodically measured using a galvanostat device from April 2017 to August 2021. The OCP average values showed that all the rebars considered in this study were in active corrosion. Faraday’s law was used to determine the rebar calculated mass loss from the measured corrosion current and the elapse time between measurements. The rebar mass loss was in turn used to model the loss of the physical properties of the rebar (yield strength, ultimate strength, and ultimate strain) using (Vanama & Ramakrishnan, 2020) model. Analysis of these parameters results showed a direct relationship between the measured corrosion current and the calculated mass loss of the corroding rebar. The study also showed a direct relationship between the calculated mass loss of the corroding rebar and the degradation of the physical properties of the rebar.

The Florida Department of Transportation (FDOT) has been using supplementary cementitious materials while constructing steel reinforced concrete marine bridge structures for over three decades. It has been found from previous studies that such additions in concrete mix makes the concrete more durable. This research was conducted to better understand the corrosion propagation stage of steel rebar embedded in high performance concrete exposed to high humidity environment. Reinforced concrete samples that were made with binary mixes, and ternary mixes were considered. None of these concretes had any admixed chloride to start with. An accelerated chloride transport method was used to drive chloride ions into the concrete so that chlorides reached and exceed the chloride threshold at the rebar surface and hence the corrosion process initiated after a short period of time (within few days to few months). Once corrosion has initiated the corrosion propagation can be studied. Electrochemical measurements such as rebar potential measurements, Linear Polarization Resistance (LPR), Electrochemical Impedance Spectroscopy (EIS), and Galvanostatic Pulse (GP) measurements were taken at regular intervals (during and after the electro-migration process) to observe the corrosion propagation in each sample. During the propagation stage, reinforcement eventually reached negative potentials values (i.e., Ecorr≤ –0.200 Vsce) for all the samples. The corrected polarization resistance (Rc) was calculated by subtracting the concrete solution resistance from the apparent polarization resistance measured. The Rc values obtained from LPR and GP measurements were converted to corrosion current (as the corroding area is unknown), and these corrosion current values measured over time were used to obtain the calculated mass loss (using Faraday’s Law). A comparison was made of the calculated corrosion current obtained using the LPR and GP tests. A comparison of mass loss was also obtained from the values measured from LPR and GP tests. From the experimental results, it was observed that the corrosion current values were largely dependent on the length of solution reservoirs. For specimens cast with single rebar as well as three rebars, the most recent corrosion current values (measurements taken between July 2018 to October 2020) in general were larger for the rebars that are embedded in specimens prepared with SL mix, followed by specimens prepared with FA, T1, and T2 mixes respectively. The range of corrosion current values (most recent) were 0.8-33.8 μA for SL samples, 0.5-22.5 μA for FA samples, 0.8-14.8 μA for T1 samples, and 0.7-10.4 μA for T2 samples respectively. It was also found that the calculated mass loss values were larger for rebars that are embedded in specimens (single rebar and three rebars) prepared with SL mix, followed by specimens prepared with FA, T1, and T2 mixes respectively. The range of calculated mass loss values were 0.07-1.13 grams for SL samples, 0.06-0.62 grams for FA samples, 0.12-0.54 grams for T1 samples, and 0.06-0.40 grams for T2 samples respectively. A variety of corrosion related parameters (Ecorr, Rs, Rc, and Icorr) and calculated theoretical mass loss values observed, were due to the changing parameters such as concrete compositions, concrete cover thickness, rebar diameter, total ampere-hour applied, and reservoir size. The specimens showed no visual signs of corrosion such as cracks or corrosion products that reached the concrete surface. The actual size of the corroding sites was unknown as the specimens were not terminated for forensic analysis. The size of the corroding sites could affect how much corrosion products are required to crack the concrete. It is speculated that the corrosion products in liquid form penetrated the pore structure but did not build up enough to cause cracks. No cracks or corrosion bleed outs were observed within the monitored propagation period of approximately 1600 days.