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Corrosion in Concrete

Critical Chloride Content in


Reinforced Concrete
Sonjoy Deb, B.Tech,’Civil’
Associate Editor

“The steel rebar inside reinforce concrete structures is susceptible to corrosion when permeation of chloride from deicing salts or
seawater results in the chloride content at the surface of the steel exceeding a critical chloride threshold level (CTL). The CTL is an
important influence on the service life of concrete structures exposed to chloride environments. The key factor on CTL was found to
be a physical condition of the steel–concrete interface, in terms of entrapped air void content, which is more dominant in CTL rather
than chloride binding, buffering capacity of cement matrix or binders.”

A
fter it was recognised in the second half of the last common causes of degradation of reinforced concrete
century that chloride may induce steel corrosion in structures. Both for the design of new structures and for
reinforced concrete structures, great research efforts condition assessment of existing structures, knowledge of
have been made in this regard: over the last fifty years, reliable CTL values is important as the remaining service
a considerable amount of papers has been published life is often considered as the time required to reach the
presenting values for critical threshold chloride content chloride threshold value at the depth of the reinforcement.
(CTL) in reinforced concrete. Considering marine exposure In probabilistic service life modelling, CTL has been
conditions and the extensive use of de-icing salts in many identified to be one of the most decisive input parameters.
countries, chloride induced corrosion is one of the most Despite the multitude of studies undertaken, many aspects

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Corrosion in Concrete

of chloride induced reinforcement corrosion in concrete are chloride content associated with visible or “acceptable”
still incompletely understood and no general agreement on deterioration of the reinforced concrete structure (Definition 2).
a CTL value has been achieved. Results reported in the
It has to be emphasized that the two definitions are related
literature scatter over a large range. This is not only the
to different phenomena: the de-passivation-criterion in
result of different definitions, measuring techniques and
Definition 1 only considers the initiation stage, whereas
testing conditions, but also owing to the stochastic nature
in the case of Definition 2 with visible or acceptable
and complexity of initiation of pitting corrosion. Thus, often
deterioration as a criterion, also the propagation stage is
conservative values are now a days used as critical chloride
included. As a result, the two definitions lead to different
content: In European countries as well as in North America
CTL values. Figure 1 illustrates this by combining Tuutti’s
it has become common practice to limit the tolerable
corrosion model with an assumed curve representing the
chloride content to or around 0.4% by weight of cement.
chloride concentration at the steel reinforcement vs. time.
In probabilistic modelling the critical chloride content is a
The figure clearly shows that using the practical definition
stochastic variable as e.g. in the fib model code for service
leads to higher CTL values. It is important to understand
life design, where CTL is defined by a beta distribution with
that this is only the result of a longer time passing until the
a lower boundary of 0.2% chloride by weight of cement
chloride content is determined. The rate at which corrosion
and a mean value of 0.6% by weight of cement. Although
proceeds has a large influence on when this is done and
there is a strong need for reliable CTL values, an accepted
thus greatly affects the chloride threshold value when
or standardized test method to measure critical chloride
applying this definition. Definition 1 is more precise, since it
does at present not exist. The present review summarises
expresses the chloride content that is directly related to de-
the state of the art regarding critical chloride content in
passivation. In Definition 2, the chloride content associated
reinforced concrete. It is not only aimed at collecting CTL
with an acceptable degree of corrosion has no theoretical
values reported in the literature, but also all the relevant
background: the amount of chloride that is measured at
details about experimental procedures are collated.
that time has nothing to do with the degree of corrosion
or the corrosion rate. Also the term “acceptable degree” is
imprecise and thus definition 2 results in a larger scatter of
CTL values. In the literature, these two definitions are often
mixed up. Care has thus to be taken when comparing and
evaluating results reported by different researchers.

Initiation Propagation

high corrosion rate


Degree of corrosion

low corrosion rate


acceptable
deterioration

Marine exposure and the extensive use of de-icing salts in many countries are Time
the most common causes of degradation of reinforced concrete structures
Chloride concentration
at reinforcement

Concept of critical chloride content 2

Reinforcement corrosion in non-carbonated, alkaline 2


concrete can only start once the chloride content at the 1
steel surface has reached a certain threshold value. In the
literature, this value is often referred to as critical chloride
content or chloride threshold value. In the present work CTL Time
is used. Two different ways of defining CTL are common:
1 Threshold according to scientific definition (depassivation)
From a scientific point of view, the critical chloride content
Threshold according to practical definition
can be defined as the chloride content required for de- 2
(visible or “acceptable” deterioration)
passivation of the steel (Definition 1),whereas from a
practical engineering point of view CTL is usually the Figure 1: Definitions for chloride thresholds (based on Tuutti’s model)

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Corrosion in Concrete

Expression of CTL this. These proposals have been challenged by current


thinking, when considering that (1) bound chlorides at the
- Free chloride content
steel depth are released to form free chlorides when the
The representation of CTL reflects the aggressive ion pH drops due to depassivation, and (2) cement hydration
content and inhibitive properties of the cement matrix. products such as calcium hydroxide resist a fall in pH at a
Chloride ions which are removed from the pore solution particular value of the pH. It should be noted that current
as the result of an interaction with the solid matrix (bound guidelines and standards do not address the free chloride
chloride) are relatively immobile and may not be transported content in relation to corrosion risk, largely for the reasons
to the steel surface. This should in theory favour the use mentioned above. The free chloride content is more often
of the free chloride content (water soluble chloride) to expressed as a function of hydroxyl ion concentration in the
represent the CTL. Results by Petters on show a wide range pore solution, or the mole ratio of chloride to hydroxylions.
of the CTL values in terms of free chloride concentration,
- [Cl-]:[OH+]
ranging from 0.28 to 1.8 M in mortar specimens with
water/cement ratios between 0.3 and0.75. More recent This approach assumes that bound chlorides are not a risk
works by Alonso et al. reported CTL values in terms of free to corrosion, and that the hydroxyl ion concentration reflects
chloride content by weight of cement, ranging from 0.3% the inhibitor content of the environment by sustaining the
to 2.0%.Early works suggested that only the free chloride high pH of the pore solution. In early works, the relation
contributes to the corrosion process and hence the free between free chloride and hydroxyl concentration was used
chloride content was regarded as the best expression of to express the CTL in terms of the ratio of free chloride to

Table: Chloride threshold level reported by various authors with varying conditions
Condition Threshold Values Detection method Reference
Total chloride (%, cem.) Free Chloride (%, cem.) [Cl ]/[OH ]
– –

Pore solution 0.6 Half-cell potential [2]


0.3 Polarisation [33]
Specimen + internal C1” 8–63 Polarisation [34]
0.5–2.0 Macrocell current [1]
0.079–0.19 AC impedance [81]
0.32–1.9 Mass loss [14]
0.78–0.93 0.11–0.12 0.16–0.26 Half-cell potential [12]
0.45 (SRPC) 0.10 0.27
0.90 (15% PFA) 0.11 0.19
0.68 (30% PFA) 0.07 0.21
0.97 (30% GGBS) 0.03 0.23
0.35–1.00 0.14–0.22 C1”/OH” = 0.3 [48]
Speciment + external C1” 0.227 0.364 1.5 Polarisation [28]
0.5–1.5 Half-cell potential [11]
0.70 (OPC) Mass loss [15]
0.65 (15% PFA)
0.50 (30% PFA)
0.20 (50% PFA)
1.8–2.9 Polarisation [26]
0.5–1.4 Non mentioned [25]
0.6–1.4 Macrocell [50]
Structure 0.2–1.5 Mass loss [3]
Note: SRPC: sulphate resistant Portland cement, PFA: pulverised fly ash, GGBS: ground granulated blast furnace slag, OPC: ordinary Portland cement.

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Corrosion in Concrete

hydroxyl concentration. This expression of the CTL is still cement (SRPC), 30% pulverized fly ash (PFA) and 65%
currently used. A threshold ratio varying from 0.3 to 40.0, as ground granulated blast furnace slag (GGBS), respectively.
given in Table 1, was reported. Thomas determined the CTL of OPC and 30% PFA content
as 0.7% and 0.5% by weight of cement, respectively. Based
- Total chloride
on these data, the CTL for OPC and 30% PFA equate to
The representation of the CTL by the total chloride level the same mole ratio of 0.01[Cl-]:[H+]. A mole ratio of
is the most widely used approach, and is the approach 0.01 also approximates to 0.65% and 0.5% chloride by
adopted in standards. Table 2 gives the limit of the total weight of cement in SRPC and 65% GGBS concretes,
chloride content of concrete from each standard. The respectively. The ratio of total chloride to ANC is probably
representation of the CTL as the total chloride content as the best representation of the CTL, since it considers all
a percentage by weight of cement, is favored because it potentially important inhibitive (cement hydration products)
is relatively easy to determine and because it involves the and aggressive (total chloride) factors.
corrosion risk of bound chloride and the inhibitive effect
Influencing parameters
of cement hydration products. At the stage of corrosion
initiation, the pH in the vicinity of the steel falls locally as From an electrochemical point of view, it is the potential
a result of an electro chemical reaction with chloride and of the steel, Ecorr, relative to the pitting potential, Epit, that
ferrous ions during pit nucleation. Corrosion is initiated in determines whether corrosion will start or not. The pitting
the form of pitting where the local pH falls below 10. The potential depends on both environmental influences
drop in pH releases at least 90% of the total surrounding (chloride content) and on properties of the metal such
chloride ions to participate in the corrosion process with as the degree of alloying (e.g. stainless steel). The open
access to oxygen and water as well as chloride accelerating circuit potential of the passive steel, on the other hand, only
the rate of corrosion. This suggests that the total chloride depends on the environment (pH and oxygen content).
content is a more accurate indicator of corrosion risk and Where as parts of the steel electrode are in contact with
the inhibitive nature of cement may thus be better reflected the concrete pore liquid, others might be covered with
by the total cement content rather than the pore solution hydration products and thus to a certain extent be shielded
pH. Hence, the total chloride content to cement weight from aggressive species in solution. The critical chloride
is the better representation of the CTL because (1) the content in concrete is thus not only a matter of pure electro
inhibitive properties of cement matrix are reflected by its chemistry, but also of physical protection of the steel
cement content and (2) the total aggressive potential of electrode. Numerous parameters affect the value of CTL
chloride ions is represented. and many of them are interrelated:

- [Cl-]:[H+] - Steel–concrete interface

In a recent work, it was suggested that a more appropriate - Concentration of hydroxide ions in the pore solution (pH)
representation of the inhibitive and aggressive properties of - Electrochemical potential of the steel
concrete is provided, respectively, by its acid neutralization - Binder type
capacity (ANC) and acid soluble chloride content. The
- Surface condition of the steel
acid neutralization capacity has been used to quantify the
buffering capacity of concrete. The content of acid needed - Moisture content of the concrete
to reduce the pH of concrete and cement paste suspended - Oxygen availability at the steel surface
in water, up to a particular value, has been reported by - w/b ratio
Sergi and Glass. The acid (moles H+/kg binder) required
to reduce the pH to 10 was determined as 18.9, 17.5, - Electrical resistivity of the concrete
15.4 and 14.5 mol/kg for OPC, sulfate resisting Portland - Degree of hydration

Table 2: Maximum chloride content values set by various ACI and BS documents
Type Maximum chloride content (%, cem.)
BS 8110 ACI 201 ACI 357 ACI 222
Prestressed concrete 0.10 0.06 0.08
Reinforced concrete exposed to chloride in service 0.20 0.10 0.10 0.20
Reinforced concrete that will be dry or protected from moisture in service 0.40
Other reinforced concrete 0.15

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Corrosion in Concrete

- Chemical composition of the steel Barrier coating


- Temperature
- Chloride source (mixed-in initially or penetrated into The corrosion of reinforcement in concrete can be
hardened concrete) prevented by coating the steel with epoxy, which stops
aggressive ions reaching the steel surface. Care is required
- Type of cation accompanying the chloride ion
in the handling, transporting, storing and placing of epoxy-
- Presence of other species, e.g. inhibiting substances.
coated steel since damage can impair its corrosion pro-
It has been suggested to consider the condition of the
steel–concrete interface as the most dominating influencing
factor, together with the pH of the concrete pore solution
and the steel potential.

The variety of factors involved indicates that the concept of


critical chloride content faces some difficulties regarding a
unique chloride threshold value applicable to a wide range
of structures.

Raising threshold values

- Corrosion inhibitors

The advantage of using corrosion inhibitors to provide


corrosion protection is that the inhibitor is well distributed
throughout the concrete, which means that it protects all the
steel. A corrosion inhibitor modifies the surface chemistry
of steel to mitigate or prevent the corrosion process. While Hot dipped galvanized steel coil
numerous corrosion inhibitors have been suggested, the
tection performance. Erdogdu et al. showed that the
detrimental effects of many of them in concrete limit their
corrosion rate of coated steel bars was below 0.01 mA/m2
commercial use. Calcium nitrite has been widely used
after 25 months exposure, compared to 2–100 mA/m2 for
as a corrosion inhibitor in concrete since the middle of
uncoated steel bars after 5 months exposure. Al-Amoudiet
the 1970s, because of its inhibiting effect as well as its
al. showed the effect on CTL of epoxy-coated steel with
compatibility with concrete. It enhances the compressive
various degrees of coating damage. With 1% damage to
strength at an early age, and accelerates the setting time
the coating, the CTL was about 2% by weight of cement,
within the range recommended by standards.
while at 2% damage, the CTL was below 0.4%.
- Coating of reinforcing steel Recent studies have shown that epoxy-coated steel can
give good, long term performance even on severe exposure
Galvanisation
to chloride conditions and considering the effects of bond
A galvanised (zinc) coating acts both as a sacrificial loss when properly coated and handled. Cement-based
coating in protecting steel. It is reported in laboratory and coatings rather than resin coatings have been suggested
field studies that galvanising increases the CTL. Treadaway because they perform better due to the higher bond strength
et al. showed that galvanised steel in a concrete structure as well as corrosion protection.
exposed to corrosive conditions delayed the initiation
of corrosion and resulted in a CTL of 0.9% by weight of
cement. The results of the monitoring of concrete structures
in seaside environments over an 8–23 year period
suggested a CTL of 0.64% when using galvanised steel,
while untreated steel showed a CTL of 0.2%. Bautista and
Gonzalez found that the corrosion rate for galvanised steels
was much lower than that for bare steel; the corrosion rate
for galvanised steel ranged from 0.2 to 1.2 lA/cm2, while for
bare steel it ranged from 0.4 to 10 lA/cm2 after 12 months
exposure to a chloride solution. The inhibiting effect of
galvanizing appears to be enhanced in high-performance
concrete, with the time to corrosion considerably delayed. Liquid Epoxy Coatings for steel

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Corrosion in Concrete

Conclusion at the steel–concrete interfaces (i.e. a reduction of


bond), which may be attributed to hydrogen evolutionor
The present study revealed the following conclusions, with smooth surface of coating, restricts the use in concrete
respect to CTL representation, influencing factors, and structures.
methods to raise the CTL.
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