Evaluation of Service Life of Reinforced Concrete Structures in The Middle East

American University
y in Dubai
A School of Engineering
Infrastructure Sustainability
and
Assessment Center
Evaluation of Service Life of Reinforced Concrete
Structures in the Middle East
By
MEDRC
2010 International Concrete Sustainability Conference, Dubai, UAE
What is Durability
Durability by definition is the ability of concrete to
resist weathering action, chemical attack, and
abrasion
b i while
hil maintaining
i t i i itits d
desired
i d engineering
i
i
properties
C
t ingredients,
i
di t proportions
ti
d iinteraction
t
ti
Concrete
and
Placement and curing
Concrete Sustainability and Durability

Concrete is Durable Construction Material
Enhancing Concrete Durability
Use of Supplementary Cementing Materials (SCM)
Extend the Structure Service Life
Minimize maintenance
Construction in the Middle East

First Generation of Construction (1970s)
Foreign codes
Ignorance of the unique environment of the
region
Poor quality concrete
Severe deterioration
Concrete Durability Parameters

Alkali Silica Reactivity (ASR)
Delayed Ettringite Formation
Sulphate Attack
Corrosion of reinforcing steel
Alkali Silica Reactivity

This is caused by reaction of certain
aggregates with alkali in cement to form
expansive gel that eventually leads to craking
Delayed Ettringite Formation

DEF is mainly associated with steam cured
precast members.
Curing temperature higher than 70 C leads
to formation of DEF cracking.
Thermal effects (mass concrete)
Use of SCM
Sulphate Attack
A reaction between sulphate ions and
calcium hydroxide and form gypsum and
ettringite.
BRE and ACI 201 Classification in UAE
Low w/c ration and use of SCM
Long-Term Sulfate Attack Study (PCA)
10
Corrosion
Deterioration of a material as a result of reaction
What is Corrosion
with its environment-M.G. Fontana
Destructive attack of a metal by chemical or

electrochemical reaction with its environment-H.H.
Uhling.
Metal corrode because they have a strong driving
force to return to their natural state
11
Requirements for Corrosion

Cathode
Anode
Electrolyte
Electrical connection between anode and cathode
12
Corrosion of Steel in Concrete

Cathode and anode sites co-exist on the Steel
The steel is the conductor,
conductor and
Concrete acts as electrolyte
13
14
15
Industrial Structures
16
Marine Structures
17
Corrosion damage on
reinforced concrete bridge
structures
18
Corrosion damage and catastrophic

failure in parking garages
19
Why Should We Care About Corrosion

Why Should we Care about Corrosion
Safety
Conservation of Resources
Cost
20
Cost of Corrosion
1995 report:
$300 Billion/yr (4.2% of the GNP)
2002 NACE Report:

$276 Billion/yr (3.1% of the GNP)
Utilities
35%
Transportation
p
22%
Infrastructure
16%
Government
15%
Production & Mfg. 13%
21
Cost of Corrosion in the GCC States2004

Kingdom of Bahrain
0.5 B.
State of Kuwait
2.17 B.
Sultanate of Oman
1.3 B.
State of Qatar
1.1 B.
Kingdom of Saudi Arabia
13.0 B.
United
Arab
Emirates
U it d A
bE
i t
3.7
B.
37B
22
Why Should We Care About Corrosion
Middle East Durability

Research Consortium
Program
23
Service Life
Hundred-Year Service Life

Requirement in the Region
24
25
26
Service Life
The period of time during which a structure meets or exceeds
Service Life
the minimum requirements set for it
Requirements limitation can be technical, functional or

economical
Durability
ASR
Sulfate attack
Corrosion
27
Kysti Tuutti
Tuuttis Service Life
Model
Loss of cross-section
Limit
End of
S i Lif
Service
Life
Low-quality
covercrete
Corrosion Rate
(m/year)
High-quality
covercrete
Time
28
DC/dt = D. d2C/dx2
C Chloride content
T time
X depth (from exposed surface)
D apparent diffusion coefficient
29
Diffusion
Surface
Concentration
Concentration Profile
Time = t
Depth, X
Courtesy: N. Carino
30
Ficks Second Law Solution

Fick
C x, t = Cs (Cs- Ci) x ERFC (x/sqrt (Dt)
Cx,t = the
h chloride
hl id concentration
i at concrete depth
d h x andd time
i t
Cs = the chloride concentration at the surface,
Ci = the initial chloride concentration,
D = the apparent chloride diffusion coefficient (m2/sec, in.2/year), and
ERFC is an error function
31
Chloride Diffusion Analysis

-
Cl Diffusion Coefficient Prediction
Results
0.16
Mean Cover
0.13
0.02
m /s
%
%
0.12
Max Cover
C
Min Cover
0.1
Prediction when
Corrosion initiated
0.08
Threshold Cl
0.06
Cl (% by wt. conncrete)
6.10E-13
D=
Cs =
Co =
0.14
0.04
Measured
Data
0.02
0
Fitted curve
0
10
20
30
40
Samples
C x = C sn (1 erf
x
t
2 D ca .t o .( ) n
to
50
60
70
80
90
100
Depth (mm)
Best Fit
32
Service Life
Hundred-Year Service Life

How to achieve it???
33
How to Achieve it
Concrete Mix Design
Use of corrosion inhibitor and other corrosion
preventive methods.
Construction practice
Curing, surface protection, curing temperature
Q
Q procedures
p
QA/QC
34
How to Achieve it,cont.
For Deep tunnels (inner tunnel)

tunnel), use of in-situ
concrete liner and HDPE liner
Closed Monitoring of Design Parameters
Crack limits
Concrete cover
35
MEDRC Experimental Program

Selected Concrete Mix Design.
Laboratory Tests
Service Life Prediction
Field Testing Stations
36
Selected Mix Designs

Mix Des. Mix 1
OPC
400
Mix 2
Mix 3
Mix 4
Mix 5
400
400
400
136
Mix 6
400
SRC
264
GGBS
MS
Fly Ash
Total
Cement
400
400
400
400
400
400
Water
200
200
200
160
160
160
w/c
0.50
0.5
0.5
0.4
0.4
0.4
37
Selected Mix Designs, cont.

Mix Des.
Mix 7
Mix 8
Mix 9
Mix
10
Mix
11
OPC
400
400
400
400
136
SRC
264
GGBS
32
MS
Fly Ash
120
Total
Cement
400
400
Water
160
w/c
0 40
0.40
20
264
20
120
80
400
400
400
160
160
160
160
04
0.4
04
0.4
04
0.4
04
0.4
38
Concrete Mixing
39
Concrete Mixing
40
Laboratory Testing Program

Standard Durability tests.
ASTM G 109 Testing Program
Service Life Monitoring Parameters
41
Standard Durability Tests

Water Permeability, BS EN 12390/DIN 1048
Water Absorption,
Absorption BS 1881-122
Rapid Chloride Penetration, ASTM C 1202
42
RCPT
R id Chl
Rapid
Chloride
id permeability
bilit T
Testt
An Acceptance Test???
43
ASTM G 109 Test
44
ASTM G 109 Test
45
ASTM G 109 Specimens
46
Specimen Preparation
47
Specimens Preparation
48
49
50
51
52
Service Life Prediction Parameters

Chloride Migration Coefficient Test NT Build 492
Diffusion Coefficient Test NT Build 443
53
Chloride Migration Coefficient NT 492
54
Chloride Migration Coefficient NT 492
55
NT Build 443 Diffusion Coefficient

Coating specimens
Immersion in salt solution for 35 days
Use grinded powder samples for chloride
measurement and developing chloride profile
Curve-fitting chloride profile to Ficks second law.
56
Field Testing Stations

Selected Concrete mixes
Relatively large-scale specimens
Long-term marine exposure
Corrosion activity monitoring
Correlation with Laboratory finding
57
Selected Sites
The selected sites cover most of the ME marine
exposure conditions
Arabian Gulf exposure (Dubai)
Dead Sea
Mediterranean Sea
58
Progress Test Results

Chloride Permeability
Chloride Migration Coefficient-NT Build 492
Diffusion Coefficient-NT Build 443
59
RCP Test Results
60
Migration Coef. Vs. Diffusion Coef.
61
62
What Is A Durability Assurance Plan ?

A management process which gives an
Asset Owner confidence that the asset
under construction will achieve its design life
f
l mechanism
h i
ffor allll parties
i iin the
h
A formal
construction process to maximize delivery of
a durable
d bl structure
t t
63
Why Durability Assessment Planning ?

Match the design with the environmental
conditions, service life, construction techniques
and maintenance requirements
Optimise the process of resource distribution
(i.e. money, materials & time)
Provides conduit between design, construction
& maintenance during service life
64
Conclusions
Arabian Peninsula and Gulf region is most corrosive
location in the world
Corrosion is the main durability factor leads to
deterioration of concrete structures
Use of Quality Concrete and corrosion protection
systems such as corrosion inhibitors is the key to
achieve the required service life
MEDRC focuses on assessing and optimizing the
service life of RC structures in the Middle East
This study will provide tools to the construction
community in the region to achieve long lasting
concrete.
t
65
Thank you
Questions?
66

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American University

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

Concrete Sustainability and Durability

2010 International Concrete Sustainability Conference, Dubai, UAE

Construction in the Middle East

2010 International Concrete Sustainability Conference, Dubai, UAE

Concrete Durability Parameters

2010 International Concrete Sustainability Conference, Dubai, UAE

Alkali Silica Reactivity

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

Delayed Ettringite Formation

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

Long-Term Sulfate Attack Study (PCA)

2010 International Concrete Sustainability Conference, Dubai, UAE

with its environment-M.G. Fontana

Destructive attack of a metal by chemical or

2010 International Concrete Sustainability Conference, Dubai, UAE

Requirements for Corrosion

2010 International Concrete Sustainability Conference, Dubai, UAE

Corrosion of Steel in Concrete

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

Corrosion damage and catastrophic

2010 International Concrete Sustainability Conference, Dubai, UAE

Why Should We Care About Corrosion

2010 International Concrete Sustainability Conference, Dubai, UAE

2002 NACE Report:

2010 International Concrete Sustainability Conference, Dubai, UAE

Cost of Corrosion in the GCC States2004

Kingdom of Saudi Arabia

2010 International Concrete Sustainability Conference, Dubai, UAE

Why Should We Care About Corrosion

Middle East Durability

2010 International Concrete Sustainability Conference, Dubai, UAE

Hundred-Year Service Life

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

the minimum requirements set for it

Requirements limitation can be technical, functional or

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

Ficks Second Law Solution

2010 International Concrete Sustainability Conference, Dubai, UAE

Chloride Diffusion Analysis

Cl Diffusion Coefficient Prediction

2010 International Concrete Sustainability Conference, Dubai, UAE

Hundred-Year Service Life

2010 International Concrete Sustainability Conference, Dubai, UAE

2010 International Concrete Sustainability Conference, Dubai, UAE

How to Achieve it,cont.

For Deep tunnels (inner tunnel)

2010 International Concrete Sustainability Conference, Dubai, UAE

MEDRC Experimental Program