EXPERIMENTAL WORK
3.1 General
The experimental work dealt with the preparation and testing of
constituents of concrete mixes according to standard specifications to produce
high quality concrete having corrosion resistance in aggressive solutions.
However, physical tests included: compressive strength, water absorption and
electrical resistance tests were employed. The investigation of corrosion problem
of embedded steel in concrete in term of time to corrosion initiation was
conducted using half-cell potential system, while accelerated corrosion technique
was used to measure corrosion current with time to cracking of concrete cover
due to reinforcement steel corrosion in chloride solution and chloride-sulfate
containing solution. The effect of water reducing agent admixture (HRWRA
additive) on the reinforcement corrosion was also studied and evaluated. The
details of experimental work, properties and specifications of materials, mix
proportions and concrete tests are presented in this chapter. Figure (3.1)
illustrates the details of the experimental program adopted throughout the present
study.
27
Chapter Three
Experimental Work
a) Materials
Cement
sulfate Portland cement, type V, ASTM C 150 [56], commercially known
(valkon), produced in Pakstan was used in the present study. The chemical
composition and physical properties testing were carried out in the "Laboratory
of Civil-Engineering Department-College of Engineering-University of Basra".
The results indicated that the cement conformed to Iraqi specifications No.
5/1984 [57], appendix (A) Tables (A1 and A2).
Fine Aggregate
Natural sand from Al-Zubair, Basra south region was used. The sulfate
and chloride content and sieve analysis of the fine aggregate used are illustrated
in appendix (A) Tables (A3 and A4), respectively. These conformed to Iraqi
specifications No.45/1984 [58].
Coarse Aggregate
Crushed gravel of 19mm maximum size was used as coarse aggregate.
The sulfate and chloride content and sieve analysis results of the coarse
aggregate are illustrated in appendix (A) Tables (A3 and A5), respectively.
These conformed to Iraqi specifications No.45/1984 [58].
High Range Water Reducing Admixture (HRWRA)
High range water reducing admixture (HRWRA) superplasticizer, sold
commercially as (plastocrete-N) was used. It is a chemical base of Modified
28
Chapter Three
Experimental Work
c) Reinforcement Steel
For corrosion testing measurements, deformed steel bars of 12 mm
diameter and 200 mm length were used for the test of reinforcement specimens.
The chemical composition (wt %) was carried out using "Spectrometric
Analytical Instrument" (TXC25 model, 1200137, Germany), in the applied
mechanics laboratory-Department of Mechanical Engineering-College of
Engineering-University of Basra. The results were shown in Table 3.1. Three
tensile bars specimens were tested in "the Laboratory of Manufacturing Process
Materials Engineering Department-College of Engineering-University of Basra".
The testing results for deformed bars (grade 40) were compared to the ASTM
A615/A615M-04b [60]. The results of testing of the properties of reinforcing
bars are presented in Table 3.2. All bars were treated according to the procedure
29
Chapter Three
Experimental Work
given by ASTM G1-03 [61] by pickling with a 10% sulfuric acid (H 2SO4)
solution for 5 minutes, and then rinsed in water prior to wire brushing to remove
any remaining rust. The bars were wipped with clean cloth and allowed to airdrying. Then un-embedded end of the bar was coated with chemical resistance
epoxy paint (See appendix-C) then covered by electroplater's tape in order to
eliminate the crevice corrosion , leaving an inside 112.5 mm length of bar
uncovered.
Table 3.1 Chemical composition (wt %) of the used steel.
Fe
Si
Mn
Cr
Mo
98.500
0.200
0.080
0.900
0.005
0.005
0.085
0.003
Ni
Al
Co
Cu
Nb
Ti
0.025
0.010
0.010
0.028
0.003
0.003
0.003
0.025
Table 3.2 The results of testing of physical properties of deformed steel bars.
Properties
Test results
Yield
Ultimate
Elongation
strength
strength
(MPa)
(MPa)
400
572
16
280
420
12
ASTMA615/615M-04b
minimum. Limit
30
Chapter Three
Experimental Work
with cement content of 405 kg/m , while the effective water to cement ratio of
0.45. The mixing ratio 1: 1.5: 3 for cement, sand, and gravel respectively were
utilized in all the concrete mixtures. The materials were mixed by an electrically
driven batch mixer.
Six types of concrete mixes were prepared throughout the present study:
1. One concrete mix: this was prepared as reference concrete mix without any
admixture.
2. Four concrete mixes: containing super plasticizer in four percentages (0.125%,
0.250%, 0.375%, and 0.500% by weight of cement).
31
Chapter Three
Experimental Work
(3.1)
The water reduction reached its maximum value at the optimum dosage of
HRWRA. Table 3.3 shows the water reduction for various types of concretes
relative to reference concrete.
32
Chapter Three
Experimental Work
3. The remaining quantity of water was added and the mixture was mixed for
further two minutes and the water was adjusted to maintain a slump within the
range of 100 5 mm for each mix.
4. The molds were cleaned and oiled before casting and compacting then the
specimens were covered with polyethylene sheets to prevent moisture
evaporation from the concrete surface.
Table 3.3 The proportions of HRWRA admixture for each mix and w/c
reduction calculated from equation 3.1.
Type of mixes
Reduction in W/C
Symbol of mix
HRWRA %
W/C
ratio
Ratio
Ref.
0.000
0.45
0.000
MS1
0.125
0.43
4.445
MS2
0.250
0.42
6.667
MS3
0.375
0.40
11.111
MS4
0.500
0.37
17.780
Chapter Three
Experimental Work
Dimensions-mm
Type of Test
Performed
100x100
Compressive Strength
100x100
Water Absorption
100x100
Electrical resistance
75x150
Electrochemical Tests
20 Cylinder
34
Chapter Three
Experimental Work
oven, it was allowed to cool in dry air to a temperature of 20 to 25C and the
mass (A) was determined. The specimens were immersed again in solution for
48 h. It was surface-dried, by removing surface moisture with a moistened towel,
and its mass (B) was re-determined according to ASTM C 642-97. The
absorption after immersion can be determined according to following equation
[66]:
= (
) 100
(3.2)
Test Procedure
The D.C. electrical resistance measurements was carried out using a)
Power supply and b) two multimeters, for voltage and current measurements and
can be explained as follows:
1. The gap between the test specimens and the external brass plate
electrodes was filled by cement paste with w/c ratio equal to that of
specimen tested itself , to avoid a significant change in resistivity.
2. The instruments are turned
on , and
the
high
performance
digital
Chapter Three
Experimental Work
D.C. voltage mode. While, the second digital multimeter was set on D.C. current
mode.
3. The specimens response to each voltage unity from 1-10 volts was recorded.
At every selected voltage, the simultaneous values of current were recorded. The
resistance of concrete was determined by the reverse slope of the line of voltagecurrent plot.
A) Test specimens
The concrete cylinders of 75x150 mm reinforced with central deformed
bar of 12 mm diameter were used as illustrated in Figure (3.8). The working
electrode is presented by 1 m long an isolated copper wire welded to the upper
portion of reinforcement bars thats exposed to air.
36
Chapter Three
Experimental Work
B) Test procedure
The half-cell potential measurements were carried out using a) reference
electrode-SCE and b) high performance digital voltmeter, as D.C. potential
measuring instrument and can be explained as follows:
1. The reinforcing steel is electrically connected to the positive terminal of
voltmeter and the reference electrode to the negative terminal of the same
voltmeter, Figure (3.9).
2. The reference electrode was placed adjacent to the working electrode of the
test specimen and only the porous end immersed in the solution, Figure (3.10).
3. The function switch of the voltmeter is turned to D.C , and the range
switch to 2 volt range, then the half-cell potential can be read directly on the
display of voltmeter. The results of half cell potentials can be interpreted
according to ASTM C876 [67] as in T able 3.5. The results obtained were shown
in the chapter of results and discussion.
Table 3.5 Corrosion interpretations (ASTM C876) [67].
Half-cell potential reading,
Corrosion activity
mV SCE
< -400
Severe corrosion
< -270
-120 to -270
> -120
37
Chapter Three
Experimental Work
38
Chapter Three
Experimental Work
hummered to remove the corroded bars. The corroded bars were cleaned with a
wire brush to ensure they were free of any adhering concrete or corrosion
products, and then soaked in a chemical solution (1:1 of HCl and water)
according to ASTM G1-03 method [61]. The clean bars were then reweighed and
the percentage mass loss for each bar was calculated based on equation (3.4)
% =
100
39
(3.4)
Chapter Three
Experimental Work
Preparation of Materials
Mixing
Fresh Concrete
Slump Test
Curing
Testing
Concrete Testing
Testing
Electrochemical Measurements
Half-cell
Potential
Measurement
s
Compressive
Strength Test
Absorption
Test
Accelerated
Corrosion
Measurement
s
Weight Loss
Electrical
Resistance
Test
40