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Steen Rostam
ABSTRACT
Concrete has been the most important building material for more than 100
years, and is likely to remain so for the next century. The engineering challenges
of this building material and its development into world wide domination has intrigued researchers, designers and architects throughout the years. Therefore, no
other building material represents the centennial celebration of a technical university institute as legitimately as concrete.
Durability issues were threatening the general recognition of the merits of
concrete. Recent years valuable research will allow today's grossly over-simplistic
deem-to-satisfy design methods to be replaced by scientifically sound probabilistic service life design methods. The same reliability-based design procedures are
being used as used for structural design.
The problems to be met are multidisciplinary in nature. This requires coordinated efforts of all parties involved, which will reflect on future engineering
curricular now on the verge of being updating in this direction.
Introduction
Concrete is the most versatile and robust construction material available and has obtained a
dominating position in construction.
The formability of structural concrete represents its unique usefulness with remarkable architectural challenges as exemplified in Figure 1. Thus it becomes an economic disaster when
urban dwellings, large bridges, or major marine structures deteriorate just after a few years in
service.
The reasons for premature deterioration are very complex, Figure 2, but the main causes
have now been identified. It is essential to have these causes highlighted aiming at rectifying
design methods, construction procedures, material compositions as well as maintenance and
repair procedures, to ensure more reliable structures in the future.
Steen Rostam
With respect to deterioration, concrete structures have some important characteristic properties, which differ fundamentally from structures made from other structural materials. These
properties are the following (fib 1999):
The quality and the performance of concrete adopted at the design and contracting
stages are assumed values.
The true quality and performance characteristics of structural concrete are created
through the actual execution process during construction on site. Hence, this very short
period of time (hours and days) constitutes the most important phase during which the
true initial qualities are established.
If durability performance turns out to be sub-standard, this is most often not apparent
nor detectable until some time has passed due to the nature of the deterioration of concrete structures. The time passed before premature deterioration becomes apparent may
often be longer than the contracted liability period, but very much shorter than the service life expected by the owner.
To manage these special properties of concrete structures a durability based design concept, a
conscious execution, and a planned inspection and maintenance is needed.
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The main issue when deciding upon a specific service life is to clarify the event, which will
identify the end of the service life. The requirement for a specific service life performance of a
structure is therefore closely associated with the short and long-term costs of fulfilling this requirement. The owner must therefore acknowledge that he has to take decisions on both the
service life and on the performance requirements, and he must accept both the short and the
long-term costs associated with his decisions.
For the everyday building the national codes and regulations have defined society's service
life requirements - often not explicitly but implicitly through the standards and codified design
requirements. 50 years seems to be a general objective of most codes.
The Technical service life is the time in service until a defined unacceptable state of deterioration has been reached by the structure, see Figure 3. In the following the main focus will
be on how to design for a specific technical service life.
Figure 3:
Service life of
concrete structures. The wellknown two-phase modelling
of deterioration.
Environmental loading
With respect to service life design one of the most important decisions to be taken by the designer is the determination of the exposure conditions for which each member of a structure
shall be designed, as the structure itself has decisive influence on the future micro-climate to be
expected.
The exposure shall be related to the type and severity of deterioration that may result from
the exposure. In this respect a differentiation is needed between mechanisms deteriorating concrete and mechanisms leading to reinforcement corrosion.
Different parts of a structure may therefore be in different exposure conditions. Obvious
examples are the submerged, the tidal, the splash and the atmospheric zones of a marine structure, but also different geographic orientations (north/south/east/west, or seaward/landward
orientation) may be in different exposure classes. Even very local differences can be taken into
account such as vertical faces, horizontal surfaces facing upward (risk of ponding) or facing
downward.
Materials and structural resistance
Having identified the environmental aggressivity the next step of the durability design is to
identify the relevant degradation mechanisms. Mathematical models describing the time de-
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Initiation
1
Propagation
2
Time
Damage
Events
1
2
Depassivation
Cracking
Spalling
Collapse
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The initiation phase ends when the chloride concentration at the reinforcement reaches a
critical threshold value. Carbonation of concrete can be treated in a similar manner. Depassivation does not necessarily represent an undesirable state, as illustrated in Figure 4. However,
this event must have occurred before corrosion will begin.
Fick's 2nd law of diffusion is commonly used to model the penetration of chlorides into
concrete. The model provides also the basis for modelling the transition between passivation
and onset of corrosion by giving as a result the time until the critical chloride concentration
reaches the level of the reinforcement.
Solving the diffusion law leads to the following expression:
C(x, t)
C(x,t)
Cs
t
x
erf
D(t)
= Cs [1 - erf (
x
2 D(t ) t
)]
The corrosion process starts (onset of corrosion), when the chloride concentration at the level
of the reinforcement is higher than the critical value, Ccr.
In this equation the calculated surface chloride concentration Cs represents the environmental load and is taken as time independent. The chloride diffusion coefficient, D(t)
characterises the concretes ability to withstand the ingress of chlorides.
The chloride diffusion coefficient was earlier considered as time independent. However, it
has been confirmed both in laboratory and in-situ testing that this resistance is improved with
time. The time dependent diffusion coefficient may be expressed as:
t
D(t ) = D0 0
t
D0 is a measured reference chloride diffusion coefficient at the age t0. In a design phase the
concrete resistance D0 may be measured in the laboratory by a bulk diffusion test or by a migration test.
The exponent governs how fast the diffusion coefficient is improved with time. The decrease of the diffusion coefficient with age is due to a combined effect of continued hydration
of the concrete and ion exchange with the environment, such as physical and chemical binding
within the concrete.
Based on these formulae, the time to onset of corrosion may be calculated. This is a deterministic way of calculating service life using the mean values or fixed characteristic values of
the relevant parameters (concrete cover, surface chloride concentration, diffusion coefficient,
and critical chloride concentration). This type of calculation does not include the obvious uncertainty of the various parameters in a consistent manner.
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Corrosion of reinforcement
Normal reinforcement is very efficiently protected against corrosion when cast into a good
quality alkaline and chloride free concrete. This is the well-known unique benefit of using reinforced concrete structures in building and construction. Only when carbonation reaches the
level of the reinforcement, or more seriously, when chlorides in sufficient quantity reach the
surface of the reinforcement will the passivating effect be eliminated and corrosion may start.
Available corrosion models
Corrosion leads to the formation of expansive rust products leading eventually to cracking and
later spalling of the concrete cover. Models are available to calculate the rate of corrosion as
well as to determine the time to cracking and subsequent spalling of the concrete, see
(DuraCrete 1998, DuraCrete 1999).
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The corrosion rate is very sensitive to the electrolytic resistivity of the concrete, which in
turn is governed by the concrete mix and in particular by the moisture content in the concrete
and the oxygen availability. Hence, the corrosion rate is very low or negligible in dry concrete
due to low conductivity, and the corrosion rate is also very low in water saturated concrete
due to the low availability of oxygen.
Field tests and laboratory investigations have shown that a crack width at the surface of
about 1 mm could be a crude assumption of spalling being imminent.
Although such assumptions are very crude at this stage, it allows a rational calculation to
be made, and on this basis improved models can be developed. Basically it shall be emphasised
that a crude model based on some engineering evaluation is better than no model, and certainly
better than pure guesswork.
Design strategy
In principle two basically different design strategies for durability can be followed, (Rostam
and Schiessl 1994):
A. Avoid the degradation threatening the structure due to the type and aggressivity of the
environment.
B. Select an optimal material composition and structural detailing to resist, for a specified
period of use, the degradation threatening the structure.
Strategy A can be subdivided into three different types of measures:
A.1. Change the micro-environment, e.g. by tanking, membranes, coatings etc.
A.2. Select non-reactive, or inert, materials, e.g. stainless steel reinforcement, nonreactive aggregates, sulphate resistant cements, low alkali cements.
A.3. Inhibit the reactions, e.g. cathodic protection. The avoidance of frost attack by air
entrainment is also classified in this category.
Most of the measures indicated above do not provide a total protection. The effect of the
measures depends on a number of factors. For example, the efficiency of a coating depends on
the thickness of the coating, and on its permeability relative to the permeability of the concrete.
Strategy B represents different types of design provisions. For example corrosion protection could be achieved by selecting an appropriate cover and a suitable dense concrete mix. In
addition, the structure can be made more resistant against aggressive environments of different
sorts by appropriate detailing such as minimising the exposed concrete surface, by rounded
corners, and by adequate drainage.
Modelling of deterioration processes is only relevant for Strategy B. An outline of a procedure for Design Strategy B could be the following:
Start with the definition of the performance and service life criteria related to the environmental conditions to be expected.
The next important element is the realistic modelling of the actions (environment) and
the material resistance against these actions.
Based upon the performance criteria, performance tests are indispensable for quality
control purposes. The performance tests must be suitable both to check the potential
quality of the material under laboratory conditions and, even more important, the in
situ quality.
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Carbon steel
1.0
4.5
5.5
5.5 6
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Reinforcement = 6.1 %
Reinforcement = 8.3 %
Reinforcement = 13.1 %
Large
Large
Small
Rein forcemen t
Remaining works
Reinforcement
Concrete works
Remaining works
Rein forcemen t
Remaining works
Additional initial costs replacing black steel (BS) with stainless steel (SS)
50% BS to SS:
10% BS to SS:
5.0%
1.1%
7.0%
1.4%
11.0%
2.3%
Figure 7: Comparative costs for the design of three new concrete jetties in Norway
1995-1996, two large and one small jetty. The total costs for reinforcement placed in the form relative to the total construction costs. The increased construction costs if 50% or 10% of the reinforcement is replaced
with SSR at a unit weight price being 5 times the cost of ordinary mild
steel reinforcement, (Markeset 2000).
In Figure 7 the total initial cost of replacing some of the mild steel reinforcement with SSR is
presented for three real constructions made during the years 1995-1996. Although the cost of
SSR in this case is 5 times the cost of ordinary reinforcement the effect of introducing this
highly reliable and durable element in the most critical zones of an exposed structures turns
out to be marginal. Such experience will have a very positive economic effect if a whole life
cycle cost optimisation is performed.
A very valuable and convincing documentation of the performance of SSR in highly chloride contaminated concrete is presented by the 60 year old 2 km long concrete pier out into the
Mexican Gulf at Progreso in Mexico reinforced with stainless steel, see Figure 8. No corrosion
has taken place within the structure, despite the harsh environment and poor quality materials
used in the construction. The chloride levels, at the surface of the reinforcement were between
10 and 20 times the traditionally assumed corrosion threshold level, (Knudsen et al 1999).
The Danish contractor Christiani & Nielsen made this very foresighted design for durability in a very aggressive environment for concrete structures.
From a practical point of view the SSR technology is particularly interesting because it
"only" solves the corrosion problem. All other techniques and technologies within design, production and execution of reinforced concrete structures remain unchanged, a fact that is very
attractive to the traditionally very conservative construction industry.
As it is recognised that the most serious durability problem for concrete structures in the
Gulf Countries is reinforcement corrosion. It becomes evident that (fib 1999): The reliable
and readily availability of stainless steel reinforcement at reasonable and foreseeable prices
may change - or revolutionise - major parts of the building sector in aggressive environments,
simply by solving the corrosion problem.
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The planned inspection of the structure
Northern Europe
0.8
Middle East
0.7
Critical concentration
1
0.9
0.6
0.5
0.4
0.3
0.2
0.1
90
Northern Europe
80
Middle East
Acceptance criteria
70
60
50
40
30
20
10
0
0
20
34.1 40
0
60
68.2
80
100
20
34.1 40
48.6
60
68.2
80
91.0
100
Figure 10 highlights the fact that the deterministic approach only provides a 50% probability of
achieving the required 50 years corrosion free service life. This fact is often overlooked in
usual design for durability. If, say only a 10% risk of having corrosion initiated before 50 years
is considered acceptable, then much larger covers are required, as seen from Figure 10.
The deterministic approach used here is based on mean values of the governing parameters. In the probabilistic approach the mean values and their known or assumed uncertainties
are used together with the relevant distribution functions. This latter approach makes it not
only possible to relate cover thickness to probability of corrosion but also to quantify the consequences of differently chosen risks of corrosion. These consequences relate not only to concrete quality and cover thickness, but more importantly also to the economic consequences.
The Load-and-Resistance-Factor-Design (LRFD) for Service Life
Having decided the level of reliability required for the service life, then the design basis is
equivalent to the well-known situation for structural design. This means that the input parame-
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Figure11: Required concrete cover for service life of 50 and 100 years for the concrete jetty in the example, (Larssen 2000).
For the given acceptance limit (probability of corrosion initiation of 10 %) the cover thickness
needed for 50 years service life becomes 75 and 93 mm for a critical chloride concentration of
0.10 and 0.05 %, respectively. If the critical chloride concentration is 0.05 % the required
cover thickness becomes 93 mm for achieving the target service life of 50 years. However, if
the critical chloride concentration is 0.10 % a cover thickness of 93 mm gives 100 years service life. This illustrates the importance of the concrete cover, and the importance of the assumed threshold value for corrosion initiation.
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Figure 13: Mounting of proprietary corrosion sensors in existing quays. The picture
to the right shows the sensor, a temporary micro-amp meter and the
small titanium pin as cathode placed just above the instrument, (Schiessl
and Raupach 1992).
By taking sensor readings as part of a regular inspection routine, say each half-year or so, the
rate of chloride penetration can be determined with time, and updating of the assumed chloride
diffusion coefficient - or of the value of the ageing factor alpha - can be made. This will then
provide data for an updating of the residual service life of the structure.
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Steen Rostam
the critical parameters in the finished structure. This could conveniently be done and reported
as part of the handing-over of the structure from the contractor to the owner. This would provide a Birth Certificate, (Rostam 1999), which includes a first forecast of the service life,
based on factual data.
The Birth Certificate would then provide the basis for - and be part of - the future Maintenance Plan in support of the operation and maintenance of the structure in use.
At later inspections the service life data can be updated through renewed testing, and used to
update the expected residual service life as well as provide the necessary data for updating also
the Maintenance Plan, allowing preventive maintenance introduced at optimal timing. This
procedure will result in an ever-increasing accuracy of the residual service life forecast and help
minimise the maintenance costs.
Conclusions
Reliability based service life design is a multi-disciplinary engineering challenge
Transition from deem-to-satisfy durability design to reliability based service life design is a
multi-disciplinary challenge for the materials and structural engineering profession. Society
demands sustainable and environmentally friendly engineering solutions and owners demand
reliable service lives of structures. This will set new standards for future Research, Development and Education (R,D&E). Universities engineering curricular must adapt to the multidisciplinary demands, which will face future engineers. A Centennial celebration of an internationally renown R,D&E Institute is an appropriate occasion to synthesis its valuable past and project this into a new multidisciplinary format spearheading the new developments now so much
in demand.
Modelling of deterioration mechanisms is a key issue
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