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Organisationseinheit der BAM
This specification describes how corrosion monitoring is used to check the condition of reinforced and prestressed concrete members. In this specification, the term "corrosion monitoring" covers all methods in which it is possible to continuously track corrosion-relevant variables in the area of stationary, built-in sensors. This specification does not cover other possible methods, such as potential field measurements, involving the use of mobile, portable sensors that are placed temporarily on the membersurface to take measurements.
The corrosion resistance of aluminium surfaces is closely linked to the surfacecstate after a grinding process. For years, iron‐containing abrasive materials were suspected to lead to increased corrosion susceptibility after processing of aluminium surfaces. To prove a possible correlation between the iron content of an abrasive and the corrosion behaviour of aluminium components, scientific investigations and experimentally practical corrosion tests are necessary.
For the current investigation, specimens of a technical Al‐Si alloy from the same batch were used. The test specimens were mechanically ground with various resin‐bonded model abrasives containing different iron contents. The performed corrosion tests did not reveal a negative influence of the different iron‐containing abrasives on the corrosion behaviour of the Al–Si alloy.
However, the most sensitive measuring method (electrochemical noise)
showed differences in the surface activity depending on the type of abrasive.
Due to the large number of stainless steels with different chemical composition and different microstructure the selection of the suitable material represents a huge challenge. In order to facilitate the appropriate grade selection, in the current European standard EN 1993-1-4 a procedure is defined based on the use of a look-up table considering the key variables that influence the selection of stainless steels. The table uses descriptions that competent designers should be able to readily understand or define without prior knowledge. The output from the look-up table is used to select alloys based on a Corrosion Resistance Class (CRC) from I to V. The advantage of this approach is that the designer simply specifies the relevant CRC and does not need to consider in detail which of the many (very similar) alloys to specify.
Chloride contents at the steel–mortar interface that initiate steel corrosion were determined for carbon steel in alkali‐activated fly ash mortar for three different exposure conditions: exposure to 1 M NaCl solution; leaching in deionized water and then exposure to 1 M NaCl solution; and leaching in deionized water, aging in air at 20°C and natural CO2 concentration, and then exposure to 1 M NaCl solution. For comparison, a Portland cement mortar, exposed to 1 M NaCl solution, was studied. The median values of the corrosion‐initiating chloride contents (average over the full length of the rebar) in the alkali‐activated fly ash mortar varied between 0.35 and 1.05 wt% Cl with respect to binder, consistently lower than what was obtained for the Portland cement mortar, but with no clear trend regarding the exposure conditions. For most of the alkali‐activated fly ash mortar specimens, preferential corrosion at the connection between the working electrode and the external measurement setup was observed, while preferential corrosion did not occur for the Portland cement mortar. Scanning electron microscopy and auxiliary experiments in synthetic solutions indicated that this behavior was caused by inhomogeneities at the steel–mortar interface in the alkali‐activated mortar, likely due to its peculiar rheological properties in the fresh state.
Corrosion of steel reinforcement in concrete is one of the major deterioration mechanisms limiting the service life of reinforced concrete structures. While for conventional (Portland cement-based) concretes a great amount of experience exists in this regard, the factors that determine the onset of reinforcement corrosion in alkali-activated materials are incompletely understood yet. One aspect of corrosion protection is leaching and the accompanying changes of the concrete pore solution. In the present study, alkali-activated fly ash mortars with embedded carbon steel rebars were exposed to de-ionised water for periods up to 330 days, and the electrochemical response of the steel (free corrosion potential, polarisation resistance), the alteration of the mortar (ohmic resistance, mechanical strength, pore size distribution) as well as the pore solution composition were monitored. Although substantial alkali leaching was observed, the pH of the pore solution remained at values sufficient to protect the embedded steel from depassivation. The mortar did not exhibit indications of significant deterioration. Thus, the present results suggest that leaching is not critical for protection of steel reinforcement in alkali-activated fly ash mortars and concretes.
Corrosion behavior of galvanized reinforcement in chloride containing mortar and carbonated mortar
(2018)
Korrosionseigenschaften von feuerverzinktem Betonstahl unterscheiden sich grundlegend von herkömmlichen Betonstahl. In diesem Vortrag sind Beispiele für das Korrosionsverhalten in chloridhaltigen und carbonatisierten Mörteln dargestellt
Nine different stainless steel alloys were exposed for 5 years under marine environment and their corrosion behaviour was compared and assessed. The investigation of four different surface finishes for all alloys tested further enabled to consider industry-specific features of the surface finish for the material comparison. The results of the exposure tests yield conclusions regarding the influence of alloy composition, surface finish and exposure duration under marine environment. The three duplex stainless steels revealed excellent corrosion resistance even in case of crevices during the 5 years of exposure under the given exposure conditions. Also the molybdenum-alloyed ferritic steel 1.4521 showed good corrosion resistance comparable to the classical austenitic materials 1.4301 and 1.4404.
Alkali-activated fly ash mortars were studied with regard to durability-relevant transport coefficients and the electrochemical behaviour of embedded carbon steel bars on exposure of the mortars to leaching, carbonation and chloride penetration environments. The transport coefficients differed considerably between different formulations, being lowest for a mortar with BFS addition, but still acceptable for one of the purely fly ash-based mortars. Leaching over a period of ~300 days in de-ionized water did not lead to observable corrosion of the embedded steel, as shown by the electrochemical data and visual inspection of the steel. Exposure to 100 % CO2 atmosphere caused steel depassivation within approx. two weeks; in addition, indications of a deterioration of the mortar were observed. The results are discussed in the context of the different reaction products expected in high- and low-Ca alkali-activated binders, and the alterations caused by leaching and carbonation.
Electrochemical potential mapping according to guideline B3 of DGZfP (German Society for Nondestructive Testing) is a recognized technique for the localization of corroding reinforcing steels. In reinforced concrete structures the measured potentials are not necessarily directly linked to the corrosion likelihood of the reinforcing steel. The measured values may be significantly affected, different from, e.g., stress measurement, by different influences on the potential formation at the phase boundary metal/concrete itself as well as the acquisition procedure. Due to the complexity of influencing factors there is a risk that the results are misinterpreted. Therefore, in a training concept firstly the theoretical basics of the test method should be imparted. Then, frequently occurring practical situations of various influencing factors will be made accessible to the participants by a model object specially designed for this purpose. The aim is to impart profound knowledge concerning the characteristics of potential mapping for detecting corrosion of reinforcing steel in order to apply this technique in practice as reliable and economical test method.
The salinization and contamination of metal surfaces by chloride-containing aerosols is of great importance with regard to corrosion phenomena of damaged coated metal surfaces and stainless steels in the maritime sector and in offshore applications. Detailed questions have to be answered to clarify whether and to what extent salinization of the surface has an influence on the adhesion and durability of coatings in repairing applications and on pitting occurrence on stainless steels under atmospheric conditions. The questions arise which degree of salinization is reached after which period of time and how a defined and reproducible salinization can be simulated in the laboratory for further systematic investigations. The article is dedicated to these questions. Results of a field trial on the Island of Heligoland are presented and a simple procedure for a defined loading of metal surfaces with chlorides at a laboratory scale using a design of experiments (DoE) approach is introduced.
Alkali-activated materials such as geopolymers are currently receiving a lot of attention because of their potential to be used as binders for concrete with advantageous engineering properties and reduced manufacturing CO2 emissions. Knowledge of the durability of steel in these concretes and related properties of alkali-activated materials is a prerequisite for their application as building materials, if they are to be used for steel reinforced elements. However, to date only limited data exists on this topic. The present contribution focuses on durability-related transport properties of geopolymer-based mortars (as model systems for concrete). We report results of accelerated carbonation, rapid chloride migration (RCM) and air permeability measurements as well as porosity data for fly ash-based geopolymer mortars, including mixes containing ground granulated blast furnace slag (GGBFS). In addition, we report polarization resistance data and corrosion potential vs. time curves for carbon steel bars embedded in two of the fly ash-based geopolymer mortars and a CEM I-based mortar (as reference).
Despite comparable total porosities, the carbonation depths, the chloride migration coefficients and the air permeabilities of the mortars differed significantly. In general, the addition of GGBFS to the binders improved the performance (decreased transport coefficients); however, this was not found to be true for the air permeability in all cases. This latter effect can be explained by drying damage of the C-(A-)S-H gel in GGBFS-containing binders. On the other hand, low transport coefficients can also be achieved by optimization of the binder formulation without the addition of GGBFS, which is also reflected in the material’s air permeability. Thus, there exists no simple correlation between air permeability (of harshly dried mortars) and durability-related transport coefficients for the studied alkali-activated materials.
The corrosion potential vs. time curves in combination with polarization resistance values reveal that the steel reinforcement in geopolymer mortars assumed a passive state. However, this happened considerably later than for steel in CEM I-based mortars. The free corrosion potential of carbon steel reinforcement in the geopolymer mortars had different values than the free corrosion potential values for the CEM I-based mortar for both the active and the passive state; possible reasons for this behavior are discussed.
Carbon-based conductive coatings are complex composites, consisting of an organic or inorganic binder and conductive carbon components, for application as anodes in impressed current cathodic protection systems of reinforced concrete structures. The electrochemical properties of three coatings at different humidity and in saturated calcium hydroxide solution were studied by electrochemical methods, such as electrochemical impedance measurement, measuring of open circuit potential over time and galvanostatic polarization.
The presented investigations have proved the principal suitability of the KorroPad method to assess the passive layer stability of stainless steels. The electrochemical mode of action could be described in detail and limitations of the applicability have been demonstrated. The influence of different surface finishes has been investigated and verified by known methods for describing corrosion resistances. As a result, the increased corrosion susceptibility of two ground surfaces has been detected, but also the corrosion resistance of further surface finishes could be confirmed.
Carbon-based conductive coatings are complex composites, consisting of an organic or inorganic binder and conductive carbon components, for application as anodes in impressed current cathodic protection systems of reinforced concrete structures. The electrochemical properties of three coatings at different humidity and in saturated calcium hydroxide solution were studied by electrochemical methods, such as electrochemical impedance measurement, measuring of open circuit potential over time and galvanostatic polarization. The dissolved organic and inorganic carbons in electrolyte solution were quantified by using a photometric method. The structures of the coatings were investigated before and after the electrochemical tests by microscopy and scanning electron microscope/EDX analysis. The results of the electrochemical impedance measurements show that the tested coatings all have a relatively low resistance, which is between 100 and 200 Ω. The binder and the surface porosity influence the degradation behavior of those coatings. Especially the organic binder reacts with the strong alkaline medium under dissolving of organic carbon.
Steel in concrete is protected by the alkaline pore water environment and the resulting formation of a protective passive layer against corrosion. Adverse environmental conditions due to carbonation or chloride ingress can destroy the passive layer on the steel surface. Corrosion processes starting in those areas lead to uniform corrosion or local corrosion like pitting corrosion. In comparison to uniform corrosion pitting corrosion is a form of increased local corrosion and thus leads to a progressive reduction in cross-section of the reinforcing steel. The corrosion products are first absorbed by the pores of the concrete matrix, without causing visible external changes at the concrete surface.
Carbon‐based conductive coatings are complex composites, consisting of an organic or inorganic binder and conductive carbon components, for application as anodes in impressed current cathodic protection systems of reinforced concrete structures. The electrochemical properties of three coatings at different humidity and in saturated calcium hydroxide solution were studied by electrochemical methods, such as electrochemical impedance measurement, measuring of open circuit potential over time and galvanostatic polarization. The dissolved organic and inorganic carbons in electrolyte solution were quantified by using a photometric method. The structures of the coatings were investigated before and after the electrochemical tests by microscopy and scanning electron microscope/EDX analysis. The results of the electrochemical impedance measurements show that the tested coatings all have a relatively low resistance, which is between 100 and 200V. The binder and the surface porosity influence the degradation behavior of those coatings. Especially the organic binder reacts with the strong alkaline medium under dissolving of organic carbon.
Systematic laboratory and field exposure tests allow to compare nine different stainless steels (three ferritic, three austenitic, and three duplex grades) for civil engineering applications. The influence of surface finish was also taken into account by choosing five different industry-specific features. The three duplex stainless steels revealed excellent corrosion resistance under most of the test conditions. Especially for applications in civil engineering the lean duplex steels offer distinct advantages. The manganese-alloyed 1.4376 and the ferritic steel 1.4509 cannot be recommended as alternative materials as they did not perform satisfactorily.
Electrochemical half-cell potential measurements for the detection of reinforcement corrosion
(2014)
This specification describes the application of electrochemical half‐cell potential measurements (frequently also called potential mapping) for the detection of reinforcement corrosion in reinforced concrete structures. Areas of corroding reinforcement steel can be located in a nondestructive manner by means of this procedure. Half‐cell potential measurements are used in order to detect chloride‐induced corrosion. However, it is not recommended in order to assess the risk of carbonation‐induced corrosion. For this purpose the determination of the carbonation depth and the concrete cover appear to be more appropriate.
The content of this specification exclusively refers to the application of mobile, local variable reference electrodes, which are only placed on the concrete surface while measuring. The technique distinguishes itself thereby from the range of corrosion monitoring systems with stationary installed reference electrodes and sensor systems, respectively, whereby it is possible to continuously track measurements within the area of the installed electrodes. However, these methods are not dealt with in this specification.
Case studies
(2013)
In this paper, some quite different survey tasks are described, and it can be seen that corrosion surveys will follow a certain scheme of data acquisition (first NDT measurements, than detailed testing on suspect areas), but the individual scope of on-site measurements may have a vast variety according to the local circumstances, and the interpretation always has to refer to a wider set of information than the data readings only.
In addition to constructional requirements in civil engineering stainless steels often have to fulfil high visual demands. Unexpected impairments of the visual appearance of stainless steels under low corrosive conditions are a widespread problem today. Frequently it is supposed that this is caused by changes in the alloy composition, worse environmental conditions or improper handling. Within a research project the systematic investigation of several cases of damaged stainless steel bars has shown that the reasons are based on well-known material defects like chemical inhomogeneities (e.g. precipitations or local carburization) or geometrical defects (e.g. undercuts, rolling defects or shell formation). Thus, the failures could be clearly identified as production failures of the respective semi-finished products.
The reduction of the chromate contents in cements affects the electrochemical reactions of galvanized reinforcing steels in fresh concrete. By means of electrochemical measurements and bar pull-out tests the effect of chromates on the formation of protective coatings at the zinc and the bond behaviour have been investigated using chromate-containing and chromate-reduced cements. The results have shown that the bond zone was affected as a result of chromate reduction for cement types CEM I and CEM II. The disturbance to the bond zone should be considered as long-term in relation to the pore structure which is formed. The effects on the bond are largely compensated for as the concrete ages. The results of the related bond strength with displacement paths of 0.1 and 0.5?mm, respectively, are still within the range of expected figures for non-galvanized reinforcing steel despite the structural disturbance. Under practical aspects it is not necessary that the existing structural disturbance with respect to bond strength is taken into consideration.
In indoor swimming pools stainless steels are used not only due to structural and economic reasons but also due to aesthetic considerations. And therefore not only safety relevant load bearing components have to fulfil their tasks but also the visual appearance should be free of any staining. In a lot of cases basic requirements (e.g. design criteria, material selection and maintenance) being essential parts of technical regulations were not taken into account. Typical case studies with explanation of the cause of the corrosion problems and possibilities to prevent them are shown in the present paper.
Risk of stress corrosion cracking of prestressing steels in contact with galvanized components
(2010)
Investigations of corrosion on small cathodes in reinforced concrete - observations and suggestions
(2009)
Corrosion of steel reinforcement in concrete exposed to chloride containing environments is a serious
problem in civil engineering practice. The standards and guidelines contain only minimum
requirements regarding concrete quality and concrete cover. In very critical cases, for example the
ingress of chlorides, the application of different coatings is currently the only possibility to protect the
reinforced concrete structures. In this case the modelling of reinforcement corrosion would be more
practical. One sub-project of a DFG-research project (FOR 537) is currently performed at the Federal
Institute for Materials Research and Testing (BAM). Aim of the sub-project is the description of
corrosion propagation and the characterization of the corrosion on specimens with small cathodes by
electrochemical parameters. The electrochemical parameters are determined by suitable
electrochemical measurements, considering concrete parameters as well as different environmental
conditions.
In order to clarify under which practical conditions real risks for hydrogen-induced stress corrosion cracking of prestressing steels exist laboratory investigations in aqueous solutions and concrete as well as tests with stressed prestressing steels were carried out. While different distances between steel and zinc (cathode and anode) showed only a negligible influence on the polarisation of the steel a significant dependence on the area ratio steel/zinc was observed. A critical area ratio of 10:1 can be defined above which polarisation of the steel to hydrogen evolution potentials is unlikely. The results obtained in the laboratory concerning the critical area ratio were confirmed by on-site investigations in a precasting plant. Exposure tests with hydrogen loading did not lead to fractures during the testing time for approved prestressing steels. The characteristic mechanical values determined immediately after the hydrogen loading tests did not show significant changes. Thus, an indirect contact between prestressing steels and galvanised elements can be estimated as uncritical. But a direct contact has to be excluded by compliance with DIN 1045-1, i.e minimal distance of 2 cm between prestressing steel and galvanised elements.
About the long-term protection behaviour of corrosion protection materials (filling materials) for prestressed systems under critical environmental conditions is only little known. The corrosion protection effect is usually based on theoretical considerations and is proven by short-term tests. The selection of the different products is mainly made according to economical or workability criteria. In a research project the barrier effect of different commercial corrosion protection materials (waxes as well as oil-based greases) against water, their tendency for undercutting as well as their additional corrosion protection effect were investigated. The exposure tests were carried out with non-stressed as well as stressed prestressing steel specimens which were subjected to critical conditions (condensed water, artificial soil solution, direct soil contact). Parallel to these long-term exposure tests the applicability of different electrochemical techniques and their significance with respect to testing the corrosion protection ability and water absorption was evaluated. Within the project a suitable method for simple testing the performance of corrosion protection materials under real conditions was developed. By means of a small compact cell submicroscopical reactions of the used sensors could be measured. The high sensitivity of this measuring technique enables the detection of degradation processes at thin protection layers.
Chloride-induced damage of reinforcing steel is especially for parking garages and bridges often very severe as large amounts of chlorides act on horizontal surfaces which could lead to fast ingress of these detrimental ions up to the level of the reinforcement and subsequently to high rates of corrosion.
In order to avoid the disadvantages of conventional rehabilitation (unreliable prognosis with patch repair or high costs and regular maintenance with cathodic protection using impressed current) a new combined protection system was developed where the principle of drying out the concrete (by means of a surface protection system) is combined with a temporary cathodic protection (by means of a sprayed zinc layer) during the transitional period of the drying out process.
This new system was tested both in the laboratory and on-site at a pilot application. Based on the results obtained the possibilities and limitations of the new system are discussed in this paper.
Use of Embeddable Sensors in an Integrated Monitoring System for Reinforced Concrete Structures
(2003)
Long-term experiences with cathodic corrosion protection of steel reinforced concrete structures
(2002)
Prestressing steels can be exposed in prestressed concrete structures in construction stage (ungrouted duct) to environmental conditions causing formation and growth of hydrogen induced cracks with brittle fracture of the steel. The risk of this hydrogen induced stress corrosion cracking can be minimized by appropriate treatment, but there is a requirement for construction to approve only prestressing steel having no enhanced susceptibility to stress corrosion cracking. The paper describes the historical development of the different test methods proposed in the past and gives an overview on the general requirements for a suitable test method to assess the hydrogen-induced stress corrosion susceptibility of prestressing steels.
Since 1982, based on investigations on construction sites and transfer of the results into laboratory tests, a test method is available enabling realistic estimation of suitable application possibilities of prestressing steels. This so called DIBt-test is approved to distinguish between prestressing steels susceptible to hydrogen induced stress corrosion cracking and those suitable and therefore approvable steels at practical environmental conditions. Furthermore the test enables estimation of corrosion risk for newly developed prestressing steels with higher strength.
Translated Abstract
Beurteilung der Prüfverfahren zur Untersuchung der Spannungsrisskorrosionsempfindlichkeit von Spannstählen
Spannstähle können in Spannbetonbauwerken im Bauzustand (unverpresstes Hüllrohr) Umgebungsbedingungen ausgesetzt sein, die zur Bildung und Ausbreitung wasserstoffinduzierter Risse mit Sprödbruch des Stahles führen können. Das Risiko dieser wasserstoffinduzierten Spannungsrisskorrosion kann einerseits durch eine sachgemäße Verarbeitung der Spannstähle minimiert werden, andererseits besteht die Notwendigkeit nur solche Spannstähle für die Baupraxis zuzulassen, die unter baupraktischen Bedingungen keine erhöhte Empfindlichkeit für Spannungsrisskorrosion besitzen. Die vorliegende Arbeit beschreibt die historische Entwicklung der verschiedenen vorgeschlagenen Prüfverfahren und gibt einen Überblick über die allgemeinen Anforderungen an ein geeignetes Verfahren zur Beurteilung der wasserstoffinduzierten Spannungsrisskorrosionsempfindlichkeit von Spannstählen.
Seit 1982 steht, begründet durch Untersuchungen auf Baustellen und Umsetzung der Ergebnisse in Laborversuchen, ein Prüfverfahren zur Verfügung, das eine wesentlich realistischere Einschätzung der Einsatzmöglichkeiten von Spannstählen zulässt. Dieser sog. DIBt-Test hat sich bewährt, um unter praktischen Umgebungsbedingungen gegen H-induzierte Spannungsrisskorrosion empfindliche Spannstähle von geeigneten und damit zulassungswürdigen Stählen zu unterscheiden. Des weiteren erlaubt die Prüfung ebenfalls eine Abschätzung des Korrosionsrisikos für neuentwickelte, höherfeste Spannstähle.