An experimental and numerical study of the pattern of cracking of concrete due to steel reinforcement corrosion

In this work, cracking of concrete due to steel reinforcement corrosion is experimentally and numerically studied. The tests combined accelerated corrosion—to generate the cracks—with impregnation under vacuum with resin containing fluorescein—to enhance their visibility under ultraviolet light. In parallel, a model—called expansive joint element—was developed to simulate the expansion of the oxide and finite elements with an embedded adaptable cohesive crack were used to describe concrete cracking. The results show that a good agreement exists between the experimental and numerical crack patterns, which constitutes promising progress towards a comprehensive understanding of corrosion-induced cracking in reinforced concrete.

Cover cracking of the reinforced concrete due to rebar corrosion induced by chloride penetration

This paper is focused on the problem of the chloride-induced corrosion of the rebar in reinforced concrete, with special application to the slabs and decks of the bridges. High superficial concentrations may be usual in these structures (marine environments or de-icing salts in roadway bridges, e.g.). Like any aggressive agent such as water, gases or other dissolved ions, chloride induced deterioration is very conditioned by possibilities of transport through concrete mass.

Cover cracking of the reinforced concrete due to rebar corrosion induced by chloride penetration

Este artículo estudia el proceso de fisuración del hormigón por corrosión de la armadura. Se presenta un modelo de transporte de cloruros en el hormigón, que contempla la no-linealidad de los coeficientes de difusión, las isotermas de absorción y el fenómeno de convección. A partir de los resultados de penetración de cloruros, se establece la corrosión de la armadura con la consiguiente expansión radial. La fisuración del hormigón se estudia con un modelo de fisura embebida. Los dos modelos (iniciación y propagación) se incorporan en un programa de elementos finitos. El modelo se contrasta con resultados experimentales, obteniéndose un buen ajuste. Una de las dificultades es establecer el umbral de concentración de cloruros que da lugar al inicio de la corrosión de la armadura.This paper is focused on the chloride-induced corrosion of the rebar in RC. A comprehensive model for the chloride ingress into concrete is presented, with special attention to non-linear diffusion coefficients, chloride binding isotherms and convection phenomena. Based on the results of chloride diffusion, subsequent active corrosion is assumed and the radial expansion of the corroded reinforcement reproduced. For cracking simulation, the Strong Discontinuity Approach is applied. Both models (initiation and propagation corrosion stages) are incorporated in the same finite element program and chained. Comparisons with experimental results are carried out, with reasonably good agreements being obtained, especially for cracking patterns. Major limitations refer to difficulties to establish precise levels of basic data such as the chloride ion content at concrete surface, the chloride threshold concentration that triggers active corrosion, the rate of oxide production or the rust mechanical properties.

Fracture of concrete structural members subjected to blast

If reinforced concrete structures are to be safe under extreme impulsive loadings such as explosions, a broad understanding of the fracture mechanics of concrete under such events is needed. Most buildings and infrastructures which are likely to be subjected to terrorist attacks are borne by a reinforced concrete (RC) structure. Up to some years ago, the traditional method used to study the ability of RC structures to withstand explosions consisted on a choice between handmade calculations, affordable but inaccurate and unreliable, and full scale experimental tests involving explosions, expensive and not available for many civil institutions. In this context, during the last years numerical simulations have arisen as the most effective method to analyze structures under such events. However, for accurate numerical simulations, reliable constitutive models are needed. Assuming that failure of concrete elements subjected to blast is primarily governed by the tensile behavior, a constitutive model has been built that accounts only for failure under tension while it behaves as elastic without failure under compression. Failure under tension is based on the Cohesive Crack Model. Moreover, the constitutive model has been used to simulate the experimental structural response of reinforced concrete slabs subjected to blast. The results of the numerical simulations with the aforementioned constitutive model show its ability of representing accurately the structural response of the RC elements under study. The simplicity of the model, which does not account for failure under compression, as already mentioned, confirms that the ability of reinforced concrete structures to withstand blast loads is primarily governed by tensile strength.

Experimental and numerical analysis of concrete Slabs subjected to Blast

This paper summarizes the research activities focused on the behaviour of concrete and concrete structures subjected to blast loading carried out by the Department of Materials Science of the Technical University of Madrid (PUM). These activities comprise the design and construction of a test bench that allows for testing up to four planar concrete specimens with one single explosion, the study of the performance of different protection concepts for concrete structures and, finally, the development of a numerical model for the simulation of concrete structural elements subjected to blast. Up to date 6 different types of concrete have been studied, from plain normal strength concrete, to high strength concrete, including also fibre reinforced concretes with different types of fibres. The numerical model is based on the Cohesive Crack Model approach, and has been developed for the LSDYNA finite element code through a user programmed subroutine. Despite its simplicity, the model is able to predict the failure patterns of the concrete slabs tested with a high level of accuracy

Behaviour of Concrete Structural Members Subjected to Air Blast Loading

Numerical analysis is a suitable tool in the design of complex reinforced concrete structures under extreme impulsive loadings such as impacts or explosions at close range. Such events may be the result of terrorist attacks. Reinforced concrete is commonly used for buildings and infrastructures. For this reason, the ability to accurately run numerical simulations of concrete elements subjected to blast loading is needed. In this context, reliable constitutive models for concrete are of capital importance. In this research numerical simulations using two different constitutive models for concrete (Continuous Surface Cap Model and Brittle Damage Model) have been carried out using LS-DYNA. Two experimental benchmark tests have been taken as reference. The results of the numerical simulations with the aforementioned constitutive models show different abilities to accurately represent the structural response of the reinforced concrete elements studied.

Cover cracking of reinforced concrete due to rebar corrosión induced by chloride penetration

Este artículo estudia el proceso de fisuración del hormigón por corrosión de la armadura. Se presenta un modelo de transporte de cloruros en el hormigón, que contempla la no-linealidad de los coeficientes de difusión, las isotermas de absorción y el fenómeno de convección. A partir de los resultados de penetración de cloruros, se establece la corrosión de la armadura con la consiguiente expansión radial. La fisuración del hormigón se estudia con un modelo de fisura embebida. Los dos modelos (iniciación y propagación) se incorporan en un programa de elementos finitos. El modelo se contrasta con resultados experimentales, obteniéndose un buen ajuste. Una de las dificultades es establecer el umbral de concentración de cloruros que da lugar al inicio de la corrosión de la armadura.This paper is focused on the chloride-induced corrosion of the rebar in RC. A comprehensive model for the chloride ingress into concrete is presented, with special attention to non-linear diffusion coefficients, chloride binding isotherms and convection phenomena. Based on the results of chloride diffusion, subsequent active corrosion is assumed and the radial expansion of the corroded reinforcement reproduced. For cracking simulation, the Strong Discontinuity Approach is applied. Both models (initiation and propagation corrosion stages) are incorporated in the same finite element program and chained. Comparisons with experimental results are carried out, with reasonably good agreements being obtained, especially for cracking patterns. Major limitations refer to difficulties to establish precise levels of basic data such as the chloride ion content at concrete surface, the chloride threshold concentration that triggers active corrosion, the rate of oxide production or the rust mechanical properties.

Design of a 3D printing capable of creating multiple objects simultaneously

Proyecto de Fin de Carrera de Ingenieria Industrial, versando sobre el completo diseño de una impresora 3D

Experimental and numerical study of bond response in structural concrete with corroded steel bars

Corrosion can affect the bond between reinforcing bars and concrete and hence the transfer of longitudinal stresses. Although a number of experimental studies on bond failure have been conducted in recent years, the findings have diverged rather widely, due primarily to differing test conditions. The present paper reports on an experimental programme consisting of eccentric pull-out tests run on corroded steel bars in specimens subjected to accelerated or natural corrosion. An axisymmetric bi-dimensional FE model with finite deformations initially developed to study bond mechanics with sound steel bars, has been enhanced to consider bond effects in corroded steel bars. The model simulation is compared to some of the experimental results for corroded and sound bars and the findings are analysed.

Experimental and numerical study of cracking of concrete due to reinforcement corrosion

La corrosión del acero es una de las patologías más importantes que afectan a las estructuras de hormigón armado que están expuestas a ambientes marinos o al ataque de sales fundentes. Cuando se produce corrosión, se genera una capa de óxido alrededor de la superficie de las armaduras, que ocupa un volumen mayor que el acero inicial; como consecuencia, el óxido ejerce presiones internas en el hormigón circundante, que lleva a la fisuración y, ocasionalmente, al desprendimiento del recubrimiento de hormigón. Durante los últimos años, numerosos estudios han contribuido a ampliar el conocimiento sobre el proceso de fisuración; sin embargo, aún existen muchas incertidumbres respecto al comportamiento mecánico de la capa de óxido, que es fundamental para predecir la fisuración. Por ello, en esta tesis se ha desarrollado y aplicado una metodología, para mejorar el conocimiento respecto al comportamiento del sistema acero-óxido-hormigón, combinando experimentos y simulaciones numéricas. Se han realizado ensayos de corrosión acelerada en condiciones de laboratorio, utilizando la técnica de corriente impresa. Con el objetivo de obtener información cercana a la capa de acero, como muestras se seleccionaron prismas de hormigón con un tubo de acero liso como armadura, que se diseñaron para conseguir la formación de una única fisura principal en el recubrimiento. Durante los ensayos, las muestras se equiparon con instrumentos especialmente diseñados para medir la variación de diámetro y volumen interior de los tubos, y se midió la apertura de la fisura principal utilizando un extensómetro comercial, adaptado a la geometría de las muestras. Las condiciones de contorno se diseñaron cuidadosamente para que los campos de corriente y deformación fuesen planos durante los ensayos, resultando en corrosión uniforme a lo largo del tubo, para poder reproducir los ensayos en simulaciones numéricas. Se ensayaron series con varias densidades de corriente y varias profundidades de corrosión. De manera complementaria, el comportamiento en fractura del hormigón se caracterizó en ensayos independientes, y se midió la pérdida gravimétrica de los tubos siguiendo procedimientos estándar. En todos los ensayos, la fisura principal creció muy despacio durante las primeras micras de profundidad de corrosión, pero después de una cierta profundidad crítica, la fisura se desarrolló completamente, con un aumento rápido de su apertura; la densidad de corriente influye en la profundidad de corrosión crítica. Las variaciones de diámetro interior y de volumen interior de los tubos mostraron tendencias diferentes entre sí, lo que indica que la deformación del tubo no fue uniforme. Después de la corrosión acelerada, las muestras se cortaron en rebanadas, que se utilizaron en ensayos post-corrosión. El patrón de fisuración se estudió a lo largo del tubo, en rebanadas que se impregnaron en vacío con resina y fluoresceína para mejorar la visibilidad de las fisuras bajo luz ultravioleta, y se estudió la presencia de óxido dentro de las grietas. En todas las muestras, se formó una fisura principal en el recubrimiento, infiltrada con óxido, y varias fisuras secundarias finas alrededor del tubo; el número de fisuras varió con la profundidad de corrosión de las muestras. Para muestras con la misma corrosión, el número de fisuras y su posición fue diferente entre muestras y entre secciones de una misma muestra, debido a la heterogeneidad del hormigón. Finalmente, se investigó la adherencia entre el acero y el hormigón, utilizando un dispositivo diseñado para empujar el tubo en el hormigón. Las curvas de tensión frente a desplazamiento del tubo presentaron un pico marcado, seguido de un descenso constante; la profundidad de corrosión y la apertura de fisura de las muestras influyeron notablemente en la tensión residual del ensayo. Para simular la fisuración del hormigón causada por la corrosión de las armaduras, se programó un modelo numérico. Éste combina elementos finitos con fisura embebida adaptable que reproducen la fractura del hormigón conforme al modelo de fisura cohesiva estándar, y elementos de interfaz llamados elementos junta expansiva, que se programaron específicamente para reproducir la expansión volumétrica del óxido y que incorporan su comportamiento mecánico. En el elemento junta expansiva se implementó un fenómeno de despegue, concretamente de deslizamiento y separación, que resultó fundamental para obtener localización de fisuras adecuada, y que se consiguió con una fuerte reducción de la rigidez tangencial y la rigidez en tracción del óxido. Con este modelo, se realizaron simulaciones de los ensayos, utilizando modelos bidimensionales de las muestras con elementos finitos. Como datos para el comportamiento en fractura del hormigón, se utilizaron las propiedades determinadas en experimentos. Para el óxido, inicialmente se supuso un comportamiento fluido, con deslizamiento y separación casi perfectos. Después, se realizó un ajuste de los parámetros del elemento junta expansiva para reproducir los resultados experimentales. Se observó que variaciones en la rigidez normal del óxido apenas afectaban a los resultados, y que los demás parámetros apenas afectaban a la apertura de fisura; sin embargo, la deformación del tubo resultó ser muy sensible a variaciones en los parámetros del óxido, debido a la flexibilidad de la pared de los tubos, lo que resultó fundamental para determinar indirectamente los valores de los parámetros constitutivos del óxido. Finalmente, se realizaron simulaciones definitivas de los ensayos. El modelo reprodujo la profundidad de corrosión crítica y el comportamiento final de las curvas experimentales; se comprobó que la variación de diámetro interior de los tubos está fuertemente influenciada por su posición relativa respecto a la fisura principal, en concordancia con los resultados experimentales. De la comparación de los resultados experimentales y numéricos, se pudo extraer información sobre las propiedades del óxido que de otra manera no habría podido obtenerse. Corrosion of steel is one of the main pathologies affecting reinforced concrete structures exposed to marine environments or to molten salt. When corrosion occurs, an oxide layer develops around the reinforcement surface, which occupies a greater volume than the initial steel; thus, it induces internal pressure on the surrounding concrete that leads to cracking and, eventually, to full-spalling of the concrete cover. During the last years much effort has been devoted to understand the process of cracking; however, there is still a lack of knowledge regarding the mechanical behavior of the oxide layer, which is essential in the prediction of cracking. Thus, a methodology has been developed and applied in this thesis to gain further understanding of the behavior of the steel-oxide-concrete system, combining experiments and numerical simulations. Accelerated corrosion tests were carried out in laboratory conditions, using the impressed current technique. To get experimental information close to the oxide layer, concrete prisms with a smooth steel tube as reinforcement were selected as specimens, which were designed to get a single main crack across the cover. During the tests, the specimens were equipped with instruments that were specially designed to measure the variation of inner diameter and volume of the tubes, and the width of the main crack was recorded using a commercial extensometer that was adapted to the geometry of the specimens. The boundary conditions were carefully designed so that plane current and strain fields were expected during the tests, resulting in nearly uniform corrosion along the length of the tube, so that the tests could be reproduced in numerical simulations. Series of tests were carried out with various current densities and corrosion depths. Complementarily, the fracture behavior of concrete was characterized in independent tests, and the gravimetric loss of the steel tubes was determined by standard means. In all the tests, the main crack grew very slowly during the first microns of corrosion depth, but after a critical corrosion depth it fully developed and opened faster; the current density influenced the critical corrosion depth. The variation of inner diameter and inner volume of the tubes had different trends, which indicates that the deformation of the tube was not uniform. After accelerated corrosion, the specimens were cut into slices, which were used in post-corrosion tests. The pattern of cracking along the reinforcement was investigated in slices that were impregnated under vacuum with resin containing fluorescein to enhance the visibility of cracks under ultraviolet lightening and a study was carried out to assess the presence of oxide into the cracks. In all the specimens, a main crack developed through the concrete cover, which was infiltrated with oxide, and several thin secondary cracks around the reinforcement; the number of cracks diminished with the corrosion depth of the specimen. For specimens with the same corrosion, the number of cracks and their position varied from one specimen to another and between cross-sections of a given specimen, due to the heterogeneity of concrete. Finally, the bond between the steel and the concrete was investigated, using a device designed to push the tubes of steel in the concrete. The curves of stress versus displacement of the tube presented a marked peak, followed by a steady descent, with notably influence of the corrosion depth and the crack width on the residual stress. To simulate cracking of concrete due to corrosion of the reinforcement, a numerical model was implemented. It combines finite elements with an embedded adaptable crack that reproduces cracking of concrete according to the basic cohesive model, and interface elements so-called expansive joint elements, which were specially designed to reproduce the volumetric expansion of oxide and incorporate its mechanical behavior. In the expansive joint element, a debonding effect was implemented consisting of sliding and separation, which was proved to be essential to achieve proper localization of cracks, and was achieved by strongly reducing the shear and the tensile stiffnesses of the oxide. With that model, simulations of the accelerated corrosion tests were carried out on 2- dimensional finite element models of the specimens. For the fracture behavior of concrete, the properties experimentally determined were used as input. For the oxide, initially a fluidlike behavior was assumed with nearly perfect sliding and separation; then the parameters of the expansive joint element were modified to fit the experimental results. Changes in the bulk modulus of the oxide barely affected the results and changes in the remaining parameters had a moderate effect on the predicted crack width; however, the deformation of the tube was very sensitive to variations in the parameters of oxide, due to the flexibility of the tube wall, which was crucial for indirect determination of the constitutive parameters of oxide. Finally, definitive simulations of the tests were carried out. The model reproduced the critical corrosion depth and the final behavior of the experimental curves; it was assessed that the variation of inner diameter of the tubes is highly influenced by its relative position with respect to the main crack, in accordance with the experimental observations. From the comparison of the experimental and numerical results, some properties of the mechanical behavior of the oxide were disclosed that otherwise could not have been measured.

Effects of traffic loads on reinforced concrete railroad culverts

In the context of the present conference paper culverts are defined as an opening or conduit passing through an embankment usually for the purpose of conveying water or providing safe pedestrian and animal crossings under rail infrastructure. The clear opening of culverts may reach values of up to 12m however, values around 3m are encountered much more frequently. Depending on the topography, the number of culverts is about 10 times that of bridges. In spite of this, their dynamic behavior has received far less attention than that of bridges. The fundamental frequency of culverts is considerably higher than that of bridges even in the case of short span bridges. As the operational speed of modern high-speed passenger rail systems rises, higher frequencies are excited and thus more energy is encountered in frequency bands where the fundamental frequency of box culverts is located. Many research efforts have been spent on the subject of ballast instability due to bridge resonance, since it was first observed when high-speed trains were introduced to the Paris/Lyon rail line. To prevent this phenomenon from occurring, design codes establish a limit value for the vertical deck acceleration. Obviously one needs some sort of numerical model in order to estimate this acceleration level and at that point things get quite complicated. Not only acceleration but also displacement values are of interest e.g. to estimate the impact factor. According to design manuals the structural design should consider the depth of cover, trench width and condition, bedding type, backfill material, and compaction. The same applies to the numerical model however, the question is: What type of model is appropriate for this job? A 3D model including the embankment and an important part of the soil underneath the culvert is computationally very expensive and hard to justify taking into account the associated costs. Consequently, there is a clear need for simplified models and design rules in order to achieve reasonable costs. This paper will describe the results obtained from a 2D finite element model which has been calibrated by means of a 3D model and experimental data obtained at culverts that belong to the high-speed railway line that links the two towns of Segovia and Valladolid in Spain

Optimization of prestressed concrete bridge decks

In this paper a summary of the methods presently used for optimization of prestressed concrete bridge decks is given. By means of linear optimization the sizes of the prestressing cables with a given fixed geometry are obtained. This simple procedure of linear optimization is also used to obtain the ‘best’ cable profile, by combining a series of feasible cable profiles. The results are compared with the ones obtained by other researchers. A step ahead in the field of optimization of prestressed bridge decks is the simultaneous search of the geometry and size of the prestressing cables. A non-linear programming for optimization is used, namely, ‘the steepest gradient method’. The results obtained are compared with the ones computed previously by means of linear programming techniques. Finally, the general problem of structural optimization is considered. This problem consists in finding the sizes and geometries of the prestressing cables as well as the longitudinal variation of the concrete section.

Computer analysis and design of concrete shell roofs

This paper is a preliminary version of Chapter 3 of a State-of-the-Art Report by the IASS Working Group 5: Concrete Shell Roofs. The intention of this chapter is to set forth for those who intend to design concrete shell roofs information and advice about the selection, verification and utilization of commercial computer tools for analysis and design tasks.The computer analysis and design steps for a concrete shell roof are described. Advice follows on the aspects to be considered in the application of commercial finite element (FE)computer programs to concrete shell analysis, starting with recommendations on how novices can gain confidence and competence in the use of software. To establish vocabulary and provide background references, brief surveys are presented of, first,element types and formulations for shells and, second, challenges presented by advanced analyses of shells. The final section of the chapter indicates what capabilities to seek in selecting commercial FE software for the analysis and design of concrete shell roofs. Brief concluding remarks summarize advice regarding judicious use of computer analysis in design practice.

Modelling of chloride penetration into non-saturated concrete: case study application for real marine offshore structures

The aim of this paper is to explain the chloride concentration profiles obtained experimentally from control samples of an offshore platform after 25 years of service life. The platform is located 12 km off the coast of the Brazilian province Rio Grande do Norte, in the north-east of Brazil. The samples were extracted at different orientations and heights above mean sea level. A simple model based on Fick’s second law is considered and compared with a finite element model which takes into account transport of chloride ions by diffusion and convection. Results show that convective flows significantly affect the studied chloride penetrations. The convection velocity is obtained by fitting the finite element solution to the experimental data and seems to be directly proportional to the height above mean sea level and also seems to depend on the orientation of the face of the platform. This work shows that considering solely diffusion as transport mechanism does not allow a good prediction of the chloride profiles. Accounting for capillary suction due to moisture gradients permits a better interpretation of the material’s behaviour

Effects of hydrogen assisted stress corrosion on damage tolerance of a high-strength duplex stainless steel wire for prestressing concrete

The study brings new insights on the hydrogen assisted stress corrosion on damage tolerance of a high-strength duplex stainless steel wire which concerns its potential use as active reinforcement for concrete prestressing. The adopted procedure was to experimentally state the effect of hydrogen on the damage tolerance of cylindrical smooth and precracked wire specimens exposed to stress corrosion cracking using the aggressive medium of the standard test developed by FIP (International Prestressing Federation). Stress corrosion testing, mechanical fracture tests and scanning electron microscopy analysis allowed the damage assessment, and explain the synergy between mechanical loading and environment action on the failure sequence of the wire. In presence of previous damage, hydrogen affects the wire behavior in a qualitative sense, consistently to the fracture anisotropy attributable to cold drawing, but it does not produce quantitative changes since the steel fully preserves its damage tolerance.