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Central Electrochemical Research Institute, Corrosion Testing and Evaluation Division, CECRI Nagar, Karaikudi 630 006, India
Abstract
Various non-destructive quantitative techniques based on electrochemical methods for measuring the corrosion rate of steel embedded
in concrete have been used. The most important is the linear polarization method. In practice, this method gives lower corrosion rates of
steel in concrete due to inclusion of the resistance of the concrete in the measurement. In order to eliminate the resistance of the concrete,
a galvanostatic pulse method is used. In this method the current pulse is applied to the steel in concrete and the polarizing potential is
sampled after the switching off the pulse. The performance of the galvanostatic pulse technique for monitoring the corrosion of steel in
concrete has been assessed by comparing the corrosion rate values obtained by the weight loss method and linear polarization resistance
method for steel reinforced in M15, M20, M30 and M35 grade concrete containing 0–5% NaCl. It is found that the galvanostatic pulse
technique is able to give reliable corrosion rate values of steel in concrete.
2006 Elsevier Ltd. All rights reserved.
0958-9465/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.cemconcomp.2006.03.005
S. Sathiyanarayanan et al. / Cement & Concrete Composites 28 (2006) 630–637 631
influence of cover depth [14], its high resistivity and limited time constant involved in exponential decay has been uti-
oxygen access [15]. lized for estimating the polarization resistance (Rp) values
An acoustic method can successfully be applied to the by assuming a suitable value for the interfacial double
cases where the cracks have initiated internally without layer capacitance. Assumption of suitable double layer
any visible indications at the surface. A crude form of capacitance value for quantification purposes poses low
doing this is by sensibly hearing the characteristic hollow reliability. Hence a different methodology for deriving
sound by simply striking the surface with a hammer. the quantified data on corrosion rate without any such
Because of the corrosion of steel rebars, volume of rod assumption is very much needed. In this paper, the perfor-
increases due to the existence of corrosion products. This mance of the device developed based on galvanostatic pulse
increase in volume leads to crack initiation. Existence of method which can measure the polarized potential with
an internal crack can be judged by striking the surface with and without IR drop of the concrete is assessed for measur-
a hammer and distinguishing the hollow sound from that ing the corrosion rate of steel in concrete.
of a crack free concrete surface. Although this method
seems to be rather primitive, this is quite often used 2. Principle
successfully. A more sophisticated form of doing this pro-
cedure with the help of piezo electric transducers and In general, the galvanostatic pulse method is character-
advanced electronic system for the analysis is also available ized by impressing a small amplitude, short interval anodic
now a days [16,17]. This requires more practical experience current pulse, applied galvanostatically with the help of an
and interpreting capacity. external counter electrode over the concrete surface and
Even these acoustic techniques cannot be successfully analyzing the resultant change in potential of the steel
used immediately just after the attack of the passive layer reinforcement.
by aggressive ions and initiation of corrosion. As the ano- The potential transient for a given current step of DI to a
dic and cathodic areas are locally separated, electrochemi- typical Randles circuit under galvanostatic condition is
cal transport processes lead to the rust formation not given by
directly at the anodic sites. The corrosion products are gen-
erated at sites where Fe2+ ions and OH ions meet and the gt ¼ DIRc þ DIRp ð1 expðt=CRp ÞÞ ð1Þ
dissolving capacity of the iron hydroxide is exceeded.
Hence it takes some time for visual indications on the where gt is the total change in the potential of the test elec-
surface by the way of rust staining. trode, DIRc is the ohmic drop in the concrete, Rp and C are
Electrochemical noise measurements [18] used for pre- the polarization resistance and electrical double layer
dicting the localized corrosion phenomenon at laboratory capacitance of the corroding interface. Upon the interrup-
has been extended to predict the corrosion rate of steel tion of the current pulse, the ohmic drop contribution DIRc
rebar embedded in concrete [19,20] and a reasonable corre- is immediately lost by the electrode potential and a sudden
lation of potential noise vs corrosion rate has been fall of potential to a value within few microseconds gives
obtained. the actual polarization of the test specimen. In the absence
Electrochemical linear polarization resistance (LPR) of any further current, the potential decays exponentially
and AC impedance methods have been used to monitor with time according to
the corrosion of steel in concrete for a number of decades
[21–24]. Gonzalez et al. [25,26] reviewed the limitations gt =gmax ¼ expðt=CRp Þ ð2Þ
imposed by such LPR measurements for steel in concrete.
Glass et al. [27] have studied the sensitivity of time con- where gmax is the maximum polarization at the time of cur-
stants of potential-time constant on application of galvano- rent interruption and gt is the polarization at any instant of
static pulse to the reinforced steel in concrete. Suitable time.
model has been assigned which accurately fitted the tran- Typical schematic potential transient for a current
sient data of actively corroding steel in concrete. Gonzalez pulse under galvanostatic condition is shown in Fig. 1
et al. [28] have studied the relation between the time con- where an anodic current pulse (Fig. 1(a)) of amplitude
stant of potential transients with corrosion rate, the effect Di is impressed between the time t = t0 to t = t1. Upon
of magnitude of applied perturbing signal on corrosion rate applying the current pulse, the potential of the system
measurement and the effect of non-uniformity of the poten- shifts to a value equivalent to DIRc in few microseconds
tial distribution over the reinforcement surface. Birbilis and thereafter increases gradually to a maximum value
et al. [29] have proposed a circuit model for analyzing the gmax. At the instant of time t = t1 when the current pulse
transient response of steel in concrete. Newton and Sykes is switched off, the potential value drops suddenly to a
[30] have examined the galvanostatic pulse technique as value equivalent to DIRc (IR drop) and starts decaying
an alternative method of impedance analysis for steel exponentially. As the passive steel can easily be polarized,
corrosion in mortar under immersed condition. non-corroding reinforcement rod shows much higher
These earlier studies have been dealing with analyzing potential difference (Fig. 1(b)) than that of a corroding
the potential transient for calculation of Rp values. The (Fig. 1(c)).
632 S. Sathiyanarayanan et al. / Cement & Concrete Composites 28 (2006) 630–637
Table 1
Details of concrete mix proportions
Concrete Average Mix proportions
grade compressive
Cement Fine Course W/C
strength (MPa)
aggregate aggregate ratio
M15 15 1 1.56 2.24 0.50
M20 20 1 1.71 2.09 0.50
M30 30 1 1.14 1.86 0.38
M35 35 1 1.14 1.86 0.35
Fig. 3. Schematic diagram of special probe: (1) PVC; (2) reference
electrode; (3) hole for wetted sponge; (4) SS counter electrode; (5) wetted
sponge; (6) electrical connection for counter electrode.
Fig. 4. Photograph of the galvanostatic pulse instrument with probe and concrete sample.
634 S. Sathiyanarayanan et al. / Cement & Concrete Composites 28 (2006) 630–637
Potential ( V vs SCE )
2.0
2.0
Preceding results show how the developed instrument
1.5
can be used to predict qualitatively the corroded areas of
a reinforcing steel in concrete. The same measurement
can be used for getting quantified corrosion rate. Under
1.0
high anodic polarization conditions, leading to potential
shift in the tafel region, the current can be given as
0.5
ia ¼ icorr expð2:3ga =ba Þ ð6Þ
0.0 where ga is the overpotential, ba is the anodic tafel slope
and icorr is the corrosion current.
-0.5 The OFF potential is stored in the memory of the devel-
0 1 2 3 4 5
oped instrument which is the over potential (ga) without
Chloride Concentration ( % ) the incorporation of ohmic drop. The ba value of 0.07 V
Fig. 9. Potential value of steel in M35 grade concrete in the presence of for steel in concrete containing chloride has been found
chloride: (d) ON potential; (s) OFF potential; (j) open circuit potential. by Tafel polarization method [33]. Using this ba in the
Table 2
Experimental results with the developed instrument for steel in M20 concrete
Condition OCP V ON potential OFF potential Visual Corrosion rate (mmpy)
vs SCE V vs SCE V vs SCE observation [gravimetric method]
Chloride free +0.097 +3.83 +0.575 No corrosion Nil
+3% Chloride 0.342 +0.106 0.313 Moderately corroded 0.0570
+5% Chloride 0.413 0.265 0.406 Fully corroded 0.080
Chloride free but with 0.581 +0.605 +0.428 No corrosion Nil
continuous immersion in
3% NaCl for 18 months
636 S. Sathiyanarayanan et al. / Cement & Concrete Composites 28 (2006) 630–637
Table 3
Corrosion rates of steel in concrete obtained by galvanostatic pulse technique
Concrete Chloride OCP V OFF potential Polarization ga Corrosion rate
grade concentrations, % vs SCE V vs SCE V vs SCE (mmpy)
M15 0 0.024 0.603 0.579 4.375E10
1 0.213 0.189 0.024 0.036
3 0.321 0.316 0.005 0.068
5 0.299 0.295 0.004 0.070
M20 0 0.097 0.575 0.478 1.20E8
1 0.210 0.026 0.184 0.00001
3 0.342 0.313 0.029 0.031
5 0.413 0.406 0.007 0.064
M30 0 0.049 0.505 0.554 9.95E10
1 0.200 0.284 0.484 9.92E9
3 0.286 0.182 0.104 0.0026
5 0.431 0.411 0.020 0.041
M35 0 0.036 0.575 0.611 1.53E10
1 0.207 0.259 0.466 1.79E8
3 0.340 0.333 0.007 0.064
5 0.370 0.323 0.047 0.017
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